JP5613359B2 - X-ray counter - Google Patents

Description

  The present invention relates to an X-ray counter that accurately measures the number of a large number of articles stored inside a container or the like.

In many cases, electronic components mounted on a circuit board are stored in a tray or wound on a reel.
In factories or the like that handle electronic parts, measurement is performed at a constant frequency in order to manage the type and number of electronic parts that are actually present in the factory.
In general, as a means of measuring the number of electronic components stored in a tray or reel without visual observation, a method of calculating based on the weight of the entire tray or reel and the weight of a single electronic component, When stored, a method is known in which a carrier tape is pulled out from a reel, and electronic components are measured one by one using a known measuring device while being wound around the other reel.

As a well-known measuring apparatus, for example, in Patent Document 1, as shown in FIG. 12, the inspection object placed on the belt conveyor is irradiated with fan-shaped X-rays (hatched area) from an upper X-ray source, An X-ray inspection apparatus is disclosed that detects the transmitted X-rays with a line sensor below the belt conveyor and measures the number of images by creating an image of the object to be inspected.
Further, in Patent Document 2, X-rays are irradiated from above on a plurality of contents overlapping in the vertical direction in a container, and the number of contents is determined based on the difference in the density values of the X-rays reaching the line sensor. An X-ray inspection apparatus for measuring is disclosed.

Japanese Patent No. 3839658 JP 2010-38629 A

However, the prior art has the following problems.
That is, in the method of measuring the number of electronic components based on the weight of the tray or reel, there is a problem that the accuracy is lowered when there is a variation in the weight due to individual differences of the electronic components.
Also, in the method of measuring the electronic components one by one while pulling out the carrier tape from the reel and winding it with the other reel, the electronic component may be damaged or dropped from the carrier tape by the external force acting on the electronic component during pulling and winding. There is a problem that the winding work takes time.

The technique described in Patent Document 1 is a line extending in the direction (Y direction) perpendicular to the transport direction (X direction) from the X-ray source arranged above the belt conveyor while moving the belt conveyor in the forward and reverse directions. A fan-shaped X-ray is irradiated toward the sensor.
Here, as shown in FIG. 13A, when the cross section along the transport direction (X direction) of the X-rays irradiated from the X-ray source is viewed, the incident angle θ1 with respect to the edge portion of the inspection object is 90 degrees. Therefore, the position (distance from the center line Lx in the X direction of the X-ray) δ1 where the X-rays transmitted through the edge portion enter the X-ray line sensor is hardly separated in the X direction from the edge portion.
On the other hand, as shown in FIG. 13B, when a cross section of the X-ray in the direction orthogonal to the transport direction (Y direction) is viewed, the incident angle θ2 with respect to the edge portion of the inspection object is considerably smaller than 90 degrees. The position (distance from the center line Ly of the X-ray in the Y direction) δ2 at which the X-ray transmitted through the edge enters the X-ray line sensor is considerably separated from the edge in the Y direction.

Thus, when comparing the positions (δ1 and δ2) of the X-rays incident on the X-ray line sensor, since δ2 is relatively larger, the contour of the inspection object formed on the line sensor is in the Y direction. The shape is greatly distorted.
Therefore, when the article to be counted is an electronic component stored in a tray or a reel, the contours of two electronic components adjacent to each other in the Y direction may overlap on the line sensor, and this may occur in the image processing stage. There is a problem that it is difficult to demarcate the boundary line of the electronic component, resulting in a counting error.

Further, the technique described in Patent Document 2 is an effective technique when the articles overlap in the vertical direction in the container, and is arranged adjacent to the XY direction (in the horizontal plane) like an electronic component stored in a tray or a reel. It is not suitable for counting used articles.
Such a problem may occur not only for electronic components stored in a tray or reel, but also for all articles that are adjacently arranged in the XY direction.

  In view of such problems, it is an object of the present invention to provide an X-ray counter that accurately measures the number of a large number of articles stored in a container.

An X-ray counter of the present invention is an X-ray counter that measures the number of a large number of articles stored in an inspection object using X-rays, positioning means for positioning the inspection object, and an inspection object An X-ray irradiation means for irradiating X-rays from the first direction, a sensor arranged in a plane orthogonal to the first direction and detecting X-rays irradiated to the inspection object, and a detection result by the sensor An image creation means for creating an image inside the object to be inspected based on the image, and an image composition means for synthesizing the image created by the image creation means as necessary, and the contour of each article drawn on the sensor by X-rays Is determined based on the distance between adjacent articles and the thickness of each article in the first direction, and the positioning means obtains an internal image of the inspection object over the entire plane orthogonal to the first direction. Times needed to get within range Only moves within a plane perpendicular to the object to be inspected in the first direction, to create an image at the each position in the image creating means captures the image data within the distance range at each position after movement, the image synthesizing The means synthesizes the images to create one image inside the inspection object.

