WO2012165419A1 - Lighting system, inspection system and control system - Google Patents

Lighting system, inspection system and control system Download PDF

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Publication number
WO2012165419A1
WO2012165419A1 PCT/JP2012/063732 JP2012063732W WO2012165419A1 WO 2012165419 A1 WO2012165419 A1 WO 2012165419A1 JP 2012063732 W JP2012063732 W JP 2012063732W WO 2012165419 A1 WO2012165419 A1 WO 2012165419A1
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WO
WIPO (PCT)
Prior art keywords
tube
illumination
mark
inspection
inspected
Prior art date
Application number
PCT/JP2012/063732
Other languages
French (fr)
Japanese (ja)
Inventor
田中　修
建司 矢萩
利克 吉村
Original Assignee
ライオン株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by ライオン株式会社 filed Critical ライオン株式会社
Priority to KR1020137019655A priority Critical patent/KR101955238B1/en
Priority to CN201280026172.5A priority patent/CN103562710B/en
Priority to JP2013518097A priority patent/JP5847176B2/en
Publication of WO2012165419A1 publication Critical patent/WO2012165419A1/en

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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84—Systems specially adapted for particular applications
    • G01N21/88—Investigating the presence of flaws or contamination
    • G01N21/90—Investigating the presence of flaws or contamination in a container or its contents
    • G01N21/909—Investigating the presence of flaws or contamination in a container or its contents in opaque containers or opaque container parts, e.g. cans, tins, caps, labels
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84—Systems specially adapted for particular applications
    • G01N21/88—Investigating the presence of flaws or contamination
    • G01N21/8806—Specially adapted optical and illumination features
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2201/00—Features of devices classified in G01N21/00
    • G01N2201/06—Illumination; Optics
    • G01N2201/061—Sources

Definitions

  • the present invention relates to an illumination system, an inspection system, and a control system.
  • FIG. 13 is a schematic diagram showing a state of the filling machine P0 that performs a process of filling a tube such as a plastic tube or a laminate tube with contents.
  • the filling machine P0 which performs the process of filling the contents in the tube is installed in the clean room R.
  • the filling machine P0 is covered with a protective cover made of metal as a base material so that dust and dust do not enter the tube.
  • This protective cover has a transparent portion such as polycarbonate. For this reason, the worker W can visually confirm the tube in the filling machine P0 with the light from the illumination L0 installed in the clean room R.
  • the tube is filled with contents, and the tube opening position is inspected after heat sealing by melting and crimping the tube opening end.
  • an operator visually inspects the position of the tube design.
  • it is necessary to perform this inspection in-line in the production process, which requires a lot of labor and labor.
  • Patent Documents 1 and 2 describe techniques for inspecting the appearance of an object to be inspected by image processing.
  • Japanese Patent Application Laid-Open No. H10-228561 describes a technique for inspecting the surface of an inspection object based on a change in reflected light by irradiating the inspection object with inspection light.
  • the filling machine is covered with a metal cover, the filling machine is bright enough to allow a person to visually observe the design of the tube in the filling machine, but to take an appropriate inspection image for image processing. Has insufficient light. For this reason, it is conceivable to illuminate the inside of the filling machine and directly irradiate the tube with light for imaging. However, when the tube surface is glossy, there is a problem that halation occurs on the tube surface and a stable inspection image cannot be acquired.
  • the present invention has been made in view of the above points, and an object of the present invention is to design a tube design by image processing even if the tube surface is glossy while preventing dust and dust from being mixed in the tube. It is an object of the present invention to provide an illumination system, an inspection system, and a control system that can capture an image capable of detecting the position of the camera.
  • An illumination system captures an image of a first surface having a mark and a glossy surface around the mark among inspection objects on which marks are printed, and based on the captured image. It is used in an inspection system for inspecting the design position of the inspection object.
  • This illumination system is disposed on the back side of the first surface of the inspection object, and has an upper end located above the inspection object and a lower end located below the mark, and emits light.
  • the illumination directly irradiates light to the back surface of the first surface of the back surface of the inspection object, and indirectly transmits light to the first surface of the inspection object via the reflecting member. Irradiate.
  • the illumination system is disposed on the opposite side of the illumination with respect to the reflecting member, and includes at least the mark and the left and right ends of the inspection object by imaging the first surface of the inspection object. You may further provide the imaging part which acquires an image.
  • the material of the reflecting surface of the reflecting member may be polytetrafluoroethylene.
  • An inspection system detects the design position of the inspection object using the illumination system.
  • the inspection system includes: an imaging unit that images the first surface of the inspection object; a determination unit that determines a range where the mark should exist in an image captured by the imaging unit; and the determination unit A detection unit that detects a design position of the inspection object based on the presence or absence of the mark in the determined range.
  • the control system determines whether the inspected product is non-defective or defective through the production line using the above-described inspection system.
  • the control system includes a control unit that determines a non-defective product or a defective product of each of the inspection objects flowing through the production line based on a detection result by the detection unit.
  • the inspection object is irradiated with illumination from the back of the first surface on which the mark is printed, and the light irradiated from the illumination is reflected by the reflecting member onto the first surface of the inspection object. For this reason, even when the surface of the inspection object is glossy, the halation can be prevented and the mark of the inspection object can be clearly imaged. This makes it possible to detect the position of the design by image processing even if the surface of the inspection object has a glossy surface while covering the filling machine to prevent dust and dust from entering the inspection object. Can be imaged.
  • the inspection object according to the present embodiment is a tube T such as a plastic tube or a laminate tube, and the printed surface around the mark I is glossy.
  • the gloss in the present embodiment refers to a characteristic such that when light from a light source is reflected by a reflecting object, a mirror image of the light source is reflected on the reflecting object surface. For example, when light is directly applied to a glossy object such as aluminum or stainless steel, a mirror image of the light source is reflected on the surface.
