JP6343225B2 - Scaffolding control device - Google Patents

Description

  The present invention relates to a scaffold lifting control apparatus that automatically adjusts the height of a work scaffold so that the distance from the workpiece surface to the eye of an inspector is substantially constant.

  Conventionally, a defect inspection process for inspecting defects such as scratches formed on the surface of a workpiece moving on a line is generally a visual inspection by an inspector. For example, when the work is a car body (body shell), the inspector visually checks the painted surface of the body shell that is continuously transferred from the work platform installed on one side of the line to check for defects. To detect. At this time, since the height of the body shell differs in each part (front part, roof part, rear part, etc.), for example, it is disclosed in Patent Document 1 (Japanese Patent Laid-Open No. 10-258998). In addition, the height of the line of sight with respect to the painted surface is adjusted by raising and lowering the work scaffold (elevating platform) according to the change in the height of the body shell.

  However, if the inspector adjusts the height of the work platform while inspecting the coating surface for defects, there is a disadvantage that the work efficiency is deteriorated by the time required for the operation.

  For example, Patent Document 2 (Japanese Patent Application Laid-Open No. 2004-10340) discloses a height detection read / write on a work scaffold (work floor) as an automatic adjustment of the height of the work scaffold according to the work situation of an inspector. On the other hand, a technique has been disclosed in which an antenna is provided, and a height detection tag is wound around the wrist and the work scaffold is moved up and down following the vertical movement of the wrist.

  In other words, in this document, the height from the work platform that is easy for the inspector to work to the hand is registered in the computer as the reference height, and the work platform is raised when the wrist touches the high position of the workpiece. On the other hand, if the wrist touches the low position of the work, raise the work platform so that the height from the work platform to the hand is within a certain range with respect to the reference height Thus, the worker can continue working without greatly changing his posture.

JP-A-10-258998 JP 2004-10340 A

  When the technique disclosed in Patent Document 2 described above is used for the defect inspection of the workpiece surface, the inspector can raise and lower the work scaffold only by raising and lowering the wrist according to the workpiece height. Efficiency can be improved.

  By the way, as shown in FIG. 8, when the relationship between the eye height [mm] from the workpiece surface (surface to be inspected) and the defect detection rate [%] is examined, it is the highest at a certain height (h [mm]). The defect detection rate is obtained. However, in the technique disclosed in Patent Document 2 described above, by detecting the height to the hand of the inspector, the work scaffold is raised and lowered, the distance between the eye height and the inspection surface is not constant, There is a limit to stably obtaining a high defect detection rate because variations due to individual differences tend to occur in the determination of pass / fail of defect detection.

  In view of the above circumstances, the present invention is automatic so that the work surface (surface to be inspected) and the eye level of the inspector are within a certain range without the inspector moving up and down the work platform according to the work height. It is an object of the present invention to provide a scaffold lifting control device that can be moved up and down to suppress variation in pass / fail judgment due to individual differences among inspectors, and to always obtain a high defect detection rate.

  The present invention provides a work scaffold on which an inspector stands, a scaffold elevating means for elevating the work scaffold, and an individual for obtaining individual information relating to the eye level of the inspector, provided on one side of a line for moving a workpiece Information acquisition means, type information acquisition means provided on the upstream side of the work scaffold to acquire the type information of the workpiece, and passage provided on the upstream side of the work scaffold to detect passage of the specific part of the work Detecting means and elevating control means for controlling the elevating operation of the scaffold elevating means, and the elevating control means obtains the eye height based on the individual information of the inspector acquired by the individual information acquiring means. Based on the type information specified by the type specifying unit, the type specifying unit for specifying the type of the workpiece based on the type information acquired by the type information acquiring unit, When the passage of the specific part of the workpiece acquired by the data acquisition unit is detected by the data acquisition means for acquiring the height data of the specific part of the workpiece and the passage detection means, the coverage of the specific part is detected. A scaffold for calculating the scaffold height of the work scaffold based on the height of the inspection surface, the eye height obtained by the eye height calculating means, and a preset reference height from the specific part to the eye of the worker Height calculating means, and scaffold driving signal output means for outputting a driving signal corresponding to the scaffold height calculated by the scaffold height calculating means to the scaffold lifting means.

  According to the present invention, when the height data of the specific part of the workpiece set in advance is acquired based on the type information regarding the workpiece, and the passage detection unit detects the passage of the specific part of the workpiece, the coverage of the specific part is detected. The scaffold height of the work scaffold is calculated based on the height of the inspection surface, the eye level of the inspector, and the preset reference height from the specific part to the height of the line of sight, and the scaffold is lifted based on this scaffold height Since the means is raised and lowered, the work scaffold is automatically raised and lowered so that the height from the workpiece surface to the eye of the inspector falls within a certain range. As a result, the inspector does not have to move up and down the work platform according to the work height, so work efficiency is improved, and variation in pass / fail judgment due to individual differences among the inspectors can be minimized. A high defect detection rate can be obtained stably.