The sensor is a line sensor disposed along a second direction orthogonal to the first direction, and the positioning means is inspected so that the outlines of the articles drawn on the sensor by X-rays do not overlap. When the object is moved one or more times in the second direction, the image creating means captures image data of the inspected object at each position after the movement, creates an image at each position, and the image synthesizing means Each image is synthesized to create one image inside the object to be inspected.
Further, based on the dimension measuring means for measuring the dimension of the object to be inspected and the dimension data measured by the dimension measuring means, it is determined whether or not the positioning means needs to move the object to be inspected at least once. And determining means for performing the processing.

By moving the object to be inspected at least once in a plane orthogonal to the first direction to create an image at each position, it is possible to obtain an image within a range where X-rays are incident on the article substantially perpendicularly. Therefore, by combining these images into one whole image, even if a plurality of articles stored in the object to be inspected are arranged adjacent to each other in a plane orthogonal to the first direction, a line is obtained by X-rays. A clear image in which the outlines of the articles drawn on the sensor do not overlap can be obtained, and the number of a large number of articles stored in the container can be accurately measured.
Further, if the X-ray counting apparatus is provided with a dimension measuring means and a determining means, it is possible to save labor in counting work.

A perspective view showing the appearance of the X-ray counter The perspective view which shows the outline of a X-ray irradiation means and a line sensor Block diagram showing the configuration of the X-ray counter Figures (a) and (b) showing examples of inspected objects YZ plan view showing a state where X-rays are irradiated on the inspection object YZ plan view showing a state where X-rays are irradiated on the inspection object YZ plan view (a)-(c) which shows the state which moved the to-be-inspected object 1 time or more in the 2nd direction Diagram showing one internal image showing the entire inspection object The perspective view which shows the outline in case an X-ray irradiation means irradiates a cone-shaped X-ray and this is detected with an area sensor The perspective view which shows the outline in case an X-ray irradiation means irradiates a fan-shaped X-ray and this is detected with an area sensor The figure which shows the imaging range of a to-be-inspected object when an area sensor is used as a sensor Schematic diagram of conventional X-ray inspection equipment XZ plan view (a) and YZ plan view (b) showing problems of the conventional X-ray inspection apparatus

An embodiment of the X-ray counter 1 of the present invention will be described with reference to the drawings.
In the present embodiment, a case will be described in which a fan-shaped X-ray is irradiated from the X-ray irradiation means and this X-ray is detected by a line sensor.
As shown in FIGS. 1 to 3, the X-ray counting device 1 is a device that measures the number of a large number of articles stored in the inspection object 3 using X-rays.
An X-ray shielding box and control means 10 (control computer) are stored in the housing 2 of the X-ray counting apparatus 1, and a monitor 22a and a barcode reader 22c as necessary are provided outside the housing 2. Is placed.

The control means 10 includes a CPU 11, a ROM 12 for storing a control program and various data, a RAM 13 for providing a working area, an interface unit 14 with peripheral circuits, and the like, which are connected by a bus.
The CPU 11 includes a table control unit 15b, an X-ray source control unit 16b, a line sensor control unit 17b, a dimension measurement sensor control unit 18b, a determination unit 19, an image creation unit 20, an image composition unit 21, a display control unit 22b, and a counting unit. 23 and the like are stored, and their driving is controlled by the CPU 11 executing a control program.

As the object to be inspected 3, a reel 5 in which an electronic component 4 (article) is wound inside as shown in FIG. 4A or an electronic component 4 as shown in FIG. Although the tray 6 stored in the shape is mentioned, it is not limited to these.
As shown in FIGS. 3 and 5, the positioning means 15 is provided for positioning the inspection object 3 in the transport direction (X direction) and in the direction (Y direction) orthogonal to the X direction in the horizontal plane. The positioning means 15 includes a table 15a for placing the inspection object 3 and a table control unit 15b for moving the table 15a to a predetermined position. A known XY stage apparatus can be used as the positioning means 15.

X-ray irradiation means 16 is provided for irradiating the inspection object 3 with X-rays. The X-ray irradiation means 16 is arranged above the table 15a and emits fan-shaped X-rays from the first direction (in the present embodiment, the Z direction (vertical direction) perpendicular to the XY plane) with respect to the inspection object 3. An X-ray source 16a that irradiates the line sensor main body 17a and an X-ray source control unit 16b that controls the irradiation timing of the X-rays from the X-ray source 16a and the like are provided.
The X-ray 16c irradiated from the X-ray source 16a has a substantially rectangular shape whose cross-sectional shape in the XY plane extends in the longitudinal direction of the line sensor main body 17a (second direction described below), and goes downward. The rectangular shape has a substantially fan shape so that the short and long sides of the rectangle are large.