  • the gloss can be determined by measuring the glossiness in addition to the visual determination.
  • the glossiness is a numerical value indicating a result of regular reflection of light hitting the reflecting object surface.
  • Glossy in this embodiment means that the gloss measured by a measuring device under a predetermined measurement condition is a certain value or more (in this embodiment, 100 or more (100 or 100 OVER (reference value))). is there.
  • the glossiness of the glossy material in this embodiment is preferably 1000 or less. Therefore, the glossiness of gloss on the printed surface around the mark I is preferably 100 or more and 1000 or less.
  • the glossiness was quoted from JIS Z 8741-1997, and measured with a Grosstec (IG-320) manufactured by Horiba, Ltd. as a measuring instrument. A method for measuring glossiness will be described.
  • Measurement object “Brilliant More Fresh Spearmint”, “Dent Health Unpolished Gel”, “Dent Health SP” “Dent Health Smi Block (registered trademark)” “Hi-Tech (registered trademark)” “Hi-tech Mild” and “Systemma Sensitive” Is a laminated tube. As shown in FIG.
  • a mark I is printed on the tube T.
  • a surface having the mark I in the tube T is defined as a front surface (first surface).
  • the back surface of the surface having the mark I in the tube T is defined as the back surface.
  • the mark I is a mark for detecting a design shift (position) in the tube T.
  • the color of the mark I (for example, black) is referred to as a mark color.
  • a portion heat-sealed by thermally melting and crimping the opening is referred to as an end seal portion E.
  • the vertical direction is determined with the end seal portion E side as the upper side and the spout (cap C) side as the lower side.
  • the left-right direction when the front surface of the tube T is viewed from the front is defined as the left-right direction. That is, the tube T is composed of first and second side surfaces that are substantially plane-symmetric. The upper ends of the first and second side surfaces are joined by an end seal portion E. The left and right ends of the first and second side surfaces are continuous. The outer surfaces of the first and second side faces are substantially opposite to each other. The outer surface of the first side surface is the front surface of the tube T. The outer surface of the second side surface is the back surface of the tube T.
  • FIG. 3 is a schematic diagram illustrating an example of a filling machine P into which the control system according to the present embodiment is introduced.
  • the filling machine P is a production line for filling the tube T with contents such as a dentifrice and heat-sealing the opening of the tube T after filling.
  • a racetrack-shaped table is installed in the center of the filling machine P.
  • a number of cylindrical tube holders installed around the table are provided in an aligned state so as to be horizontally movable in the circumferential direction of the table. These tube holders are configured to move around the table by a transport mechanism (not shown) provided along the peripheral surface of the table.
  • the tube T is supplied from the supply unit 101 of the filling machine P to the tube holder, and moves to the discharge unit 112 along the peripheral surface of the table.
  • the new tube T is supplied to a tube holder in the state opened with those cap C side facing down.
  • the tube insertion unit 102 fixes the tube T to the tube holder by inserting the tube T against the tube holder.
  • the cap confirmation unit 103 confirms that the cap C is attached to the tube T by the sensor.
  • the foreign matter removing unit 104 removes foreign matter in the tube T by blowing clean air into the tube T.
  • the brick filling unit 105 fills the tube T with the contents.
  • the mark alignment unit 106 detects the mark I of the tube T by the color sensor, and aligns the tube T so that the mark I faces a predetermined direction set in advance.
  • the product type confirmation unit 107 confirms the product type of the tube T using a camera.
  • the heat seal part 108 heat-seals by heat-melting and crimping
  • the packaging lot marking unit 109 marks the packaging lot on the end seal portion E.
  • the appearance inspection unit 110 inspects the design position of the tube T.
  • the R cutter part 111 cuts the end part of the end seal part E.
  • the discharge unit 112 discharges the tube T to the subsequent process by the damper type conveyor 113.
  • FIG. 4 is a schematic diagram showing the configuration of the control system according to the present embodiment.
  • the control system inspects the design position of the tube T in the appearance inspection unit 110 in the filling machine P.
  • the control system includes an illumination 1, a reflector 2, a camera (imaging unit) 3, an image processing device 4, and a sequencer 5.
  • the illumination 1, the reflector 2, and the camera 3 are installed in the appearance inspection unit 110 in the filling machine P.
  • the illumination 1 irradiates light to the back surface of the tube T flowing through the filling machine P and the reflector.
  • the reflection plate (reflection member) 2 reflects light from the illumination 1 to the front surface of the tube T.
  • the camera 3 captures the front side of the tube T to generate an image, and outputs the generated image to the image processing device 4.
  • an illumination system a system composed of the illumination 1, the reflector 2, and the camera 3 is referred to as an illumination system. The detailed configuration of the illumination system will be described later.
  • the image processing device 4 detects a left / right shift of the design in the tube T based on the image input from the camera 3. Then, the image processing device 4 determines whether the tube T is good or defective based on the detection result, and outputs the determination result to the sequencer 5. The sequencer 5 determines whether each tube T flowing through the filling machine P is non-defective or defective based on the input determination result, and assigns status information (non-defective or defective) to each tube T and stores it. Then, the sequencer 5 outputs an operation instruction to the damper type conveyor 113 based on the status information of each tube T.
  • the sequencer 5 when the tube T is a non-defective product, the sequencer 5 outputs an operation instruction for discharging the tube T to a post-process (first direction) on the production line to the damper conveyor 113.
  • the sequencer 5 when the tube T is a defective product, the sequencer 5 outputs an operation instruction for discharging the tube T out of the production line (second direction) to the damper conveyor 113.
  • FIG. 5 is a block diagram showing a functional configuration of the inspection system according to the present embodiment.