Schematic configuration diagram of the state where the scaffold lifting control device is arranged in the inspection station The height division gate is shown, (a) is a schematic diagram showing the measurement category of average stature, (b) is a schematic diagram showing the measurement category of short stature. Explanatory drawing which shows the timing at the time of photographing the characteristic part of the body shell Explanatory drawing of the image of the characteristic part of the body shell Explanatory drawing of the state which chooses the photosensor corresponding to body shell data for every car model from a photosensor row Explanatory drawing of surface inspection performed at the inspection station installed in the painting line Explanatory drawing which shows the inspector's eye-level height with respect to the surface to be inspected of the body shell, and the illumination height Statistical chart showing the relationship between the height from the inspection surface to the line of sight and the defect detection rate Flow chart showing height level division processing routine Flow chart showing the lighting height / scaffolding control routine (part 1) Flowchart showing the lighting height / scaffolding control routine (part 2) Flowchart showing the lighting height / scaffolding control routine (part 3) Flowchart showing the lighting height / scaffolding control routine (Part 4) The relationship between the movement of the body shell and the raising and lowering of the work platform is shown, (a) is a schematic diagram of the state where the work platform is in the initial position, and (b) is the state where the work platform is raised to a height at which the front hood can be visually observed. Schematic of The relationship between the movement of the body shell and the raising and lowering of the work platform is shown. (A) is a schematic view of the work platform raised to a height at which the periphery of the front pillar can be seen, and (b) is the work platform up to a height at which the roof can be seen. Schematic diagram of the lifted state The relationship between the movement of the body shell and the raising / lowering of the work platform is shown, (a) is a schematic view of the state of visually observing the rear periphery of the roof, and (b) is the state where the work platform is lowered to a height at which the rear part of the body shell can be seen Schematic of

  Hereinafter, an embodiment of the present invention will be described with reference to the drawings. Reference numeral 1 in FIG. 1 denotes an inspection station that performs an inspection process, and is arranged downstream of the painting process. A chain conveyor (hereinafter simply referred to as “conveyor”) 2 extending from the painting process is arranged through the inspection station 1, and a carriage 3 is transported on the conveyor 2 at a predetermined interval. . Further, a body shell 4 as a work of the vehicle body is placed on the carriage 3. As shown in FIG. 3, the body shell 4 includes a front hood 4a, a front fender panel 4b, a side door panel 4c, a roof panel 4d, a rear quarter panel 4e, a fuel lid 4f, and a rear gate 4g for a wagon type (a sedan type is a trunk lid). Such a so-called lid is temporarily attached, and coating is completed in a predetermined step in the previous coating step.

  Further, a scaffold lifting device 5 as a scaffold lifting device is disposed on one side of the conveyor 2 as a line passing through the inspection station 1, and an illuminator 6 as a lighting device is disposed opposite to the other side. The scaffold elevating device 5 includes a work scaffold 5a on which an inspector M performs an inspection work, a lift lifter 5b that supports the work scaffold 5a on the ground plane GL side, a motor actuator 5c that moves the lift lifter 5b up and down, and the like. Is provided. On the other hand, the illuminator 6 has a horizontally long rectangular shape extending in parallel with the conveyor 2, and a plurality of vertically long illuminating lamps 6a are arranged at predetermined intervals.

  As shown in FIG. 6, the illuminator 6 is supported by a work scaffold 5a via a stand frame 7, and is lifted and lowered integrally with the work scaffold 5a. Furthermore, as shown in FIG. 7, the distance W1 from the center of the body shell 4 in the vehicle width direction to the position where the inspector M stands and the distance W2 from the center of the vehicle width direction to the illuminator 6 are set to be approximately equal. (W1 = W2).

  The stand frame 7 supports the illuminator 6 in a suspended state, and a height adjusting device 8 as a height adjusting means is interposed in the suspended portion 7a. This height adjustment device 8 adjusts the height of the illuminator 6 to substantially the same position as the position of the pupil Pe of the inspector M, and an expansion / contraction part 8a configured by a known worm mechanism or the like, and the expansion / contraction part And a drive motor 8b for operating 8a.

  FIG. 14A shows a state where the work scaffold 5a of the scaffold lifting device 5 is waiting at the initial position. In this state, the work scaffold 5a is located at substantially the same height as the ground plane GL. Although not shown in the figure, a fall prevention fence is erected around the work scaffold 5a, and an entrance 5d is set on the upstream side of the conveyor 2 of the fall prevention fence.

  Further, the inspection station 1 is provided with a height sorting gate 10 at a close position on the entrance 5d side of the work scaffold 5a. This height classification gate 10 obtains the height, which is individual information related to the height of the eye of the inspector M who enters the work scaffold 5a, and divides it into a plurality of stages. As shown in FIG. 2, the ground plane GL And a photosensor array 10b as individual information acquisition means provided on the gate body 10a. The optical sensor array 10b is a transmissive type, and a plurality of transmissive optical sensors 11 each composed of a light projector 11a and a light receiver 11b using phototubes or the like are perpendicular to the opposite sides of the gate body 10a at a predetermined pitch. Is arranged.

  By the way, in this embodiment, the height classification gate 10 classifies the height of the inspector M into a predetermined level and tries to estimate the height of the inspector M's line of sight. Therefore, for example, as disclosed in Japanese Patent Application Laid-Open No. 2011-39844 and Japanese Patent Application Laid-Open No. 2012-37934, the inspector M is photographed with a camera, and the height is obtained from the image data. The height up to the pupil Pe in an upright state) may be estimated, or the line of sight of the inspector M may be recognized to directly measure the line of sight. Alternatively, the eye height of the inspector M is stored in advance, and when entering the work scaffold 5a, by reading personal information for identifying the inspector M such as ID data, the eye height registered in advance is obtained. You may make it acquire. In this case, the reader that acquires personal information is the information acquisition means of the present invention.

