JP5077093B2 - Round bar number counting device and round bar number counting method - Google Patents

Description

The present invention, round bar number counting apparatus, and relates to a round bar number counting how, more particularly, after being produced by such hot rolling and cold rolling, the round bar is cut to a predetermined length number automatically, and round bar number counting equipment which can be counted with high precision, and relates to a round bar number counting how.

A steel round bar is generally manufactured by hot rolling a square billet. After roughly rolling the billet cross-section into a round shape, hot rolling is repeated step by step until the diameter of the round bar reaches the target diameter. After the diameter is reduced to a predetermined diameter, the round bar is trimmed to a predetermined length. The rounded bar is placed on the transfer table and cooled on the cooling bed.
In such a round bar production line, in order to prevent mixing of different materials, the number of round bars that have been trimmed is counted. However, when the round bar is bent or when the round bar is placed obliquely on the transport table, there is a problem that the round bars partially overlap and cause a counting error.

In order to solve this problem, various proposals have heretofore been made.
For example, Patent Document 1 discloses that
(1) Irradiate the steel bars arranged on the transfer table with a laser beam having a certain line width from an oblique direction along the longitudinal direction of the steel bars,
(2) Photograph the crescent-shaped laser trajectory formed on the steel bar surface with a CCD shutter camera with an infrared filter installed on the reflection angle side.
(3) A laser type counting device that measures the number of crescent-shaped laser trajectories by image processing is disclosed.
In the same document,
(A) When a laser beam having a single wavelength different from the radiation light from the hot steel is used, the laser light and the radiation light can be distinguished from each other.
(B) Even if the steel bars overlap, the crescent-shaped image of the steel bar surface is separated, so that the steel bars can be counted,
Is described.

JP-A-9-305737

In Patent Document 1, when laser light having a certain line width is irradiated from an oblique direction of a steel round bar, the crescent-shaped laser trajectory formed on the surface of the round bar is separated. The point which can measure the number is indicated. However, even when the laser beam is irradiated obliquely, there is a problem that the laser trajectory is not completely separated and a counting error occurs depending on how the round bars are overlapped. Furthermore, since the way of lighting on the surface of the round bar is different depending on the overlapping state of the round bar, the measurement accuracy of the other state is reduced when measuring the other state under the condition that the certain state can be accurately measured. There is.
Moreover, the surface of the hot-rolled steel round bar is covered with an oxide scale, and the skin is in a rough state. In addition, there are atmospheric fluctuations around the heated round bar. Therefore, when optically measuring the number of hot-rolled steel round bars, if laser light with high straightness is used, the laser light diffuses on the round bar surface, causing counting errors.

An object of the present invention is to provide, even if the rod is partially overlapping, round bar number counting equipment which can accurately measure the number of round bar and round bar number It is to provide a count how.
Another object of the present invention is to provide, regardless of the overlapping state of the round bar, round bar number counting equipment which can accurately measure the number of round bar and round bar number counts how the It is to provide.
Furthermore, another object to be solved The present invention may be a round bar that has been heated to a high temperature, the round bar number counting equipment which can accurately measure the number of round bar and round bar It is to provide a number count how.

In order to solve the above problems, a round bar number counting device according to the present invention is:
Irradiation means for irradiating irradiation light to a plurality of round bars arranged on the transfer table;
Digital photographing means for photographing reflected light reflected from the surface of the round bar;
Extraction means for extracting the reflected light contained in the photographed image with a plurality of extraction sensitivities;
Reflected light counting means for counting the number of reflected lights at each extraction sensitivity,
The maximum number of the reflected light at each extraction sensitivity Bei give a determination means for determining the number of said round bar,
The irradiation means includes illuminance variable means for changing the illuminance of the irradiation light into a plurality of stages,
The extraction means is configured to extract the reflected light from a plurality of images photographed with a constant threshold when extracting the reflected light and changing the illuminance of the irradiation light in a plurality of stages.
And this is the gist.
The irradiation light is preferably non-laser light.