  • the inspection system is a system that is used in the above-described control system and determines whether the tube T is a non-defective product or a defective product.
  • the inspection system includes an illumination system, an image processing device 4, an input unit 6, an illumination control unit 7, and a display unit 8. The detailed configuration of the illumination system will be described later.
  • the input unit 6 receives an input of a control value that controls the illuminance of the illumination 1.
  • the illumination control unit 7 controls the illuminance of the illumination 1 based on the control value input by the input unit 6. Specifically, the illumination control unit 7 controls the illuminance of the illumination 1 by, for example, changing the supply voltage or current to the illumination 1.
  • the display unit 8 displays an image captured by the camera 3. With this configuration, the operator can set the illuminance of the illumination 1 by the input unit 6 while confirming the image displayed on the display unit 8 when performing the inspection. Thereby, the illumination intensity of the illumination 1 can be adjusted according to the magnitude
  • An image processing apparatus 4 that determines a non-defective product or a defective product of the tube T based on an image captured by the camera 3 includes an image input unit 401, an edge detection unit 402, a window determination unit 403, a deviation detection unit 404, and a determination. 405 and a determination result output unit 406.
  • the image processing apparatus 4 determines whether the tube T is good or defective based on the position of the mark I on the tube T.
  • the image input unit 401 receives an image input from the camera 3 and outputs the input image to the display unit 8 and the edge detection unit 402.
  • the edge detection unit 402 detects the left edge of the tube T in the input image.
  • the window determination unit 403 determines a mark detection window that is a range where the mark I should be based on the leftmost edge detected by the edge detection unit 402.
  • the deviation detection unit 404 detects a design deviation of the tube T based on whether or not the mark I is present in the mark detection window determined by the window determination unit 403. Specifically, the deviation detection unit 404 counts the number of pixels of the mark color in the mark detection window, and determines that the mark I is in the mark detection window when the counted number of pixels is within a predetermined range ⁇ . .
  • the upper limit value and the lower limit value of the range ⁇ are set in advance. For example, the range ⁇ may be 80% or more of the pixels within the mark detection window.
  • the deviation detection unit 404 determines that there is no mark I in the mark detection window, and detects a design deviation of the tube T.
  • the determination unit 405 determines a non-defective product or a defective product of the tube T based on the detection result in the deviation detection unit 404. Specifically, the determination unit 405 determines that the tube T is a non-defective product when a design shift is not detected, and determines that the tube T is a defective product when a design shift is detected.
  • the determination result output unit 406 transmits the determination result by the determination unit 405 to the sequencer 5.
  • FIG. 6 is a schematic diagram showing the installation position of the illumination system according to the present embodiment.
  • the direction in which the front of the tube T is facing is defined as the front.
  • the direction in which the back surface of the tube T faces is defined as the back.
  • the illumination system includes an illumination 1, a reflection plate 2, and a camera 3.
  • the illumination system is installed in the appearance inspection unit 110 in the filling machine P.
  • a tube T is disposed between the illumination 1 and the reflector 2.
  • the illumination 1 is a surface light source such as an LED (Light Emitting Diode), and the color of the light is white.
  • the horizontal width (or vertical width) of the illumination 1 is at least larger than the horizontal width of the tube T.
  • the vertical width (or horizontal width) of the illumination 1 is at least larger than the vertical width of the mark I.
  • the illumination 1 is installed in a limited space (for example, a depth of 35 mm to 95 mm) in the filling machine P. For this reason, it is preferable to use a thin (for example, about 8 mm thick) illumination as the illumination 1.
  • the illuminator 1 is installed at a position behind the tube T with its light emitting part facing forward.
  • the illumination 1 is installed so that the reflecting plate 2 and the back surface of the tube T flowing through the filling machine P may be irradiated.
  • the illumination 1 is installed so as to irradiate the back surface of the tube T including at least the left and right ends of the tube T above the lower part of the mark I.
  • the reflecting plate 2 is a plate that reflects light.
  • the material of the reflecting surface of the reflecting plate 2 is polytetrafluoroethylene. Polytetrafluoroethylene has a higher light diffusivity than a mirror or the like. Further, the color of the reflecting surface of the reflecting plate 2 is preferably white so that the color of the reflecting plate 2 does not appear in the tube T.
  • the reflecting plate 2 is installed at a position in front of the tube T with its reflecting surface facing rearward so that the light emitted from the illumination 1 is reflected around the mark I of the tube T.
  • the angle of the reflecting surface of the reflecting plate 2 with respect to the light irradiation direction (horizontal direction) in the light source (illumination 1) is ⁇ .
  • the angle ⁇ is 30 degrees to 60 degrees, preferably 40 degrees to 50 degrees, and more preferably 45 degrees.
  • the camera 3 is a CCD (Charge Coupled Device Image Sensor) camera.
  • the camera 3 is installed at a position in front of the tube T with its optical system facing rearward. Moreover, the camera 3 is installed so that the front surface of the tube T flowing through the filling machine P can be imaged including at least the mark I and the left and right ends of the tube T.
  • CCD Charge Coupled Device Image Sensor
  • the height of the illumination 1, the reflector 2 and the camera 3, and the angle ⁇ of the reflector 2 can be adjusted. Thereby, the position of the illumination 1, the reflecting plate 2, and the camera 3 can be adjusted according to the magnitude
  • FIG. 6 shows an example of the installation positions of the illumination 1, the reflector 2, and the camera 3 with respect to the tube T having a height of 140 mm (symbol h).
  • the illumination 1 is installed 55 mm (symbol i) behind the center of the tube T and at a height of 112 mm (symbol j). That is, the illumination 1 is arranged on the back side of the tube T.
  • the upper end of the illumination 1 is located above the tube T.