  In the following, for the sake of convenience, a case where the three transmissive optical sensors 11 are arranged at a pitch of 10 cm will be described as an example. However, the photosensor array 10b may be composed of an array of four or more transmissive photosensors 11, and the transmissive photosensors 11 may be arranged at a pitch shorter than 10 cm.

  FIG. 2 shows an example of the height classification gate 10. In the height classification gate 10 shown in the figure, the average height of the adult male is set as the standard height level L2 between the second and third from the bottom, and the low height level L1 is set between the first and second. In addition, when the third transmissive optical sensor 11 from the bottom is blocked, the height level L3 is set. Note that this height level division is an example, and is not limited to this. The height level may be further divided by arranging a large number of optical sensors 11.

  Further, as shown in FIG. 1, a passage detection gate 12 as a passage detection means is disposed at the upstream end of the work scaffold 5a. The passage detection gate 12 detects whether or not preset portions P1 to P4 (see FIG. 5) of the body shell 4 that passes therethrough have passed, and a conveyor 2 that transports the body shell 4 is provided. A pair of opposed sensor posts 12a and 12b are erected on the floor surface FL at a position sandwiching the body shell 4 that is being transferred. Furthermore, a projector row 12c and a light receiver row 12d are disposed on the opposing surfaces of the sensor posts 12a and 12b. As shown in FIG. 5, the projector row 12c and the light receiver row 12d are composed of a projector (first to ninth projectors 13a to 13i in the figure) and a light receiver constituting a plurality of transmission type photosensors using phototubes or the like. (In the figure, the first to ninth light receivers 14a to 14i) are configured, and the pair of projectors 13a to 13i and the light receivers 14a to 14i are arranged at a predetermined pitch in the vertical direction from the bottom. ing. In FIG. 5, for easy understanding, the projectors 13 a to 13 i and the light receivers 14 a to 14 i are illustrated facing the body shell 4 side.

  The passage detection gate 12 detects whether or not the predetermined portions P1 to P4 of the body shell 4 that are different for each vehicle type have passed predeterminedly, based on whether or not the light receivers 14a to 14i are shielded from light. Therefore, strictly speaking, the light receivers 14a to 14i serve as passage detection means of the present invention.

  As shown in FIG. 5, in the present embodiment, the first to ninth light receivers 14 a to 14 i use the first to ninth light receivers 14 a to 14 i to approximately the central portion P <b> 1 in the height direction of the bumper beam 4 h provided at the front portion of the body shell 4, and the front fender panel 4 b. The passage of the upper part P2, the front end part P3 of the roof panel 4d, and the rear end part P4 is detected. Since the heights of the parts P1 to P4 of the body shell 4 are different for each vehicle type, in this embodiment, the characteristic part of the body shell 4 transferred on the conveyor 2 is photographed, and the vehicle type is identified from the image. Yes. A camera 15 as a type information acquisition unit that captures this characteristic portion and acquires type information is disposed on the opposite side of the scaffold lifting device 5 with the conveyor 2 interposed therebetween.

  Further, the camera 15 performs photographing by using an ON signal of the passage detection switch 16 as a trigger. As shown in FIG. 3, in this embodiment, as the characteristic part of the body shell 4 photographed by the camera 15, the shape of the fuel lid 4f that is different for each vehicle type is selected. This characteristic part may be another part. On the other hand, the passage detection switch 16 is a limit switch, and detects the passage of the arch portion 4j provided on the wheel house formed on the front fender panel 4b on the side door panel 4c side, and outputs an ON signal.

  As shown in FIG. 4, the angle of view of the camera 15 is adjusted so that all the vehicle lids 4 f moving on the conveyor 2 can be photographed in synchronization with the ON signal of the passage detection switch 16. The passage detection switch 16 detects the passage of the arch portion 4j of the wheel house and outputs an ON signal at an earlier stage than the vehicle-specific optical sensor Sen1 described later detects the passage of the bumper beam 4h.

  The light receivers 11b of the height classification gate 10 described above, the light receivers 14a to 14i provided in the sensor post 12b, and the camera 15 are connected to the input side of a lift control unit 21 as lift control means. Further, a motor actuator 5 c of the scaffold lifting device 5 and a drive motor 8 b of the height adjusting device 8 are connected to the output side of the lifting control unit 21.

  The elevation control unit 21 is composed of a well-known microcomputer and its peripheral devices. Based on the signal from the light receiver 11b of the height classification gate 10, the elevation control unit 21 determines the height levels L1 to L3 of the inspector M who performs the defect inspection. The eye level HE of the inspector M is estimated by subtracting a predetermined value from each of the height levels L1 to L3. Further, the elevating control unit 21 reads the image data transmitted from the camera 15, identifies the fuel lid 4f by pattern matching with the image data of the fuel lid 4f registered in advance, and sets the corresponding parts P1 to P4 of the vehicle type. The height data is read, and the light receivers 14a to 14i that are closest to the height of the respective parts P1 to P4 and lower than the respective parts P1 to P3 are selected from the light receiver row 12d provided in the sensor post 12.

  That is, the light receivers 14a to 14i are grouped corresponding to the parts P1 to P4 that detect passage, the first to third light receivers 14a to 14c are for detecting the passage of the bumper beam 4h, The sixth light receivers 14d to 14f are for detecting passage of the upper part P2 of the front fender panel 4b, and the seventh to ninth light receivers 14g to 14i are for detecting passage of the front end portion P3 and the rear end portion P4 of the roof panel 4d. It is set for.