In addition, the round bar number counting method according to the present invention,
An irradiation step of irradiating irradiation light to a plurality of round bars arranged on a transport table using an irradiation means;
A photographing step of photographing reflected light reflected from the surface of the round bar using a digital photographing means;
An extraction step of extracting the reflected light contained in the photographed image with a plurality of extraction sensitivities;
A reflected light counting step for counting the number of reflected lights in each of the extraction sensitivities;
The maximum number of the reflected light at each extraction sensitivity Bei example a determination step of determining the number of said round bar,
In the irradiation step, irradiation is performed by changing the illuminance of the irradiation light in a plurality of stages.
In the extracting step, the reflected light is extracted from a plurality of images taken with a constant threshold when the reflected light is extracted and the illuminance of the irradiation light is changed in a plurality of stages.
And this is the gist.

  (Delete)

When optically measuring the number of round bars arranged on the transport table, the number of reflected lights varies according to the extraction sensitivity when the round bars partially overlap. Therefore, if the reflected light on the surface of the round bar is extracted with multiple extraction sensitivities and the number of reflected light at each extraction sensitivity is counted, the true number of round bars from the maximum number of reflected light at each extraction sensitivity Can know. In addition, the number of round bars can be accurately measured regardless of how the round bars overlap.
Furthermore, if non-laser light is used as the irradiation light to irradiate the round bar, the diffusion of reflected light can be suppressed, so the number of round bars can be accurately adjusted even when the round bar is heated to a high temperature. Can be measured.

Hereinafter, an embodiment of the present invention will be described in detail.
[1. Round bar number counting device]
The round bar number counting device according to the present invention includes an irradiating means, a digital photographing means, an extracting means, a reflected light counting means, and a judging means.

[1.1 Irradiation means]
The irradiation unit is a unit for irradiating the plurality of round bars arranged on the transport table with irradiation light.
In the present invention, the material of the round bar is not particularly limited. That is, the round bar may be a metal material (for example, a steel material) or a non-metal material. Further, the temperature of the round bar is not particularly limited. That is, the temperature of the round bar may be room temperature, or may be a high temperature of several hundred ° C. to thousands of ° C. The round bar number counting device according to the present invention is particularly suitable as a device for measuring the number of metal round bars heated to a high temperature.

  The optimal color (wavelength) of the irradiation light applied to the round bar is selected according to the material and temperature of the round bar. For example, when measuring a cold round bar, light of any color can be used as irradiation light, and even red light can be used. On the other hand, when measuring a hot metal round bar, since red radiation light is emitted from the round bar, it is preferable to use irradiation light other than red. When measuring a hot round bar, the irradiation light is particularly preferably green light. When green light is used, the number of round bars can be measured without being affected by red light radiated from the hot round bars.

The irradiation light may be laser light having a single wavelength, or may be non-laser light on which light having a plurality of wavelengths is superimposed. In particular, non-laser light is suitable as irradiation light for measuring a hot round bar because it is less affected by atmospheric fluctuations.
Examples of irradiation means capable of emitting non-laser light suitable for hot round bar measurement include LED lighting, halogen lamps, fluorescent lamps, and incandescent lamps.

  The incident angle of the irradiation light is not particularly limited and can be arbitrarily selected according to the purpose. Generally, as the incident angle (the angle formed by the normal direction of the surface of the round bar and the incident direction of the irradiation light) approaches zero, the stronger reflected light is obtained, so that the measurement accuracy can be improved. Specifically, the incident angle is preferably 30 ° or less. The incident angle is more preferably 20 ° or less, and further preferably 10 ° or less.

The irradiation means may be capable of irradiating only irradiation light with a certain illuminance, or may be provided with illuminance variable means for changing the illuminance of the irradiation light in a plurality of stages. Using an irradiating means including an illuminance changing means has an advantage of facilitating extraction of reflected light by changing the extraction sensitivity in a plurality of stages as will be described later. The illuminance changing means may be any means that can change the illuminance of the irradiation light, and well-known means can be used.
Further, the illumination means may be capable of irradiating the whole round bar with irradiation light, or may be capable of irradiating a part of the round bar. Illumination means for irradiating a part of a round bar includes, for example, one that can irradiate slit light having a certain width.