  The line sensor 17 is provided for detecting the X-rays 16c irradiated by the X-ray irradiation means 16. A large number of line sensors 17 are provided along a second direction (Y direction) orthogonal to the first direction (Z direction) in the XY plane so as to detect X-rays irradiated on the inspection object 3 below the table 15a. A line sensor main body 17a configured by arranging the pixels in a line, and a line sensor control unit 17b for controlling the driving of the line sensor main body 17a and outputting image data of the captured X-rays. The X-rays irradiated from the X-ray source 16a pass through the inspection object 3 and the table 15a, reach the line sensor main body 17a, are converted into electric charges in each pixel, and are output to the image creating means 20 as image data.

The dimension measuring means 18 is provided for measuring the dimension of the inspection object 3. The dimension measuring means 18 controls a dimension measuring sensor body 18a for measuring the dimension of the inspection object 3, and controls the driving of the sensor body 18a, and outputs the measured dimension data of the inspection object 3 to the determination means 19. A dimension measurement sensor control unit 18b. For example, the dimension measuring sensor body 18a may be attached to the table 15a.
Although the detailed description will be given later, the determination means 19 receives the dimension data measured by the dimension measurement means 18, and determines whether or not the positioning means 15 needs to move the inspection object 3 one or more times in the second direction. Provided to determine.

The image creating means 20 is provided for creating an image inside the inspection object 3 based on the detection result of transmitted X-rays by the line sensor 17. The image creating means 20 creates an internal image of the inspection object 3 by capturing and processing the image data of the inspection object 3 output from the line sensor control unit 17b, and outputs it to the monitor 22a.
The image synthesizing unit 21 is provided to synthesize the image created by the image creating unit 20 as necessary. Although detailed description will be given later, when the positioning unit 15 moves the inspection object 3 in the second direction one or more times based on the determination of the determination unit 19, the image generation unit 20 creates each position after the movement. The image synthesizing unit 21 synthesizes the image of the inspection object 3 to create one internal image showing the entire inspection object 3.

  The display means 22 displays various information such as the type of the inspected object 3, the internal image of the inspected object 3 created by the image creating means 20 and the image synthesizing means 21, and the number of measured inspected objects 3. Provided with a monitor 22a and a display control unit 22b for controlling the drive of the monitor 22a. The monitor 22a may have a touch panel function, and in this case, various information can be manually input from the user via the key input circuit.

Next, the operation of the X-ray counter 1 will be described.
First, the user places the inspection object 3 on the table 15a.
Next, the dimension measurement sensor control unit 18b drives the dimension measurement sensor body 18a to measure the lengths (a, b, c) of the inspection object 3 in the X, Y, and Z directions. The measured dimension data of the inspected object 3 is output to the determination means 19 by the dimension measuring sensor control unit 18b.

The determination unit 19 that has received the dimension data refers to a reference table stored in the ROM 12 and determines whether or not the positioning unit 15 needs to move the inspection object 3 one or more times in the second direction.
The parameters included in the reference table include, for example, the length (d, e, f) in the X, Y, Z direction of the article stored in the inspection object 3, and the distance between two articles adjacent in the Y direction. g, a distance h from the X-ray source 16a to the line sensor body 17, and the like. Further, when the inspection object 3 is a reel 5, its diameter may be used.
These parameters are stored in the ROM 12 in advance, and the user may select them appropriately through the monitor 22a according to the type of the inspection object 3 or may be pasted on a part of the inspection object 3. The barcode may be stored in the ROM 12 by the user reading the barcode with the barcode reader 22c.

As shown in FIG. 5, when the length b in the Y direction of the inspection object 3 is large, among many electronic components 4 (articles) stored in the inspection object 3, the X direction is the Y direction. The angle θ2 of the X-ray incident on the edge portion of the electronic component 4 that is far from the center line Ly is considerably smaller than 90 degrees. Then, as a result that the position where the X-rays transmitted through the edge portion enter the line sensor main body 17a is considerably separated from the edge portion in the Y direction, the contours of the two electronic components 4 adjacent in the Y direction are line sensor main bodies. There is a problem of overlapping on 17a (see solid X-ray 16c and broken X-ray 16c).
Such a problem also occurs when the length f in the Z direction of the electronic component 4 is large (thickness is large), and the distance g between two electronic components adjacent in the Y direction is small (the interval is small). (Narrow). Furthermore, the same problem may occur when the distance h from the X-ray source 16a to the line sensor main body 17a is small (the interval is narrow).