  Therefore, the first to third light receivers 14a to 14c, the fourth to sixth light receivers 14d to 14f, and the seventh to ninth light receivers 14g to 14i are arranged at a constant pitch for each group, and the lifting control unit 21, one light receiver from each group (first to third light receivers 14a to 14c, fourth to sixth light receivers 14d to 14f, and seventh to ninth light receivers 14g to 14i) for each vehicle type. It selects and specifies as vehicle classification optical sensors Sen1-3.

  Based on the signals from the selected vehicle-specific optical sensors Sen1 to Sen3, the passages of the parts P1 to P4 of the body shell 4 are detected, and the eye line (pupil Pe) of the inspector M and the surface to be inspected of the body shell 4 are detected. The scaffold lifting / lowering device 5 is moved up and down so that the height h between them becomes substantially constant.

  Specifically, each control process executed by the above-described lifting control unit 21 is executed according to the routines shown in FIGS. That is, the height level classification process of the inspector M is executed in accordance with the height level classification process routine shown in FIG. 9, and the height adjustment for adjusting the elevation of the scaffold lifting device 5 and the height of the illuminator 6 is performed. The height adjustment process of the apparatus 8 is executed according to the illumination height / scaffolding control routine shown in FIGS.

  First, the height level division processing routine shown in FIG. 9 will be described. In step S1, the process waits until a blocking signal is detected from the light receiver 11b of the transmissive optical sensor 11 constituting the optical sensor row 10b of the height classification gate 10.

  That is, when the inspector M gets into the work scaffold 5a from the entrance 5d in order to perform a defect inspection on the painted surface of the body shell 4 that has been transferred to the inspection station 1 by the conveyor 2 and has been coated in a predetermined manner, The worker M passes the height division gate 10 provided on the entrance 5d side of the work scaffold 5a while wearing a cap and wearing shoes. Then, as shown in FIGS. 2A and 2B, the light reception to any one of the light receivers 11b provided in the plurality of transmission type optical sensors 11 is blocked according to the height of the inspector M.

  When the lifting / lowering control unit 21 receives the cutoff signal transmitted from any of the light receivers 11b, the program proceeds to step S2, and the height of the inspector M is determined according to the light receiver 11b that transmits the cutoff signal. It is checked whether the height level is Li (i = 1, 2, 3). That is, as shown in FIG. 2 (a), when the cutoff signals from the first and second light receivers 11b from the bottom are received, the standard height level L2 is set. Also, as shown in FIG. 5B, when the cutoff signal is received only from the first light receiver 11b from the bottom, the low height level L1 is set. Further, when the cutoff signal is received from all the light receivers 11b, the height level L3 is set.

  In step S3, the eye height HE of the inspector M corresponding to the set height level Li (i = 1, 2, 3) is calculated, and the routine is terminated. The processing in steps S2 and S3 corresponds to the eye height calculation means of the present invention.

  In the present embodiment, a specific height is set for each height level Li (i = 1, 2, 3). For example, three transmissive optical sensors 11 are arranged at a pitch of 10 cm, and the standard height level L2 is set. Is set to 170 [cm], the low height level L1 = 160 [cm] and the high height level L3 = 180 [cm]. Then, the eye height HE of the inspector M is obtained by subtracting the distance from the top of the average adult male to the eye position from each of the height levels L1 to L3.

  Since the height classification gate 10 only detects whether or not the transmission type optical sensor 11 is blocked by passing the inspector M, the inspector M does not stop at the height classification gate 10 one by one. You can ride 5a.

  Next, the illumination height / scaffold raising / lowering control routine shown in FIGS. 10 to 13 will be described. In step S11, this routine waits until the passage detection switch 16 detects passage of the arch portion 4j of the front fender panel 4b, that is, until an ON signal is received.

  When the ON signal from the passage detection switch 16 is received, the process proceeds to step S12, the camera 15 is operated, and shooting is performed at a predetermined angle of view. When the passage detection switch 16 detects the passage of the arch portion 4j of the front fender panel 4b, the camera 15 faces the vicinity of the fuel lid 4f of the rear quarter panel 4e, and image data obtained by photographing the fuel lid 4f is captured. It is transmitted to the elevation control unit 21.

  Thereafter, when the process proceeds to step S13, as shown in FIG. 4, the fuel lid 4f of the body shell 4 is changed by pattern matching between the image photographed by the camera 15 and all the template images T of the fuel lid registered in advance for each vehicle type. The vehicle type (type) of the body shell 4 is specified from the characteristic shape of the fuel lid 4f. Note that the processing in this step corresponds to the type specifying means of the present invention.

  And it progresses to step S14, it is investigated whether the vehicle type was specified by the vehicle type identification process of step S13, and when specified, it progresses to step S15, and when it cannot be specified, it jumps to step S48.

  When it is determined that the vehicle type has been specified and the process proceeds to step S15, the vehicle body data of the vehicle type is acquired from the storage means in which various vehicle body data are stored. Note that the processing in this step corresponds to the data acquisition means of the present invention.

  The vehicle body data includes three vehicle-specific optical sensors Sen1 to Sen3 selected from height data of a predetermined part of the surface to be inspected of the body shell 4 and each of the light receivers 14a to 14i constituting the sensor array 12d. Is included. As shown in FIG. 5, in this embodiment, as this height data, the height a from the floor surface FL to the upper part in the vicinity of the front and rear center of the front fender panel 4b, and the height from there to the vicinity of the front end of the roof panel 4d. b, height c from the vicinity of the bent portion of the rear gate 4g (the sedan type trunk lid) to the floor surface FL, and height d from the floor surface FL to the rear end of the body shell 4 are stored. Further, the symbol PA is a height from the height a to about ½ of the front pillar 4k, and is set for each vehicle type. Alternatively, the height PA may be a fixed value. In addition, the selection procedure of the vehicle type optical sensors Sen1 to 3 will be described later.