[1.2 Digital photography means]
The digital photographing means is means for photographing reflected light reflected from the surface of the round bar.
“Digital imaging means” refers to a device capable of converting an image into an electrical signal using an imaging device (for example, a charge coupled device (CCD), a complementary metal oxide semiconductor (CMOS), etc.). Examples of digital photographing means include a CCD area camera and a CCD line camera.
The digital photographing means is installed on the reflection angle side with respect to the irradiation means. As long as there is no hindrance to the reflected light shooting, the reflection angle (the angle formed by the normal direction of the round bar and the shooting direction of the digital shooting means) is not particularly limited, and may need to match the incident angle. Absent. As the positional relationship between the digital photographing means and the irradiating means becomes closer to the same axis (incident angle = reflection angle = 0), stronger reflected light can be obtained, so that the measurement accuracy can be improved.

[1.3 Extraction means]
The extraction means is means for extracting reflected light included in the photographed image with a plurality of extraction sensitivities.
When the surface of the round bar is irradiated with irradiation light, the illuminance of the reflected light is highest at the top of the round bar and decreases toward the side of the round bar. Therefore, when the reflected light having the illuminance below the predetermined threshold is cut, discontinuous reflected light substantially corresponding to the number of round bars can be obtained.
Extraction of reflected light is, for example,
(1) Extracting only the reflected light component of the color corresponding to the irradiation light (for example, only the reflected green component when using green light as the irradiation light) from the captured image;
(2) Color extraction can be performed by performing color binarization processing with a predetermined threshold value on the color components extracted.

The means for extracting reflected light with a plurality of extraction sensitivities includes:
(A) a first means for capturing a plurality of images by changing the illuminance of the irradiation light emitted from the irradiation means in a plurality of stages, and extracting reflected light from the plurality of images under a constant threshold condition;
(B) a second means for taking one image by irradiating the irradiation light of a certain illuminance from the irradiation means, and extracting the reflected light from the one image a plurality of times by changing the threshold value in a plurality of stages;
(C) Third means for capturing a plurality of images by changing the illuminance of the irradiation light emitted from the irradiation means in a plurality of stages, and extracting reflected light from the plurality of images by changing the threshold value to a plurality of stages ( A combination of the first means and the second means),
and so on. Any means may be used in the present invention. In particular, the first means is particularly suitable as the extraction means because it is easy to control.

[1.4 Reflected light counting means]
The reflected light counting means is a means for counting the number of reflected lights at each extraction sensitivity.
The image used for counting the reflected light may be an image that has been subjected to color extraction / binarization processing, or may be an image that has been subjected to contraction / expansion processing on the image after color extraction / binarization processing. . If further shrinkage / expansion processing is performed on the image after color extraction / binarization processing, an area irrelevant to the number of round bars is filled, which has the advantage of improving the counting accuracy. Further, the image used for counting the reflected light may be an image obtained by performing a process of restricting the measurement area to a specific area after the contraction / expansion process. The limitation of the measurement area is effective for shortening the calculation time.
Specifically, the reflected light can be counted by performing particle analysis on an image that has been subjected to various types of processing as necessary, and counting the number of the images.

[1.5 Judgment means]
The judging means is means for judging the maximum value of the number of reflected lights in each extraction sensitivity as the number of round bars.
When multiple round bars are placed on the transfer table, if the round bars run on the side walls or if multiple round bars are folded, a part of the round bars will become a shadow, and the reflected light from each round bar will be reflected. Strength is generated. For this reason, when the reflected light is extracted while changing the extraction sensitivity, the number of reflected lights increases or decreases according to the extraction sensitivity. In the present invention, the maximum value of the number of reflected lights at each extraction sensitivity is determined as the number of round bars.