  • the lower end of the illumination 1 is located below the mark I.
  • the reflecting plate 2 is inclined with respect to the light irradiation direction of the illumination 1 so as to face the first surface of the tube T.
  • the camera 3 is installed 130 mm (symbol 1) in front of the center of the tube T and 65 mm (symbol m) in front of the lower part of the reflector 2.
  • the filling machine P performs each process by setting two tubes T. Therefore, two illumination systems may be arranged side by side, and the two tubes T may be imaged and inspected substantially simultaneously. In this case, the lateral width of the illumination 1 may be increased so that the two tubes T can be irradiated with one illumination 1.
  • FIG. 7 is an image captured by the illumination system according to the present embodiment.
  • the illumination 1 irradiates the back surface of the tube T
  • the left and right ends of the tube T above the lower part of the mark I are clearly imaged. That is, as shown in FIG. 7, in the image captured by the camera 3, the illumination 1 (that is, the direct irradiation light from the illumination 1) is reflected in the background of the left and right ends of the tube T above the lower part of the mark I. ing. For this reason, the right and left ends of the tube T can be detected well. Further, since the light of the illumination 1 is diffused by the reflector 2 and applied to the mark I, halation can be prevented and the mark I can be imaged clearly.
  • FIGS. 8C and 8D are explanatory diagrams of pass / fail judgment processing in the image processing apparatus 4 according to the present embodiment.
  • the image input unit 401 acquires an image from the camera 3 (see FIG. 8A).
  • the edge detection unit 402 scans from the left to the right in the inspection window W which is a predetermined range set in advance, and detects a portion having the largest color change as the tube edge G (see FIG. 8B).
  • the window determining unit 403 determines the mark detection window M using the tube edge G as a base point (see FIGS. 8C and 8D). Specifically, the window determination unit 403 sets an area that is a predetermined pixel to the right of the tube edge G as the mark detection window M.
  • the deviation detection unit 404 counts the mark color pixels in the mark detection window M.
  • the deviation detection unit 404 detects that there is no deviation in the design of the tube T when the counted number of pixels is within the range ⁇ (see FIG. 8C).
  • the deviation detection unit 404 detects that there is a deviation in the design of the tube T when the counted number of pixels is outside the range ⁇ (FIG. 8D).
  • the determination unit 405 determines that the tube T without design deviation is a non-defective product, and determines that the tube T with design deviation is a defective product. For example, in the case of the tube T shown in FIG.
  • the image processing apparatus 4 determines that the tube T shown in FIG. 8C is a non-defective product.
  • the image processing apparatus 4 determines that the tube T illustrated in FIG. 8D is a defective product.
  • FIG. 9 is a flowchart showing a procedure of pass / fail judgment processing according to the present embodiment.
  • the edge detection unit 402 scans the inspection window W from the left to the right in the image acquired from the camera 3, and detects a portion having the largest color change as the tube edge G (step S101).
  • the window determination unit 403 determines the mark detection window M using the tube edge G as a base point (step S102).
  • the deviation detection unit 404 counts the number of pixels of the mark color in the mark detection window M (step S103).
  • the deviation detection unit 404 determines whether or not the counted number of pixels of the mark color is within the range ⁇ (the number of pixels is within a predetermined threshold) (step S104).
  • the determination unit 405 determines that the tube T is a non-defective product (OK) (step S105), and ends the process.
  • the determination unit 405 determines that the tube T is a defective product (NG) (step S106), and ends the process.
  • FIG. 10A to 10C show the imaging results of the camera 3 in the illumination system according to the present embodiment.
  • FIG. 10A shows an imaging result when the reflector 2 is made of polytetrafluoroethylene in the above-described illumination system arrangement.
  • FIG. 10B is an imaging result when the reflector 2 is a mirror in the arrangement of the illumination system described above.
  • FIG. 10C shows an imaging result when the front surface of the tube T is directly irradiated from the illumination 1.
  • the mirror has a lower light diffusivity than polytetrafluoroethylene, halation remains, and as shown in the figure, the color of the mark I may be blurred, or other colors (for example, blue) may appear in the mark color. is there. For this reason, when a mirror is used for the reflecting plate 2, the detection rate of the mark I decreases.
  • FIG. 10A when polytetrafluoroethylene is used for the reflector 2 in the illumination system according to the present embodiment, halation is prevented and the mark I and the tube edge G are imaged clearly. Can do. For this reason, a good result was obtained when the inspection was performed based on the captured image. Thereby, when the reflector 2 is made of polytetrafluoroethylene in the arrangement of the illumination system described above, the mark I can be detected with higher accuracy by image processing.
  • FIG. 11 shows the experimental results of the inspection system according to the present embodiment.
  • tube quality shows the result of having determined the quality goods or inferior goods by visual observation.
  • the inspection machine determination indicates a determination result of a non-defective product (OK) or a defective product (NG) by the inspection system.
  • the determination results obtained by the inspection system all match the visual determination results.
  • the inspection system according to the present embodiment can maintain the inspection quality when visually observed as in the conventional case.
  • FIG. 12 is a graph showing a change in illuminance at the tube T position according to the present embodiment.
  • the horizontal axis represents a control value (unit: knob volume (Vol)) for controlling the intensity (illuminance) of light emitted from the light source.
  • the vertical axis represents the illuminance at the tube T position (unit: lux (Lx)).
  • a line 201 illustrated in FIG. 12 indicates a change in illuminance when the front surface of the tube T is directly irradiated with the illumination 1.
  • a line 202 indicates a change in illuminance when a mirror is used for the reflector 2 in the illumination system according to the present embodiment.
  • a line 203 indicates a change in illuminance when polytetrafluoroethylene is used for the reflector in the illumination system according to the present embodiment.
