JPS62198704A - Measuring instrument for bimetal gap of lighting tube - Google Patents

Abstract

PURPOSE:To decide accurately whether a lighting tube is normal or not by converting image data from an image sensor into binary data and finding the minimum value of gap data from a variable counter and a dot counter. CONSTITUTION:Image data from an image sensor 6 which picks up the image of an area including the flank of the bimetal contact piece 4 of the lighting tube and a fixed electrode 2 is converted by an A/D converter 7 into binarization data. Then, (m) dots in an X direction where the gap between the fixed electrode 2 and contact piece 4 can be detected and (n) dots in a Y direction perpendicular to it are set as to the image dot data. Then, X- directional high and low level changes of the data within the extraction range are counted by the variable counter 84 and dots of data in the state of a counted value set previously by the counter 84 are counted by a dot counter 85; when the value of the counter 84 exceeds a set value, the counted value of the counter 85 is led out as gap data. This data is compared in dot units to decide whether the lighting tube is normal or not from the found minimum value and a preset permissible value.

Description

DETAILED DESCRIPTION OF THE INVENTION [Object of the Invention] (Industrial Application Field) The present invention relates to a lighting tube bimetal gap measuring device that measures the gap between a bimetal contact piece and a fixed pole in a lighting tube and determines its quality.

(Prior art) A lighting tube has two legs called wells extending from the bottom of the mount, one of which constitutes a fixed pole, and one end of a bimetal contact piece is attached to the other well. It is joined by resistance welding, for example, with its surface facing the fixed pole. In this case, the well and the bimetal contact piece are automatically joined on the lighting tube manufacturing line, but if there is a misalignment in the machine or the machine is not properly adjusted, the bimetal contact piece may not be joined correctly. As a result, the bimetallic contact piece may come into contact with the fixed pole, or conversely may come too far apart.

For this reason, it is necessary to inspect the degree of the gap between the bimetal contact piece and the fixed pole, but in the past, the gap was visually inspected after the lighting tube was manufactured to determine whether it was good or bad.

(Problem to be solved by the invention) However, when gap inspection is performed visually in this way, inspection is troublesome because it requires a skilled person, and there is a risk that there will be many erroneous inspections and a large number of defective products will be produced. there were. For this reason, the inventor of the present invention imaged the gap between the fixed pole of the lighting tube and the bimetallic contact piece using an image sensor, processed it into a binary image, detected the gap by the number of dots in the image dot data, and detected the gap between the fixed pole and the bimetal contact piece of the lighting tube. We developed something that can automatically determine pass/fail and filed an application first. (Japanese Patent Application No. 60-244308) However, in this earlier application, there is a restriction that the fixed pole and bimetal contact piece must always be within the correct inspection range, making it difficult to position the image sensor relative to the lighting tube position. There is a problem.

This invention was made in view of the above points, and its purpose is to automatically inspect the gap between the bimetal contact piece and the fixed pole in the lighting tube on the production line, and to accurately determine whether it is good or bad. It is an object of the present invention to provide a bimetal gap measuring device for a lighting tube, which can improve practicality by allowing relatively easy positioning of an image sensor with respect to the lighting tube.

[Structure of the Invention] (Means for Solving the Problems) This invention provides a bimetallic contact piece and a fixed pole of a lighting tube with l1
The image data obtained from the image sensor is binarized for each dot, and changes in the high level and low level in the X direction of the dot data in a preset extraction range of the binarized image dot data are calculated. A variable counter is used to count the number of dots, and when the count value of the variable counter is at a preset value, the number of dots is counted using the dot counter and used as gap data, and when this process is completed for all rows in the Y direction. The minimum value is determined, and the quality of the lighting tube is determined based on whether the minimum value is within the allowable value.