[2. How to count the number of round bars]
The round bar number counting method according to the present invention is:
An irradiation step of irradiating irradiation light to a plurality of round bars arranged on a transport table using an irradiation means;
A photographing step of photographing reflected light reflected from the surface of the round bar using a digital photographing means;
An extraction step of extracting the reflected light contained in the photographed image with a plurality of extraction sensitivities;
A reflected light counting step for counting the number of reflected lights in each of the extraction sensitivities;
A determination step of determining a maximum value of the number of reflected lights in each extraction sensitivity as the number of the round bars.
The details of the irradiation process, the imaging process, the extraction process, the reflected light counting process, and the determination process are the same as the irradiation means, the imaging means, the extracting means, the reflected light counting means, and the determination means, respectively. Omitted.

[3. Round bar number counting program]
FIG. 1 shows a flowchart of a round bar number counting program according to the present invention.
First, in step 1 (hereinafter referred to as “S1”), an initial value “1” is substituted for the number n of illuminance change repetitions. Next, in S2, the nth illuminance (at this time, the first) is set. In S3, the irradiation unit is caused to irradiate a plurality of round bars arranged on the transport table with irradiation light having a set illuminance (irradiation unit). In S4, the digital photographing means is made to photograph the reflected light reflected from the surface of the round bar (photographing means). Further, in S5, an image photographed by the photographing means is input to the computer (input means).

  In S6, an initial value “1” is substituted for the number m of changes in extraction sensitivity. In S7, the m-th (at this time, the first) extraction sensitivity is set, and in S8, the reflected light contained in the photographed image is extracted with the set extraction sensitivity (extraction means). After extracting the reflected light, an expansion / contraction process or a process for determining a measurement range may be performed as necessary. Further, in S9, the number of reflected lights extracted with the set extraction sensitivity is counted (reflected light counting means).

In S10, it is determined whether or not the number m of changes in extraction sensitivity has reached a predetermined maximum value (m _max ). When the maximum value (m _max ) of the number of changes in extraction sensitivity is 2 or more, since only the first extraction has been performed at this time (S10: NO), the process proceeds to S11, and the change number m is set to 1. Add Further, returning to S7, the m-th (second at this time) extraction sensitivity is set. Then, the above steps S7 to S11 are repeated until the number m of changes in extraction sensitivity reaches a predetermined maximum value (m _max ).

When the number m of changes in extraction sensitivity has reached a predetermined maximum value (m _max ), the process proceeds to S12. In S12, it is determined whether or not the reflected light is photographed by changing the illuminance of the irradiation light. When shooting a plurality of images by changing the illuminance of the irradiation light, the process proceeds to S13, and it is determined whether or not the number of repetitions n of the illuminance change has reached a predetermined maximum value (n _max ). At this point in time, only the first illuminance setting is performed (S13: NO), so the process proceeds to S14 and 1 is added to the number of repetitions n. Further, returning to S2, the nth (second at this time) illuminance is set. Then, until the maximum number of repetitions n of the illumination change is predetermined (n _max), repeats the steps of S2~S14 described above.

On the other hand, when the illuminance change is not performed (S12: NO), or when the illuminance change is performed a predetermined number of times and irradiation light irradiation, image capturing, image input, reflected light extraction, and reflected light count are performed ( In S13: YES, the process proceeds to S15.
In S15, the number of reflected lights at each extraction sensitivity is compared. Then, the maximum value of the number of reflected lights in each extraction sensitivity is determined as the number of round bars (determination means).

Note that the change in extraction sensitivity is as described above.
(1) from the image of the n _max sheets taken by changing the illuminance of the irradiation light (n _max ≧ 2), the first method of extracting reflected light at a certain threshold (m _max = 1),
(2) a second method of extracting reflected light from one image (n _max = 1) by changing the threshold value to m _max steps (m _max ≧ 2);
(3) A combination of the first method and the second method,
Any of these may be used.
Accordingly, when the first method is used, the extraction of the reflected light is repeated a number of times (n _max times) corresponding to the number of images. When the second method is used, the extraction of the reflected light is repeated a number of times (m _max times) corresponding to the number of extraction sensitivity thresholds. Further, when the first method and the second method are combined, the extraction of reflected light is repeated a number of times (n _max × m _max times) corresponding to the product of the number of images and the number of threshold values.