  • the illuminance of the tube T when the illumination system according to the present embodiment is used changes gently in a substantially linear manner with respect to the control value. For this reason, illumination intensity can be adjusted more finely according to the design and shape of the tube T.
  • the illuminance when the front surface of the tube T is irradiated directly is unstable with respect to the control value, and it is difficult to adjust the illuminance.
  • the illuminance when polytetrafluoroethylene is used for the reflecting plate 2 changes more gently than when a mirror is used for the reflecting plate 2. This is because polytetrafluoroethylene has a higher light diffusion rate than a mirror. For this reason, halation is less likely to occur when polytetrafluoroethylene is used for the reflector 2 than when a mirror is used.
  • the tube T is irradiated from the back surface with the illumination 1, and the light irradiated from the illumination 1 is reflected to the front surface of the tube T by the reflection plate 2.
  • the mark I on the tube T can be imaged more clearly by preventing halation in the filling machine P that is covered to prevent dust and dust from entering. it can.
  • the non-defective product or the defective product of the tube T can be accurately determined on the production line.
  • an operator who performs the inspection can reduce the illuminance of the illumination 1 according to the design and shape of the tube T while checking the captured image. Can be adjusted.
  • the reflector 2 is made of polytetrafluoroethylene, the light of the illumination 1 is diffused and reflected, so that the illuminance of the light reflected on the front surface of the tube T can be adjusted more finely.
  • a program for realizing each step shown in FIG. 9 is recorded on a computer-readable recording medium, and the program recorded on the recording medium is read into a computer system and executed. You may perform the process which determines a non-defective product.
  • the “computer system” may include an OS and hardware such as peripheral devices.
  • “Computer-readable recording medium” means a flexible disk, a magneto-optical disk, a ROM, a writable nonvolatile memory such as a flash memory, a portable medium such as a CD-ROM, and a storage such as a hard disk built in a computer system. Refers to the device.
  • Computer-readable recording medium refers to a volatile memory (for example, DRAM (Dynamic Random) in a computer system that becomes a server or client when a program is transmitted via a network such as the Internet or a communication line such as a telephone line. Access Memory)) is also included, which holds a program for a certain period of time.
  • the program may be transmitted from a computer system storing the program in a storage device or the like to another computer system via a transmission medium or by a transmission wave in the transmission medium.
  • a “transmission medium” for transmitting a program refers to a medium having a function of transmitting information, such as a network (communication network) such as the Internet or a communication line (communication line) such as a telephone line.
  • the program may be for realizing a part of the functions described above. What can implement
  • the material of the reflective surface of the reflecting plate 2 is polytetrafluoroethylene, it is not limited to this. As long as the material has a high diffusivity, other materials such as polypropylene and polyethylene may be used for the reflector 2.
  • the illumination 1 is an LED, but is not limited thereto.
  • the illumination 1 may use another light source such as a fluorescent lamp or a halogen lamp.
  • the present invention can be applied to lighting systems, inspection systems, and control systems.

Abstract

A lighting system is used in an inspection system which captures an image of a first surface that is a surface having a mark of an object to be inspected on which the mark is printed and that has a shine around the mark, and, on the basis of the captured image, inspects the position of a design in the object to be inspected. This lighting system is provided with: a lighting disposed on the side of a reverse surface to the first surface of the object to be inspected, has an upper end located above the object to be inspected and a lower end located below the mark, and applies light; and a reflection member which is disposed above the object to be inspected on the first surface side of the object to be inspected, is inclined with respect to the application direction of the light of the lighting so as to face the first surface of the object to be inspected, and reflects the light from the lighting. The lighting directly applies the light to the reverse surface to the first surface of the object to be inspected, and indirectly applies the light to the first surface of the object to be inspected via the reflection member.

Description

照明システム、検査システム及び制御システムLighting system, inspection system and control system
　本発明は、照明システム、検査システム及び制御システムに関する。
　本願は、２０１１年５月３０日に、日本に出願された特願２０１１－１２０９６２号に基づき優先権を主張し、その内容をここに援用する。 The present invention relates to an illumination system, an inspection system, and a control system.
This application claims priority on May 30, 2011 based on Japanese Patent Application No. 2011-120962 filed in Japan, the contents of which are incorporated herein by reference.
　図１３は、プラスチックチューブやラミネートチューブなどのチューブに内容物を充填する工程を行う充填機Ｐ０の様子を示す概略図である。
　通常、チューブに内容物を充填する工程を行う充填機Ｐ０は、クリーンルームＲ内に設置される。更に、この充填機Ｐ０は、チューブ内に埃や塵が入らないように、金属を母体とする保護用のカバーにより覆われている。この保護用のカバーにはポリカーボネート等の透明な部分がある。このため、作業員Ｗは、クリーンルームＲに設置された照明Ｌ０からの光で目視により充填機Ｐ０内のチューブを確認することができる。 FIG. 13 is a schematic diagram showing a state of the filling machine P0 that performs a process of filling a tube such as a plastic tube or a laminate tube with contents.
Usually, the filling machine P0 which performs the process of filling the contents in the tube is installed in the clean room R. Further, the filling machine P0 is covered with a protective cover made of metal as a base material so that dust and dust do not enter the tube. This protective cover has a transparent portion such as polycarbonate. For this reason, the worker W can visually confirm the tube in the filling machine P0 with the light from the illumination L0 installed in the clean room R.
　この工程において、チューブに内容物を充填し、チューブ開口端部を熱溶融して圧着することによりヒートシールした後に、チューブデザインの位置を検査する。
　従来では、このチューブデザインの位置の検査は、作業員が目視にて行っていた。しかしながら、チューブを全数検査するためには、この検査を生産工程のインラインで行う必要があり、多大な人手を要する上に手間が掛かる。 In this process, the tube is filled with contents, and the tube opening position is inspected after heat sealing by melting and crimping the tube opening end.