  Thereafter, when the process proceeds to step S16, the initial scaffold height HFin is set based on the eye height HE of the inspector calculated by the above-described height level processing routine. As shown in FIGS. 14 to 16, in the present embodiment, a scaffold height HF described later is set with reference to the floor surface FL. Therefore, the initial scaffold height set to make the reference height h of the line of sight from the surface to be inspected substantially constant without changing the height of the inspector M is HFin, and the standby position of the work scaffold 5a is the floor surface. The height is set to the same height as FL, and a value obtained by subtracting the eye height HE from the reference height h is set (HFin ← h−HE). Note that the processing in this step corresponds to the initial scaffold height calculation means of the present invention.

  This reference height h is statistically determined. When the height from the line of sight of the inspector M to the surface to be inspected is changed variously and the defect detection rate [%] on the surface to be inspected is examined, A shape close to a normal distribution as shown in FIG. 8 was obtained. In this embodiment, the height from the surface to be inspected to the area where the defect detection rate is 90 [%] is specified, the center value is specified as the reference height h, and h ± σ is set within the allowable range. ing. Accordingly, the height from the surface to be inspected to the line of sight should be within the range of h ± σ.

  Then, it progresses to step S17 and the height HL of the illuminator 6 is set. As shown in FIG. 6, the illuminator 6 is supported by the work scaffold 5 a via the stand frame 7, and as shown in FIG. 7, the inspector M and the illuminator 6 are in the width direction of the body shell 4. It is set at a substantially symmetrical position across the center (W1 = W2). Therefore, by setting the height of the illuminator 6 to the same height as the eye height HE of the inspector M (HE = HL), the illuminator 6 is projected as shown in FIGS. The incident angle θ1 of the illumination light is equal to the angle θ2 of the line of sight of the inspector M (θ1 = θ2). Therefore, the reflected light of the illumination light from the surface to be inspected is incident on the line of sight of the inspector M. Therefore, visibility is improved.

  Therefore, the elevation control unit 21 obtains the illumination height HL of the illuminator 6 that is equal to the eye height HE of the inspector M, and calculates the movement amount of the expansion / contraction part 8a provided in the height adjusting device 8 from this value. . In step S18, a drive signal corresponding to the amount of movement is output to the drive motor 8b of the height adjustment device 8, and the height of the illuminator 6 is adjusted by extending / contracting the expansion / contraction part 8a. 7 corresponds to the height from the floor surface FL to the surface to be inspected of the body shell 4, that is, the height from the portions P1 to P4 in FIG. H1 is the height from the floor surface FL to the eye of the inspector M, and h2 is the height from the floor surface FL to the illuminator 6. Further, the processing in steps S17 and S18 described above corresponds to the illumination drive signal output means of the present invention.

  Next, when proceeding to step S19, the three vehicle-specific optical sensors Sen1 to 3 for detecting the addition of the specific part of the body shell 4 stored in the vehicle body data read in step S15 described above are specified, Set. In other words, the first vehicle-specific optical sensor Sen1 is set from the first to third light receivers 14a to 14c that is closest to the heightwise central portion P1 of the bumper beam 4h. Further, the second vehicle-specific optical sensor Sen2 is selected from the fourth to sixth light receivers 14d to 14f that is closest to the upper part P2 of the front fender panel 4b and lower than the upper part P2. . Further, the third vehicle-specific optical sensor Sen3 is closest to the front end portion P3 of the roof panel 4d among the seventh to ninth light receivers 14g to 14i, and is lower than the front end portion P3, and the rear end portion P4. The one that can detect the passage of is selected.

  For example, FIG. 5 shows a SUV (Sport Utility Vehicle) type body shell 4. For this body shell 4, a second light receiver 13 b is set as the first vehicle type optical sensor Sen 1. (Sen1 ← 13b), the fifth light receiver 13e is set as the second vehicle type light sensor Sen2 (Sen2 ← 13e), and the eighth light receiver 13h is set as the third vehicle type light sensor Sen3 (Sen3 ← 13h).

  Therefore, when the body shell is a sedan type, for example, the first light receiver 13a is set as the first vehicle type light sensor Sen1 (Sen1 ← 13a), and the fourth light receiver 13d is set as the second vehicle type light sensor Sen2. Then, the seventh light receiver 13g is set as the third vehicle type optical sensor Sen3 (Sen3 ← 13g). When the body shell 4 is a minivan type, for example, the third light receiver 13c is set as the first vehicle type light sensor Sen1 (Sen1 ← 13c), and the sixth light receiver 13d is set as the second vehicle type light sensor Sen2. Is set (Sen2 ← 13f), and the ninth light receiver 13i is set as the third vehicle type optical sensor Sen3 (Sen3 ← 13i). Note that the processing in step S19 corresponds to the optical sensor specifying means of the present invention.

  Then, it progresses to step S20 and waits until the 1st vehicle type optical sensor Sen1 detects passage of the bumper beam 4h. When the first vehicle-specific optical sensor Sen1 is shielded from light, it is determined that the bumper beam 4h is passing through the passage detection gate 12, and the process proceeds to step S21. In step S21, it is checked whether or not the second vehicle type optical sensor Sen2 is shielded from light. If light is received, the process proceeds to step S22. If it is shielded from light, it is determined that the sensor is abnormal, and the process jumps to step S48. To do.