[4. Operation of Round Bar Number Counting Device, Round Bar Number Counting Method, and Round Bar Number Counting Program]
In the process of manufacturing the round bar, the round bar that has been trimmed is placed on the transport table, and the number is counted. However, if the round bar is bent or the round bar is placed obliquely on the transport table, the round bars partially overlap, causing a counting error.
In FIG. 2, the schematic diagram of the overlapping state of a round bar is shown. The overlapping state of the round bars arranged on the transport table is a case where the round bars on the side end ride on the side wall of the transport table (FIG. 2A) and a state where a plurality of round bars are folded (dango state). It is roughly divided into cases (FIG. 2B).

As shown in FIG. 2 (a), when the round bar rides on the side wall at the side edge of the transfer table, the reflected light from the round bar 1 riding on the side wall, and the reflected light from the round bar 2 adjacent thereto Will overlap. In this state, when the extraction sensitivity is set to “large”, the reflected light of the round bar 1 and the reflected light of the round bar 2 cannot be separated, and the round bar 1 and the round bar 2 are combined and counted as one. . Therefore, in order to separate the round bar 1 and the round bar 2, it is necessary to set the extraction sensitivity of the reflected light to “small”.
On the other hand, as shown in FIG. 2 (b), when a plurality of round bars are folded, the reflected light from the round bars 3 and 5 riding on them is strong, but the reflected light from the round bars 4 below them is strong. Is weakened by the reflected light from the round bars 3 and 5. In such a state, if the extraction sensitivity of the reflected light is set to “small”, the reflected light from the round bar 4 cannot be detected. Therefore, in order to detect the reflected light from the round bar 4, it is necessary to set the extraction sensitivity of the reflected light to “large”.

Therefore, in the round bar production line, if the number of round bars is counted while maintaining the extraction sensitivity “high”, the number of round bars can be accurately counted for the case of FIG. In the case of FIG. 2A, a counting error may occur in the number of round bars.
On the other hand, if the number of round bars is counted while maintaining the extraction sensitivity at “small”, the number of round bars can be accurately counted in the case of FIG. For cases, there may be a counting error in the number of round bars.

On the other hand, if the reflected light is extracted a plurality of times while changing the extraction sensitivity and the number of reflected lights at each extraction sensitivity is counted, the number of round bars can be accurately grasped.
For example, in the case of FIG. 2 (a), if extraction / counting of reflected light is performed while changing the extraction sensitivity, the number of reflected light with the extraction sensitivity “low” is equal to the number of reflected light with the extraction sensitivity “high”. Become more. Therefore, the number of round bars can be accurately grasped from the number of reflected lights with the extraction sensitivity “low”.
Similarly, in the case of FIG. 2B, when extraction / counting of reflected light is performed while changing the extraction sensitivity, the number of reflected light with the extraction sensitivity “large” is the number of reflected light with the extraction sensitivity “low”. More than the number. Therefore, the number of round bars can be accurately grasped from the number of reflected lights with the extraction sensitivity “high”.

Example 1
[1. Test method]
The number of hot-rolled steel round bars was counted using the round bar number counting device according to the present invention. For the illumination, green LED illumination was used, which was installed almost directly above the round bars arranged on the transfer table (incident angle ≈ 0 °). A CCD camera was used as the digital photographing means, and was installed almost coaxially with the LED illumination (reflection angle≈20 °).

[2. result]
FIG. 3 shows a photographed image of a round bar. FIG. 3A is an image captured by a CCD camera. Since self-emission (infrared light) is cut by the green illumination, it can be seen that the upper surface portion of the steel material is strongly reflected. FIG. 3B shows an image obtained by extracting only the reflected green component and performing color binarization processing. FIG. 3C is an image after the expansion and contraction processing is performed on the image of FIG. It can be seen that only the surface of the round bar is white. FIG. 3D shows an image after processing for determining a measurement range for counting the number of reflected lights. The white area at the center of the round bar is the measurement range. The image subjected to the measurement range processing is used for particle analysis, and the number of reflected lights is counted.