Conventionally, an operator visually inspects the position of the tube design. However, in order to inspect all the tubes, it is necessary to perform this inspection in-line in the production process, which requires a lot of labor and labor.
　そこで、チューブを撮像し、撮像した検査画像を画像処理することによりチューブデザインの位置を検出することが考えられる。特許文献１及び２には、画像処理により被検査物の外観を検査する技術が記載されている。また、特許文献３には、被検査物に検査光を照射し、その反射光の変化に基づいて被検査物の表面を検査する技術が記載されている。 Therefore, it is conceivable to detect the position of the tube design by taking an image of the tube and subjecting the taken inspection image to image processing. Patent Documents 1 and 2 describe techniques for inspecting the appearance of an object to be inspected by image processing. Japanese Patent Application Laid-Open No. H10-228561 describes a technique for inspecting the surface of an inspection object based on a change in reflected light by irradiating the inspection object with inspection light.
日本国特公平６－１２４９号公報Japanese Patent Publication No. 6-1249 日本国特開２００７－１６１２５７号公報Japanese Unexamined Patent Publication No. 2007-161257 日本国特開２００５－２９１７７１号公報Japanese Unexamined Patent Publication No. 2005-291717
　しかしながら、充填機は金属のカバーにより覆われているため、充填機内は、人が充填機内のチューブのデザインを目視可能な明るさではあるが、画像処理するための適切な検査画像を撮像するには光量が不十分である。このため、充填機内に照明を設置し、チューブに光を直接照射して撮像することが考えられる。しかしながら、チューブ表面に光沢がある場合には、チューブ表面でハレーションが起こり、安定した検査画像を取得することができない、という問題がある。 However, since the filling machine is covered with a metal cover, the filling machine is bright enough to allow a person to visually observe the design of the tube in the filling machine, but to take an appropriate inspection image for image processing. Has insufficient light. For this reason, it is conceivable to illuminate the inside of the filling machine and directly irradiate the tube with light for imaging. However, when the tube surface is glossy, there is a problem that halation occurs on the tube surface and a stable inspection image cannot be acquired.
　本発明は上記の点に鑑みてなされたものであり、その目的は、埃や塵がチューブ内に混入することを防ぎつつ、チューブ表面に光沢があるチューブであっても、画像処理によりチューブデザインの位置を検出可能な画像を撮像することができる照明システム、検査システム及び制御システムを提供することにある。 The present invention has been made in view of the above points, and an object of the present invention is to design a tube design by image processing even if the tube surface is glossy while preventing dust and dust from being mixed in the tube. It is an object of the present invention to provide an illumination system, an inspection system, and a control system that can capture an image capable of detecting the position of the camera.
　本発明は上記の課題を解決するためになされた。本発明の一態様に係る照明システムは、マークの印刷された被検査物のうち前記マークのある面であって前記マーク周囲に光沢のある第１の面を撮像し、撮像した画像に基づいて前記被検査物のデザインの位置を検査する検査システムにおいて用いられる。この照明システムは、前記被検査物の前記第１の面の背面側に配置され、前記被検査物よりも上方に位置する上端と前記マークよりも下方に位置する下端とを有し、光を照射する照明と、前記被検査物の前記第１面側であって前記被検査物よりも上方に配置され、前記被検査物の第１面と対向するように前記照明の光の照射方向に対して傾斜し、前記照明からの光を反射する反射部材とを備える。前記照明は、前記被検査物の前記背面うち前記第１の面の背面に光を直接的に照射するとともに、前記反射部材を介して、前記被検査物の前記第１面に光を間接的に照射する。 The present invention has been made to solve the above problems. An illumination system according to an aspect of the present invention captures an image of a first surface having a mark and a glossy surface around the mark among inspection objects on which marks are printed, and based on the captured image. It is used in an inspection system for inspecting the design position of the inspection object. This illumination system is disposed on the back side of the first surface of the inspection object, and has an upper end located above the inspection object and a lower end located below the mark, and emits light. Illumination to be irradiated and arranged on the first surface side of the inspection object and above the inspection object, and in the irradiation direction of the light of the illumination so as to face the first surface of the inspection object And a reflecting member that is inclined with respect to the light and reflects light from the illumination. The illumination directly irradiates light to the back surface of the first surface of the back surface of the inspection object, and indirectly transmits light to the first surface of the inspection object via the reflecting member. Irradiate.
　上記の照明システムは、前記反射部材に対して前記照明とは反対側に配置され、前記被検査物の第１の面を撮像することにより、少なくとも前記マークと前記被検査物の左右両端と含む画像を得る撮像部をさらに備えていてもよい。 The illumination system is disposed on the opposite side of the illumination with respect to the reflecting member, and includes at least the mark and the left and right ends of the inspection object by imaging the first surface of the inspection object. You may further provide the imaging part which acquires an image.
　上記の照明システムにおいて、前記反射部材の反射面の材質はポリテトラフルオロエチレンであってもよい。 In the above illumination system, the material of the reflecting surface of the reflecting member may be polytetrafluoroethylene.
　本発明の一態様に係る検査システムは、上記の照明システムを用いて前記被検査物のデザインの位置を検出する。この検査システムは、前記被検査物のうち前記第１の面を撮像する撮像部と、前記撮像部により撮像された画像において、前記マークの有るべき範囲を決定する決定部と、前記決定部により決定された範囲における前記マークの有無に基づいて前記被検査物のデザインの位置を検出する検出部と、を備える。 An inspection system according to an aspect of the present invention detects the design position of the inspection object using the illumination system. The inspection system includes: an imaging unit that images the first surface of the inspection object; a determination unit that determines a range where the mark should exist in an image captured by the imaging unit; and the determination unit A detection unit that detects a design position of the inspection object based on the presence or absence of the mark in the determined range.