Therefore, the determining means 19 is configured so that the positioning means 15 takes into account the length (a, b, c) of the inspection object 3 in the X, Y, and Z directions and each parameter stored in the ROM 12 in a comprehensive manner. It is determined whether or not the inspection object 3 needs to be moved at least once in the second direction.
For example, under the condition that the distance h from the X-ray source 16a to the line sensor body 17a does not vary, the distance g between two electronic components 4 adjacent in the Y direction and the length f in the Z direction of the electronic component 4 are separated. For example, the distance range P (see FIG. 6) in the Y direction in which the contours of the two electronic components 4 adjacent in the Y direction do not overlap on the line sensor body 17a can be calculated. That is, the distance range P can be said to be a range in which each electronic component 4 stored in the inspection object 3 can be imaged almost accurately without overlapping.

  Therefore, when the size b in the Y direction of the inspection object 3 measured by the dimension measurement means 18 is within the distance range P, the determination means 19 does not need to move the inspection object 3 in the second direction. It may be determined. On the other hand, when the size b in the Y direction of the inspection object 3 exceeds the distance range P, for example, when b / P is larger than 1, how many times the inspection object 3 is moved in the Y direction as shown in FIG. In order to acquire an internal image of the inspection object 3 within the distance range P, in other words, how many times the inspection object 3 is moved in the Y direction. The determination means 19 may determine whether or not to do so. In the case of FIG. 7, the inspection object 3 is moved twice in the second direction from the state (a) to the states (b) and (c).

If the determination unit 19 determines that the inspection object 3 does not need to be moved in the second direction, the determination unit 19 outputs a signal to that effect to the table control unit 15b, and the table control unit 15b moves the table 15a to X. Move in the direction.
Next, the X-ray irradiation means 16 starts X-ray irradiation to the inspection object 3, and the image creation means 20 takes in the image data of the inspection object 3 output from the line sensor control unit 17b and shades it. By processing by a known method such as correction, averaging processing, binarization processing, etc., one internal image (see FIG. 8) showing the entire inspection object 3 is created, and this is counted by the counting means 23 and Output to the monitor 22a.

On the other hand, when the determination means 19 determines that the inspection object 3 needs to be moved once or more, the table 15a is moved by the number of times.
Then, the image creating means 20 takes in the image data of the inspection object 3 at each position after movement, and processes this to create an image of the inspection object 3 at each position, and these are stored in the image composition means 21. Output.
The image synthesizing means 21 creates one internal image showing the entire inspection object 3 by synthesizing each image of the inspection object 3 at each position after the movement created by the image creation means 20, This is output to the counting means 23 and the monitor 22a.

The counting means 23 measures the number of electronic parts 4 stored in the inspection object 3 based on one internal image showing the entire inspection object 3, outputs the measurement result to the monitor 22 a, and stores it in the ROM 12. Remember. Then, the user places the next inspection object 3 on the table 15a.
A well-known method can be used as a method of measuring the number of electronic components 4 by the counting means 23. For example, the size data of one electronic component is read from the ROM 12 or a barcode reader, and the contour is traced by edge detection for one internal image in which the entire inspection object 3 is shown, and is closest to this size data. A thing is determined as a reference article. The number of electronic components 4 can be measured by measuring the number of portions having the same contour as the reference article using a known method such as dark portion contour detection or labeling.
If the counting means 23 cannot measure the number of electronic components 4, the image processing by the image creating means 20 is performed again to create one new internal image showing the entire inspection object 3. Then, it may be measured again by the counting means 23.

In the present embodiment, the X-ray counting apparatus 1 includes the dimension measuring means 18 and the determining means 19, and the measurement of the dimension data of the inspection object 3 and whether or not the inspection object 3 is moved in the second direction. However, the present invention is not limited to this, and the user performs measurement and input of dimension data, and the user determines whether or not the inspection object 3 needs to move in the second direction. You may decide to do it.
In addition, a single internal image showing the entire inspection object 3 is temporarily created without moving the inspection object 3 in the second direction, and the counting means 23 performs counting measurement with this image, so that the measurement can be performed accurately. In this case, the determination means 19 determines that the inspection object 3 is not moved in the second direction, and if it is found that the counting cannot be performed accurately, the determination means 19 moves the inspection object 3 in the second direction. You may decide to make it carry out.