(Function) In the present invention having such a configuration, a variable counter counts changes in high level and low level in the X direction in dot data that falls within the extraction range of the binarized image dot data, and Since the dot counter counts the number of dots when the count value of is the set value, for example, when measuring by arranging the fixed pole, bimetal contact piece, and well with fixed bimetal contact piece in that order, the fixed pole, The image data corresponding to the bimetal contact piece is set to high level, the image data corresponding to the space part is set to low level, the variable counter starts counting from the first time a high level signal is input, and the signal level changes thereafter. If the force is increased every time the variable counter counts 2, it will always indicate the space between the fixed pole and the bimetal contact piece, that is, the gap, and the image dot data at this time will be By counting the number of dots with a dot counter, the gap in one row can be measured. By measuring this for all rows and finding the minimum value, the minimum gap between the fixed pole and the bimetal contact piece can be found.
Therefore, if this minimum gap is within the allowable range, it can be determined as a good product, and if it is outside the allowable range, it can be determined as a defective product. That is, even if the fixed pole is completely within the extraction range or overlaps the edge of the extraction range, the gap can always be accurately measured as long as the gap portion is within the extraction range.

(Example) As shown in FIGS. 1 and 2, a fixing tube 2 consisting of wells and another well 3 are extended at a predetermined interval from the bottom of a lighting tube mount 1. In one step of the production line, one end of the bimetallic contact piece 4 facing the fixed pole 2 of the tool 3 is joined by, for example, resistance welding. The bimetal contact piece 4 has an inverted V shape with respect to the fixed pole 2, and a predetermined gap is provided between it and the fixed pole Ii2.

Light is irradiated from the light source 5 to the side surface of the bimetal contact piece 4 to the lighting tube member to which the bimetal contact piece 4 is joined in this manner,
The reflected light is received by a television camera 6 serving as an image sensor. This camera 6 is arranged so as to image an area including at least the side surface of the bimetal contact piece 4 and the fixed pole 2 with respect to the lighting tube member flowing on the manufacturing line.

21tl of analog image data output from the television camera 6! A/D converter 7 configuring the conversion circuit
The image is converted to 2fII and converted into digital image dot data. The image dot data from the A/D converter 7hl is transferred to the CPLJ, a ROM in which program data for interrogating each part is stored, and a RAM in which various memories and counters for data processing are formed.
, an I10 board, etc., are input to a microcomputer 8. RAM of this microcomputer 8
As shown in FIG. 4, an HL flag 81, an X direction counter 82, a Y direction counter 83, a variable counter 84, a dot counter 8s, a gap memory 86, etc. are provided.

The microcomputer 8 is provided with means for extracting mxn dot data and means for determining quality as controlled by the CPU, and when it takes in the iii* dot data from the A/D converter 7, it determines the fixed pole 2 and the fixed pole 2 from that data. The direction in which the gap with the bimetal contact piece 4 can be detected is the X direction, and the direction perpendicular to this is the Y direction, and dot data is extracted in an extraction range of m dots in the X direction and n dots in the Y direction. . In other words, the extraction range is n rows of m dots.

The microcomputer 8 performs the processing shown in FIG. First, for example, the driver j counter 85 is set to 8 bits, and r255J, which is the maximum countable value of the counter, is temporarily set in the gap memory 86, and the Y direction counter 83 is set to zero. Subsequently, the X direction counter 82, variable counter 84, and dot counter 85 are each set to zero, and the HL flag 8 is set to zero.

The dot data extracted in this state is stored in RAM,
Next, it is checked whether the m dot on the n-1th line is at H level or L level. For example, assuming that the mxn dot extraction range contains image dot data as shown in FIG. 3, all dots are at the L level in the shaded dark area A. Furthermore, at this point, the IL flag 81 and the variable counter 84 are at rOJ, so the X direction counter 82 only counts the number of dots. When entering the bright area O corresponding to the fixed pole 2, the dot data rumor changes from L level to H level, and since the HL flag 81 is rOJ, the variable counter 84
is incremented by +1, and the HL flag 81 becomes rIJ. Further, the X-direction counter 82 continues to count the number of dots. After that, when the dot data enters the shaded area C corresponding to the gap, the dot data changes from the H level to the L level, and since the HL flag 81 is "1", the variable counter 84 is incremented by 1, and the HL flag 81 becomes "0". At this point, the variable counter 84 becomes "2", so the dot counter 8s starts counting the number of dots.

Further, the X direction counter 82 continues to count the number of dots.

Furthermore, when entering the bright area 2 corresponding to the bimetal contact piece 4, the dot data changes from the L level to the H level, and since the HL flag 81 is "0", the variable counter 84
is incremented by +1, and the HL flag 81 becomes "1". In this way, the operation of counting the number of dots by the dot counter 8s is stopped.