　本発明の一態様に係る制御システムは、上記の検査システムを用いて生産ラインを流れる被検査物の良品又は不良品を判定する。この制御システムは、前記検出部による検出結果に基づいて、前記生産ラインを流れる被検査物夫々の良品又は不良品を判定する制御部を備える。 The control system according to one aspect of the present invention determines whether the inspected product is non-defective or defective through the production line using the above-described inspection system. The control system includes a control unit that determines a non-defective product or a defective product of each of the inspection objects flowing through the production line based on a detection result by the detection unit.
　本発明によれば、マークが印刷されている第１の面の背面から被検査物を照明で照射し、照明から照射される光を反射部材で被検査物の第１の面に反射する。このため、被検査物表面に光沢がある場合であっても、ハレーションを防いで被検査物のマークを鮮明に撮像することができる。これにより、充填機にカバーをして埃や塵が被検査物内に混入することを防ぎつつ、表面に光沢がある被検査物であっても、画像処理によりデザインの位置を検出可能な画像を撮像することができる。 According to the present invention, the inspection object is irradiated with illumination from the back of the first surface on which the mark is printed, and the light irradiated from the illumination is reflected by the reflecting member onto the first surface of the inspection object. For this reason, even when the surface of the inspection object is glossy, the halation can be prevented and the mark of the inspection object can be clearly imaged. This makes it possible to detect the position of the design by image processing even if the surface of the inspection object has a glossy surface while covering the filling machine to prevent dust and dust from entering the inspection object. Can be imaged.
本発明の一実施形態による用語の定義を説明するための図である。It is a figure for demonstrating the definition of the term by one Embodiment of this invention. 被検査物における光沢度の測定結果を示す図である。It is a figure which shows the measurement result of the glossiness in a to-be-inspected object. 本実施形態による制御システムが導入される充填機の一例を示す概略図である。It is the schematic which shows an example of the filling machine with which the control system by this embodiment is introduce | transduced. 本実施形態による制御システムの構成を示す概略図である。It is the schematic which shows the structure of the control system by this embodiment. 本実施形態による検査システムの機能構成を示すブロック図である。It is a block diagram which shows the function structure of the test | inspection system by this embodiment. 本実施形態による照明システムの設置位置を示す概略図である。It is the schematic which shows the installation position of the illumination system by this embodiment. 本実施形態による照明システムにより撮像された画像を示す図である。It is a figure which shows the image imaged with the illumination system by this embodiment. 本実施形態による画像処理装置における良否判定処理の説明図である。It is explanatory drawing of the quality determination process in the image processing apparatus by this embodiment. 本実施形態による画像処理装置における良否判定処理の説明図である。It is explanatory drawing of the quality determination process in the image processing apparatus by this embodiment. 本実施形態による画像処理装置における良否判定処理の説明図である。It is explanatory drawing of the quality determination process in the image processing apparatus by this embodiment. 本実施形態による画像処理装置における良否判定処理の説明図である。It is explanatory drawing of the quality determination process in the image processing apparatus by this embodiment. 本実施形態による良否判定処理の手順を示すフローチャートである。It is a flowchart which shows the procedure of the quality determination process by this embodiment. 本実施形態による照明システムにおけるカメラの撮像結果を示す図である。It is a figure which shows the imaging result of the camera in the illumination system by this embodiment. 本実施形態による照明システムにおけるカメラの撮像結果を示す図である。It is a figure which shows the imaging result of the camera in the illumination system by this embodiment. 本実施形態による照明システムにおけるカメラの撮像結果を示す図である。It is a figure which shows the imaging result of the camera in the illumination system by this embodiment. 本実施形態による検査システムの実験結果を示す図である。It is a figure which shows the experimental result of the test | inspection system by this embodiment. 本実施形態によるチューブ位置における照度変化を示すグラフである。It is a graph which shows the illumination intensity change in the tube position by this embodiment. チューブに内容物を充填する工程を行う充填機の様子を示す概略図である。It is the schematic which shows the mode of the filling machine which performs the process of filling a tube with the content.
　以下、図面を参照しながら本発明の実施形態について詳しく説明する。
　まず、図１を参照して以下で用いる語を次のように定義する。
　本実施形態による被検査物は、プラスチックチューブやラミネートチューブなどのチューブＴであり、マークＩの周囲の印刷面に光沢がある。本実施形態における光沢とは、光源からの光が反射物体により反射した際に、その反射物体表面に光源の鏡像が映るような特性のことをいう。例えば、アルミやステンレス等の光沢のあるものに直接光を当てると、その表面に光源の鏡像が映り込む。光沢は、目視判定以外に光沢度を測定することで判定できる。光沢度とは、反射物体表面に当たった光が正反射した結果を示す数値である。本実施形態における光沢のあるものとは、所定の測定条件において測定機器の測定する光沢度が、一定値以上（本実施形態では１００以上（１００または１００ OVER（参考値）））を示すものである。本実施形態における光沢のあるものの光沢度は、１０００以下であることが好ましい。よって、マークＩの周囲の印刷面に光沢の光沢度は、１００以上かつ１０００以下であることが好ましい。光沢度は、ＪＩＳ　Ｚ　８７４１－１９９７から引用し、測定機器として株式会社堀場製作所のグロスチエッカ（ＩＧ－３２０）で測定した。光沢度の測定方法について説明する。まず、円筒形のラミネートチューブから測定面のみを切り取り、その測定面を平らにした。次に、グロスチエッカにて測定面の表面の光沢度を測定した。光沢度の測定条件について説明する。ラミネートチューブの光沢度は、屈折率１．５６７のガラス板表面の光沢度を基準（１００）とし、入射角６０度・反射角６０度にて測定した。この場合におけるガラス板の鏡面反射率は１０％である。よって、鏡面反射率が１００％の場合における光沢度は、１０００である。
　図２は、目視で光沢がないと判定された（見た目光沢「なし」）測定対象物、及び、目視で光沢があると判定された（見た目光沢「あり」）測定対象物における光沢度の測定結果を示す。測定対象物「ブリリアントモア　フレッシュスペアミント」、「デントヘルス無研磨ゲル」、「デントヘルスSP」「デントヘルスしみるブロック（登録商標）」「ハイテクト(登録商標)」「ハイテクト　マイルド」及び「システマ　センシティブ」はラミネートチューブである。図２に示すように、見た目光沢「あり」である「ブリリアントモア　フレッシュスペアミント」「デントヘルス無研磨ゲル」「デントヘルスSP」及び「デントヘルスしみるブロック（登録商標）」における光沢度は「１００ ＯＶＥＲ」である。一方、見た目光沢「なし」である「ハイテクト(登録商標)」「ハイテクト　マイルド」及び「システマ　センシティブ」における光沢度は１００より小さい。 Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
First, referring to FIG. 1, the words used below are defined as follows.