Moreover, in this Embodiment, although the fan-shaped X-ray was irradiated from the X-ray source 16a, and the case where this X-ray was detected with the line sensor main body 17a was demonstrated, as shown in FIG. The X-ray source 16a may irradiate the cone-shaped X-ray 16d and the X-ray 16d may be detected by the area sensor 24, or the fan-shaped X-ray 16c may be detected from the X-ray source 16a as shown in FIG. Irradiation and the X-ray 16c may be detected by the area sensor 24.
When the cone-shaped X-ray 16d is irradiated from the X-ray source 16a, there is a problem that the outlines of the two electronic components 4 adjacent in the Y direction as shown in FIG. 5 overlap on the line sensor body 17a. Occurs in the entire XY plane. In this case, the area sensor 24 is used as the sensor, and the positioning means 15 places the inspection object 3 on the XY plane so that the contours of the electronic components 4 drawn on the area sensor 24 by the conical X-ray 16d do not overlap. It may be moved a plurality of times within. FIG. 11 shows the imaging ranges A1 to A9 when the inspection object 3 is moved eight times.

Further, as the type of the inspected object 3, a plurality of articles in the inspected object 3 such as the reel 5 and the tray 6 storing the electronic components 4 as described in the present embodiment are arranged in the XY direction (in the horizontal plane). ) Are adjacent to each other. For example, it may be foods in which a large number of foods are arranged in a horizontal plane and enclosed in a packaging container.
The X-ray counting apparatus 1 of the present invention can also be used for counting articles that are not stored in a container. For example, various parts such as screws, bolts and nuts, and articles such as tablets and capsule-shaped medicines are laid with an adhesive sheet or the like on the table 15a so as not to move on the table 15a when moved in a horizontal plane. Counting is possible if they are placed on the lever so as not to overlap each other.
Further, information such as the number of measured articles and measurement date may be output by a label printer, and the label may be attached to the inspection object 3.
The table 15a and the X-ray source 16a may be configured to be movable in the Z direction.

  The present invention is an X-ray counter that accurately measures the number of a large number of articles stored in a container, and has industrial applicability.

DESCRIPTION OF SYMBOLS 1 X-ray counter 2 Case 3 Inspection object 4 Electronic component 5 Reel 6 Tray 10 Control means 11 CPU
12 ROM
13 RAM
14 Interface unit 15 Positioning unit 15a Table 15b Table control unit 16 X-ray irradiation unit 16a X-ray source 16b X-ray source control unit 16c X-ray 16d X-ray 17 Line sensor 17a Line sensor body 17b Line sensor control unit 18 Dimension measurement unit 18a Dimensional measurement sensor body 18b Dimensional measurement sensor control unit 19 Determination unit 20 Image creation unit 21 Image composition unit 22 Display unit 22a Monitor 22b Display control unit 22c Bar code reader 23 Counting unit 24 Area sensor

Claims (3)

In an X-ray counter for measuring the number of a large number of articles stored in an object to be inspected using X-rays,
Positioning means for positioning the object to be inspected;
X-ray irradiation means for irradiating the inspection object with X-rays from the first direction;
A sensor for detecting X-rays arranged in a plane perpendicular to the first direction and irradiated on the object to be inspected;
Image creating means for creating an image inside the object to be inspected based on a detection result by the sensor;
Image synthesizing means for synthesizing the image created by the image creating means as required,
Obtain a distance range in which the outlines of each article drawn on the sensor by X-rays do not overlap based on the distance between adjacent articles and the thickness of each article in the first direction,
The positioning means moves the inspection object in a plane orthogonal to the first direction as many times as necessary to obtain an internal image of the inspection object in the entire plane orthogonal to the first direction within the distance range;
The image creation means captures image data within the distance range at each position after movement to create an image at each position,
An X-ray counting apparatus, wherein the image synthesizing unit synthesizes the images to create one image inside the inspection object.
The X-ray irradiation means emits fan-shaped X-rays;
The sensor is a line sensor arranged along a second direction orthogonal to the first direction;
When the positioning means moves the object to be inspected one or more times in the second direction so that the outlines of the articles drawn on the sensor by X-rays do not overlap, the image creating means moves the object at each position after the movement. The image data of an inspection object is taken in and the image in each said position is produced, The said image synthetic | combination means synthesize | combines each said image, and produces one image inside a to-be-inspected object. The X-ray counting device described.
A dimension measuring means for measuring the dimension of the inspection object;
2. The determination unit according to claim 1, further comprising: a determination unit that determines whether the positioning unit needs to move the inspection object one or more times based on the dimension data measured by the dimension measurement unit. 2. The X-ray counting device according to 2.

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