  In step S22, it is checked whether or not the third vehicle type optical sensor Sen3 is shielded from light. If light is received, the process proceeds to step S23. If it is shielded from light, it is determined that the sensor is abnormal, and the process jumps to step S48. To do.

  Proceeding to step S23, the scaffold height HF is a value obtained by adding a height a (the height from the floor surface FL to the upper part of the front fender panel 4b in the vicinity of the front and rear centers) set in advance to the initial scaffold height HFin. (HF ← HFin + a), the process proceeds to step S24, and the driving signal corresponding to the difference ΔHF obtained by subtracting the scaffold height HF (n-1) obtained immediately before from the scaffold height HF calculated this time is used as the scaffold lifting device. 5 to the motor actuator 5c. Note that (n-1) indicates the immediately preceding value, and in step S23, since the scaffold height HF (n-1) has not been obtained, HF (n-1) = 0. The scaffold height HF is set based on the floor surface FL.

  Then, the work scaffold 5a starts to rise from the standby position shown in FIG. 14 (a), and during that time, the body shell 4 moves in the direction of the work scaffold 5a while being mounted on the carriage 3, The inspector M standing on the scaffold 5a performs a defect inspection on the painted surface in the vicinity of the front end of the front hood 4a from the front end of the body shell 4 as the work scaffold 5a rises.

  When the work scaffold 5a reaches the scaffold height HF (= ΔHF) (see FIG. 14B), the process proceeds to step S25 to check whether the second vehicle type optical sensor Sen2 is shielded from light. The state in which the light shielding of the second vehicle type optical sensor Sen2 is detected is a state in which the vicinity of the middle of the front hood 4a passes through the passage detection gate 12. If the light is blocked, the process proceeds to step S26. If the light is received, the process waits until the light is blocked.

  When it is determined that the second vehicle type light sensor Sen2 is shielded and the process proceeds to step S26, it is checked whether or not the first vehicle type light sensor Sen1 is shielded, and if it is shielded, the process proceeds to step S27. If light is received, it is determined that the sensor is abnormal, and the process jumps to step S48. When the process proceeds to step S27, it is checked whether or not the third vehicle type optical sensor Sen3 is shielded from light. If the light is received, the process proceeds to step S28. If it is shielded from light, it is determined that the sensor is abnormal, and the process jumps to step S48. To do.

  When the process proceeds from step S27 to step S28, the height PA near the middle position of the front pillar 4k is added to the scaffold height HF (n-1) calculated in step S23 to obtain a new scaffold height HF. Set (HF ← HF (n-1) + PA). In step S29, a drive signal corresponding to the difference ΔHF obtained by subtracting the scaffold height HF (n-1) obtained immediately before from the scaffold height HF calculated this time is sent to the drive motor 8b of the height adjusting device 8. Output. The height PA to the vicinity of the intermediate position of the front pillar 4k is stored in the vehicle body data read this time. Alternatively, the height PA may be a fixed value.

  Then, the work platform 5a is further raised by the height PA, and during that time, the inspector M visually observes the painted surface from the vicinity of the rear portion of the front hood 4a to the front pillar 4k as the body shell 4 moves. And perform defect inspection.

  If the work scaffold 5a has risen to the scaffold height HF (see FIG. 15 (a)), the process proceeds to step S30, where it is checked whether the third vehicle-type optical sensor Sen3 is shielded from light. Advances to step S31, and waits until the light is blocked in the light receiving state.

  When it is determined that the third vehicle type optical sensor Sen3 is shielded and the process proceeds to step S31, it is checked whether or not the first vehicle type optical sensor Sen1 is shielded, and if it is shielded, the process proceeds to step S32. If light is received, it is determined that the sensor is abnormal, and the process jumps to step S48. When the process proceeds to step S32, it is checked whether or not the second vehicle type optical sensor Sen2 is shielded from light. If the light is shielded, the process proceeds to step S33. If the light is received, it is determined that the sensor is abnormal, and the process jumps to step S48. To do.

  In step S33, a value obtained by subtracting the height PA (see FIG. 5) from the height b is added to the scaffold height HF (n-1) obtained immediately before to calculate a new height HF (HF = HF (n-1) + (b-PA)), the process proceeds to step S34, and the drive corresponding to the difference .DELTA.HF obtained by subtracting the scaffold height HF (n-1) obtained immediately before from the scaffold height HF calculated this time. The signal is output to the motor actuator 5 c of the scaffold lifting device 5. Then, the work scaffold 5a is further raised from the current position by (b-PA). As the work scaffold 5a rises, the eye height HE (see FIG. 6) of the inspector M is exposed to the vicinity of the reference height h from the painted surface of the roof panel 4d, as shown in FIG. 15 (b). .

  Then, when the work scaffold 5a rises to the scaffold height HF obtained in step S33 described above, the process proceeds to step S35, where it is checked whether or not the third vehicle type optical sensor Sen3 is receiving light. The process proceeds to step S36, and if the light is blocked, the process waits until the light is received. In this state, as shown in FIGS. 15 (b) to 16 (a), the ascent of the work scaffold 5 a stops and the body shell 4 is placed on the carriage 3 across the front of the inspector M. The inspector M visually inspects the painted surface of the moving roof panel 4d to inspect the defect.