Also, the X-direction counter 82 continues to count the number of dots at this time as well. Further, when entering the dark area E, the dot data changes from the H level to the L level, and the HL flag 81 is "1", so the variable counter 84 is incremented by 1 and the HL flag 81 becomes "0". When the count value of the X-direction counter 82 reaches "96" while performing such processing, it is then checked whether the count value of the variable counter 84 is within the range of "3" to "6". If it is within this range, it is determined that the gap count by the dot counter 85 has been performed correctly, and the count value of the dot counter 8s is compared with the contents of the gap memory 86, and if the count value of the dot counter 85 is small, it is determined that the gap count is performed correctly. Gap memory 8 for the count value
Rewrite the contents of 6. Then, the content of the Y-direction counter 83 is incremented by 1, and the counter I-fil of the counter 83 is “9”.
The above-mentioned process is repeated until reaching 6''.

When the count value of the Y-direction counter 83 reaches "96", it is checked whether the contents of the gap memory 86 are within the preset tolerance range of a and b.
If it is between a and b, it is determined that the gap is at the correct interval and a non-defective product is determined. If it is outside the gap between a and b, it is determined that the gap is too narrow or too wide, a defective product is determined, and a reject signal is sent. Outputs Re. In the manufacturing line, a mechanism is driven by the reject signal Re to reject defective lighting tube members.

In this embodiment with such a configuration, if the fixed pole 2 and the bimetal contact piece 4 are correctly included in the extraction range as shown in FIG. is counted, and its minimum value can be found without any problem.

In addition, as shown in FIG. 6(a), there is a bright part opening corresponding to the fixed pole 2, a dark part C corresponding to the gap, and a bimetal contact piece 4.
When the bright area opening corresponding to the well 3, the dark area E, and the bright area corresponding to the other well 3 are included in the extraction range, the count 1 of the variable counter 84 becomes "1" at the first bright area opening,
In the next dark part C, it becomes "2", in the next light part it becomes "3", in the next dark part E, it becomes "4", and then in the next bright part it becomes "5".
”. At this time as well, when the count value of the variable counter 84 reaches "2", the dot counter 85 counts the width of the dark area C, and the X direction counter 82 counts "96".
'', the count value of the variable counter 84 is ``5'' and falls within the range of ``3'' to ``6'', so the dot counter 85 measures the gap and finally finds its minimum value. . Therefore, in this case as well, it is possible to accurately determine the quality of the lighting tube member.

In addition, as shown in FIG. 6(b), the first dark area A, the bright area opening corresponding to the fixed pole 2, the dark area C corresponding to the gap, the bright area opening and the dark area corresponding to a part of the bimetal contact piece 4. When E is within the extraction range, the count value of the variable counter 84 remains "0" at the first dark part A,
It becomes "1" at the next bright part, and becomes "2" at the next dark part. At this point, the dot counter 85 starts counting the number of dots in the gap. In this example, when the Y direction counter 83 is counting a small number close to "0" and when counting a large number close to "96j," the dot data corresponding to the bright area opening is not detected. The counter 85 continues counting until the X direction counter 82 counts "96".

However, when the X-direction counter 82 counts "96", the variable counter 84 is "2" and "3".
Since it is not within the range of .about.6, the count value of the dot counter 85 at this time is not compared with the contents of the gap memory 8B and is removed. Further, in the portion where dot data corresponding to the bright area opening is detected, when the bright area opening is detected, the count value of the variable counter 84 becomes "3", and the dot number counter by the dot counter 8s also ends.

After that, when the bright area opening is detected, the X direction counter 8
Even if the counter 82 finishes counting "96", the X-direction counter 82 continues to count "96" after detecting the dark area H.
Since the count value of the variable counter 84 is still "3" or "4" even after counting is completed, the count of the dot counter 85 at this time is judged to be valid and is compared with the contents of the gap memory 8S. The minimum value of the gap is always stored in the memory 86. However, even in such a case, the minimum value of the gap between the fixed pole 2 and the bimetal contact piece 4 can be determined correctly. It is possible to accurately determine the quality of lighting tube members.