FIG. 4A shows an image in which the reflected light is extracted with the extraction sensitivity “high”. Since the leftmost round bar rides on the side wall, it can be seen that the reflected light of the leftmost round bar and the adjacent round bar are not separated. Under the condition of FIG. 4A, the number of round bars was counted as 19.
On the other hand, FIG. 4B shows an image obtained by extracting the reflected light with the extraction sensitivity “low”. It can be seen that the reflected light of the leftmost round bar is separated by setting the extraction sensitivity to “small”. Under the conditions of FIG. 4B, the number of round bars was counted as 20.
From Fig. 4, if the number of reflected lights is counted by changing the extraction sensitivity and the maximum value is the number of round bars, the number of round bars can be accurately measured even if the round bars partially overlap. I understand.

  Although the embodiments of the present invention have been described in detail above, the present invention is not limited to the above embodiments, and various modifications can be made without departing from the scope of the present invention.

  A round bar number counting device, a round bar number counting method, and a round bar number counting program according to the present invention are for measuring a steel round bar produced by hot working or cold working in a production line in real time. The present invention can be used as an apparatus and method, and a program for causing a computer to execute the apparatus and method.

It is a flowchart of the round bar number count program which concerns on this invention. FIG. 2A is a schematic diagram showing a state in which a round bar at the side end rides on the side wall of the transport table, and FIG. 2B is a schematic diagram showing a state in which a plurality of round bars are folded (dango state). is there. Captured image of a round bar photographed by the round bar number counting device according to the present invention (FIG. 3A), image after color extraction + color binarization processing (FIG. 3B), after shrinkage + expansion processing The image (FIG. 3C) and the image subjected to the measurement range processing (FIG. 3D). FIG. 4A is an image of reflected light extracted with high extraction sensitivity, and FIG. 4B is an image of reflected light extracted with low extraction sensitivity.

Claims (8)

Irradiation means for irradiating irradiation light to a plurality of round bars arranged on the transfer table;
Digital photographing means for photographing reflected light reflected from the surface of the round bar;
Extraction means for extracting the reflected light contained in the photographed image with a plurality of extraction sensitivities;
Reflected light counting means for counting the number of reflected lights at each extraction sensitivity,
E Bei and determination means for the maximum value of the number of the reflected light at each extraction sensitivity, it is determined that the number of the rod
The irradiation means includes illuminance variable means for changing the illuminance of the irradiation light into a plurality of stages,
The extraction means is configured to extract the reflected light from a plurality of images photographed with a constant threshold when extracting the reflected light and changing the illuminance of the irradiation light in a plurality of stages.
Round bar number count devices.   The round bar number counting device according to claim 1, wherein the irradiation light is green light.   The round bar number counting device according to claim 1, wherein the irradiation light is non-laser light.   4. The round bar number counting device according to claim 1, wherein an incident angle of the irradiation light is 30 ° or less. 5. An irradiation step of irradiating irradiation light to a plurality of round bars arranged on a transport table using an irradiation means;
A photographing step of photographing reflected light reflected from the surface of the round bar using a digital photographing means;
An extraction step of extracting the reflected light contained in the photographed image with a plurality of extraction sensitivities;
A reflected light counting step for counting the number of reflected lights in each of the extraction sensitivities;
The maximum number of the reflected light at each extraction sensitivity example Bei a determination step of determining a number of said rod
In the irradiation step, irradiation is performed by changing the illuminance of the irradiation light in a plurality of stages.
In the extracting step, the reflected light is extracted from a plurality of images taken with a constant threshold when the reflected light is extracted and the illuminance of the irradiation light is changed in a plurality of stages.
Round bar number counting method. The round bar number counting method according to claim 5 , wherein the irradiation light is green light. The round bar number counting method according to claim 5 or 6 , wherein the irradiation light is non-laser light. The method according to claim 5 , wherein an incident angle of the irradiation light is 30 ° or less.

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