  When it is determined that the third vehicle type optical sensor Sen3 is receiving light and the process proceeds to step S36, it is checked whether or not the first vehicle type optical sensor Sen1 is shielded from light, and if it is shielded, the process proceeds to step S37. If light is received, it is determined that the sensor is abnormal, and the process jumps to step S48. In step S37, it is checked whether or not the second vehicle type optical sensor Sen2 is shielded from light. If it is shielded, the process proceeds to step S38. If it is received, it is determined that the sensor is abnormal, and the process jumps to step S48. To do.

  The state in which the third vehicle type optical sensor Sen3 is switched from light shielding to light receiving is a state in which the vicinity of the rear end of the roof panel 4d has passed through the passage detection gate 12, as shown in FIGS. The worker M visually inspects the painted surface from the vicinity of the rear part of the roof panel 4d to the vicinity of the upper part of the rear gate 4g to inspect the defect.

  In step S38, the value obtained by subtracting the height c from the value obtained by adding the heights a and b is subtracted from the previous scaffold height HF (n-1) (see FIG. 5) to obtain a new scaffold height. The height HF is calculated (HF = HF (n-1)-(a + b-c)), the process proceeds to step S39, and the last calculated scaffold height HF (n-1) is subtracted from the calculated scaffold height HF. A drive signal corresponding to the difference ΔHF is output to the drive motor 8 b of the height adjusting device 8.

  The difference ΔHF is a negative value, and the motor actuator 5c rotates backward to lower the work scaffold 5a. As a result, as shown by a one-dot chain line in FIG. 16 (a), the line of sight of the inspector M gradually decreases as the work platform 5a descends, so that the coating surface from the vicinity of the upper portion of the rear gate 4g to the vicinity of the center in the height direction is reduced. Visual inspection for defects.

  Then, after reaching the scaffold height HF calculated in step S38 described above, the process proceeds to step S40, where it is determined whether the second vehicle-type optical sensor Sen2 is receiving light, and if it is receiving light, the process proceeds to step S41. When the light is blocked, the process waits until the light is received. When the light is received, the process proceeds to step S41. As shown in FIG. 5, in the state where the second vehicle-specific optical sensor Sen2 is switched from light shielding to light receiving, the defect inspection up to the vicinity of the height c is completed.

  Then, when proceeding to step S41, it is checked whether or not the first vehicle-type optical sensor Sen1 is shielded from light. If it is shielded, the process proceeds to step S42. , Jump to step S48. When the process proceeds to step S42, it is checked whether or not the second vehicle type optical sensor Sen2 is shielded from light. If the light is received, the process proceeds to step S43. If the light is shielded, it is determined that the sensor is abnormal, and the process jumps to step S48. To do.

  In step S43, the difference between the heights c and d is subtracted from the scaffold height HF (n-1) obtained immediately before (see FIG. 5) to calculate a new scaffold height HF (HF = HF (n-1)-(cd)), the process proceeds to step S44, and the drive signal corresponding to the difference .DELTA.HF obtained by subtracting the scaffold height HF (n-1) obtained immediately before from the scaffold height HF calculated this time. Is output to the motor actuator 5 c of the scaffold lifting device 5. The difference ΔHF is a negative value, and the motor actuator 5c rotates in the reverse direction to further lower the work scaffold 5a. As a result, the inspector M visually inspects the coating surface from the vicinity of the center of the rear gate 4g in the height direction to the lower portion to inspect the defect.

  Note that the processing in steps S23, S28, S33, S38, and S43 described above corresponds to the scaffold height calculation means of the present invention. Further, the processes in steps S24, S29, S34, S39 and S44 described above correspond to the scaffold drive signal output means of the present invention.

  When the work scaffold 5a reaches the scaffold height HF obtained in step S43 described above, the process proceeds to step S45, where it is determined whether the first vehicle-type optical sensor Sen1 is receiving light. Advances to step S46, and if light is blocked, waits until light is received.

  When it is determined that the first vehicle type optical sensor Sen1 is receiving light and the process proceeds to step S46, it is checked whether or not the second vehicle type optical sensor Sen2 is receiving light. If it is received, the process proceeds to step S47. If the light is shielded, it is determined that the sensor is abnormal, and the process jumps to step S48. When the process proceeds to step S47, it is checked whether or not the third vehicle type optical sensor Sen3 is receiving light. If it is receiving light, the process proceeds to step S49. If it is blocked, it is determined that the sensor is abnormal, and the process branches to step S48. To do.

  In step S48, the inspector M is informed that a detection error has occurred in the passage detection gate 12 by display on the monitor, lighting of the indicator lamp, sound from the speaker, etc., and the process proceeds to step S49.

  When the process proceeds from step S47 or step S48 to step S49, the elevation control unit 21 drives the motor actuator 5c to return the work scaffold 5a to the standby position shown in FIG. 4 is finished, and waits until the next body shell 4 turns on the passage detection switch 16.

  In addition, when the inspector M finds a defect on the painted surface, the inspector M marks the defective portion and performs repair work on the corresponding portion in the next repair process. In addition, for the body shell 4 in which the error is notified, the fact that it is an inspection error is displayed in a predetermined manner, and a defect inspection is separately performed in the next repairing process or the like.

  As described above, in this embodiment, the eye height HE of the inspector M is obtained, and based on the eye height HE, the eye of the worker M is previously set on the painted surface of the body shell 4 that moves on the conveyor 2. Since the work scaffold 5a is automatically raised and lowered to the set reference height h, the height of the line of sight of the inspector M with respect to the painted surface is substantially constant, and pass / fail judgment by defect inspection of the inspector M is performed. Variations can be minimized. As a result, a high defect detection rate can be stably obtained. Further, it is not necessary for the inspector M to raise and lower the work scaffold 5a one by one according to the height of the painted surface as in the prior art, and the work efficiency is improved.