Furthermore, as shown in FIG. 6(C), a bright part corresponding to a part of the fixed pole 2, a dark part C corresponding to the gap, a bright part opening corresponding to the bimetal contact piece 4, a dark part E, and other wells are added. When the bright area and the dark area corresponding to 4 are within the extraction range, the count value of the variable counter 84 is "1" at the bright area.
Then, it becomes "2" in the next dark part C. At this point, the dot counter 85 starts counting the number of dots in the gap. When the dot data corresponding to the bright area opening is detected, the dot counter 8s ends its counting operation. Further, when the bright part opening is detected, the count l-II of the variable counter 84 becomes "3".

Furthermore, the variable counter 84 becomes "4" when the dark part H is detected.
When a bright area is detected, the value becomes "5", and when a dark area is detected, the value becomes "6".

At this point, when the X direction counter 82 finishes counting "96", the count value of the variable counter 84 at that time becomes "6", so the count of the dot counter 85 at this time is judged to be valid. It is compared with the contents of the gap memory 86, and the minimum value of the gap is always stored in the gap memory 86. However, even in such a case, the minimum value of the gap between the fixed pole 2 and the bimetal contact piece 4 can be determined correctly. Therefore, in this case as well, it is possible to accurately determine the quality of the lighting tube member.

In this way, not only the images of the fixed pole 2 and the bimetal contact piece 4 are correctly included within the extraction range as shown in Fig. 3, but also the fixed pole 2
Even if a part of the bimetal contact piece 4 is missing or the image of another well 3 is mixed in, as long as the dark area corresponding to the gap is entered correctly, the gap measurement will be valid in all cases. Even if there is some deviation in the positional relationship between the light tube and the camera 5, gap measurement can be performed without any problem.

That is, the camera 5 can be easily positioned with respect to the lighting tube. Also, fixing V7A2 of lighting tube and bimetal contact piece 4
The gap between the
The data is converted into a value, processed by a program, the dot data corresponding to the gap is counted, the minimum value is obtained, and the pass/fail judgment is made by comparing it with the tolerance value, so pass/fail judgment is accurate. It is possible to automate gap inspection. Due to these advantages, this device can be easily incorporated into the lighting tube manufacturing line.
Practicality can be improved.

[Effects of the Invention] As described above, according to the present invention, the gap between the bimetal contact piece and the fixed pole in the lighting tube can be automatically inspected on the production line, and pass/fail judgment can be accurately made. It is possible to provide a lighting tube bimetal gap measuring device that allows relatively easy positioning of an image sensor with respect to the tube and improves practicality.

[Brief explanation of drawings]

The figures show an embodiment of the present invention. Fig. 1 is a block diagram, Fig. 2 is a partially enlarged view showing the gear up of the bimetal contact piece and the fixed pole, and Fig. 3 is an area A of Fig. 2. FIG. 4 shows an example of a pattern based on binarized image dot data.
The figure shows the main configuration of the RAM in the microcomputer, FIG. 5 is a flowchart showing gap measurement processing by the microcomputer, and FIG. 6 is a diagram showing another example of a pattern based on measurable image dot data. . DESCRIPTION OF SYMBOLS 1... Lighting tube mount, 2... Fixed pole, 4... Bimetal contact piece, 6... Television camera (image sensor), 7... A/D converter (211 circuit) ),
8... Microcomputer, 82... X direction counter, 83... Y direction counter, 84... Variable counter, 8s... Dot counter, 86... Gap memory. Applicant's representative Patent attorney Takehiko Suzue 1 Figure 2 Figure 13 vlJ Figure 5

Claims (1)

[Claims] An image sensor that images an area including at least the side surface of the bimetal contact piece of the lighting tube and the fixed pole, a binarization circuit that binarizes image data from the image sensor for each dot, and a contact between the fixed pole and the bimetal contact. The direction in which the gap can be detected is the X direction, and the direction orthogonal to this X direction is the Y direction.Among the image dot data from the binarization circuit, mXn of m dots in the X direction and n dots in the Y direction. means for setting dots in the extraction range; a variable counter for counting high level and low level changes in the X direction in the image dot data of the extraction range by this means for each dot row; and a count value of the variable counter is set in advance. a dot counter that counts the number of dots of the image dot data when the set value is reached, and when the count value of the variable counter exceeds the set value, the count value of the dot counter is taken out as gap data, and each dot is The present invention is characterized by comprising a means for comparing gap data for each row to obtain a minimum value, and a means for comparing the minimum value gap data obtained by this means with a preset tolerance value to determine quality. Light tube bimetal gap measurement device.