  Furthermore, since the height of the illuminator 6 disposed on the side facing the inspector M across the body shell 4 is also adjusted in accordance with the height of the eye of the inspector M, it is possible to always obtain stable illumination. And a higher defect detection rate can be obtained.

  The present invention is not limited to the above-described embodiment. For example, the type of the body shell 4 may be read from a bar code, a two-dimensional code, or an IC tag in which vehicle body information is stored. In this case, a bar code, a two-dimensional code, or an IC tag is attached to the cart 3 or the body shell 4 and is read by the camera 15, a code reader, or a tag reader. In this case, the code reader or tag reader is the type information acquisition means of the present invention.

  Further, the workpiece is not limited to the body shell of the vehicle body, and may be a completed vehicle or the like as long as it is transported on the conveyor 2 or may be other than the vehicle. Further, the surface to be inspected is not limited to the painted surface.

1 ... Inspection station,
2 ... Chain conveyor,
3 ... cart,
4 ... Body shell,
4a ... Front hood,
4b ... Front fender panel,
4c ... side door panel,
4d ... Roof panel,
4e ... Rear quarter panel,
4f ... Fuel lid,
4g ... Rear gate,
4h ... Bumper Beam,
4j ... Arch part,
4k ... Front pillar,
5 ... Scaffolding lifting device,
5a ... Working scaffold,
5b ... Lifting lifter,
5c: motor actuator,
5d ... Entrance,
6 ... Illuminator,
6a ... lights,
7 ... Stand frame,
7a ... hanging part,
8 ... Height adjustment device,
8a ... telescopic part,
8b ... Drive motor,
10 ... height division gate,
10a ... gate body,
10b ... optical sensor array,
11: Transmission type optical sensor,
11a ... Floodlight,
11b ... Receiver
12 ... Pass detection gate,
12a, 12b ... sensor post,
12c: Floodlight row,
12d: Receiver array,
13a to 13i ... Floodlight,
14a to 14i ... light receivers,
16 ... Pass detection switch,
21 ... Elevation control unit,
FL ... floor,
GL ... Ground surface,
HE ... Gaze height,
HL ... Lighting height,
ΔHF ... difference,
L1-L3 ... Height level,
M ... inspector,
P1 ... Central part,
P2 ... Upper part
P3 ... tip,
P4 ... rear end,
Pe ... Pupil,
Sen1 ... 1st vehicle type optical sensor,
Sen2 ... second vehicle type optical sensor,
Sen3 ... Third vehicle type optical sensor,
T ... Template image,
θ1 ... incident angle,
θ2 ... Angle

Claims (6)

A work platform where an inspector stands on one side of the line for moving the workpiece;
Scaffold lifting and lowering means for lifting and lowering the work scaffold;
Individual information acquisition means for acquiring individual information on the eye height of the inspector;
Type information acquisition means provided on the upstream side of the work scaffold to acquire type information of the workpiece;
Passage detection means provided on the upstream side of the work scaffold to detect passage of a specific part of the workpiece;
Elevating control means for controlling the elevating operation of the scaffold elevating means,
The elevation control means includes
Eye height calculating means for obtaining eye height based on the individual information of the inspector acquired by the individual information acquiring means;
A type specifying unit for specifying the type of the work based on the type information acquired by the type information acquiring unit;
Based on the type information specified by the type specifying means, data acquisition means for acquiring height data of the specific part of the workpiece set in advance;
When the passage detection unit detects the passage of a specific part of the workpiece acquired by the data acquisition unit, the height of the surface to be inspected of the specific part, the eye height obtained by the eye height calculation means, and the specific part A scaffold height calculating means for calculating a scaffold height of the work scaffold based on a preset reference height to the eyes of the worker;
A scaffold lift control device comprising: a scaffold drive signal output means for outputting a drive signal corresponding to the scaffold height calculated by the scaffold height calculating means to the scaffold lift means. Illuminating means for illuminating the surface to be inspected of the workpiece;
A height adjustment means for adjusting the illumination height of the illumination means,
The elevation control means includes an illumination drive signal output means for outputting a drive signal for operating the adjustment means so that illumination light incident on the surface to be inspected from the illumination means is reflected on the line of sight of the inspector. The scaffold lifting control apparatus according to claim 1, further comprising: The scaffold raising / lowering control apparatus according to claim 2, wherein a stand that supports the illumination unit extends from the work scaffold. The said individual information acquisition means is provided in the entrance side of the said working scaffold, and acquires the individual information regarding the said eye-line height when the said inspector passes, The any one of Claims 1-3 characterized by the above-mentioned. The scaffold raising / lowering control apparatus described in 1. The type information acquisition means is a camera that captures a characteristic part of the workpiece as the type information,
The scaffold lifting control device according to any one of claims 1 to 4, wherein the type specifying unit specifies the type of the workpiece based on a feature portion on an image photographed by the type information acquisition unit. . The passage detection means is composed of a sensor array in which a plurality of optical sensors are arranged in a vertical direction,
The elevation control means specifies an optical sensor that detects passage of a part corresponding to the height data from the sensor row based on height data of the specific part of the workpiece acquired by the data acquisition means. The scaffold raising / lowering control apparatus according to claim 1, further comprising: an optical sensor specifying unit.

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