The inspection object according to the present embodiment is a tube T such as a plastic tube or a laminate tube, and the printed surface around the mark I is glossy. The gloss in the present embodiment refers to a characteristic such that when light from a light source is reflected by a reflecting object, a mirror image of the light source is reflected on the reflecting object surface. For example, when light is directly applied to a glossy object such as aluminum or stainless steel, a mirror image of the light source is reflected on the surface. The gloss can be determined by measuring the glossiness in addition to the visual determination. The glossiness is a numerical value indicating a result of regular reflection of light hitting the reflecting object surface. Glossy in this embodiment means that the gloss measured by a measuring device under a predetermined measurement condition is a certain value or more (in this embodiment, 100 or more (100 or 100 OVER (reference value))). is there. The glossiness of the glossy material in this embodiment is preferably 1000 or less. Therefore, the glossiness of gloss on the printed surface around the mark I is preferably 100 or more and 1000 or less. The glossiness was quoted from JIS Z 8741-1997, and measured with a Grosstec (IG-320) manufactured by Horiba, Ltd. as a measuring instrument. A method for measuring glossiness will be described. First, only the measurement surface was cut from the cylindrical laminate tube, and the measurement surface was flattened. Next, the glossiness of the surface of the measurement surface was measured with a glossier. Glossiness measurement conditions will be described. The glossiness of the laminated tube was measured at an incident angle of 60 degrees and a reflection angle of 60 degrees, with the glossiness of the glass plate surface having a refractive index of 1.567 as a reference (100). In this case, the specular reflectance of the glass plate is 10%. Therefore, the glossiness when the specular reflectance is 100% is 1000.
FIG. 2 shows the measurement of the glossiness of a measurement object that was visually determined to be non-glossy (appearance gloss “none”) and a measurement object that was visually determined to be glossy (appearance gloss “present”). Results are shown. Measurement object “Brilliant More Fresh Spearmint”, “Dent Health Unpolished Gel”, “Dent Health SP” “Dent Health Smi Block (registered trademark)” “Hi-Tech (registered trademark)” “Hi-tech Mild” and “Systemma Sensitive” Is a laminated tube. As shown in FIG. 2, the glossiness of “Brilliant More Fresh Spearmint”, “Dent Health Non-Abrasive Gel”, “Dent Health SP” and “Dent Health Scrubbing Block (registered trademark)”, which has an apparent gloss of “Yes”, is “100”. OVER ". On the other hand, the glossiness of “High Tech (registered trademark)”, “High Tech Mild” and “Systemma Sensitive”, which is “None”, is less than 100.
　図１に戻り、チューブＴの説明を続ける。チューブＴにはマークＩが印刷されている。チューブＴにおいてこのマークＩがある面を正面（第１の面）と定義する。また、チューブＴにおいてマークＩがある面の背面を裏面と定義する。マークＩは、チューブＴにおけるデザインのずれ（位置）を検出するためのマークである。マークＩの色（例えば、黒色）をマーク色と称する。このチューブＴにおいて、開口部を熱溶融して圧着することによりヒートシールした部分をエンドシール部Ｅと称する。チューブＴが起立した状態において、エンドシール部Ｅ側を上とし、注出口（キャップＣ）側を下として上下方向を定める。キャップＣを下にしてチューブＴが起立した状態において、チューブＴの正面を正面視したときの左右方向であって、上下方向に対する直交方向を左右方向と定める。
　すなわち、チューブＴは、略面対称の第１および第２の側面からなる。第１および第２の側面の上端は、エンドシール部Ｅにより接合している。第１および第２の側面の左右両端は連続している。第１および第２の側面の外表面は、互いに略逆方向を向いている。第１の側面の外表面が、チューブＴの正面である。第２の側面の外表面が、チューブＴの背面である。 Returning to FIG. 1, the description of the tube T will be continued. A mark I is printed on the tube T. A surface having the mark I in the tube T is defined as a front surface (first surface). Further, the back surface of the surface having the mark I in the tube T is defined as the back surface. The mark I is a mark for detecting a design shift (position) in the tube T. The color of the mark I (for example, black) is referred to as a mark color. In this tube T, a portion heat-sealed by thermally melting and crimping the opening is referred to as an end seal portion E. In the state where the tube T is erected, the vertical direction is determined with the end seal portion E side as the upper side and the spout (cap C) side as the lower side. In the state where the tube T stands up with the cap C down, the left-right direction when the front surface of the tube T is viewed from the front is defined as the left-right direction.
That is, the tube T is composed of first and second side surfaces that are substantially plane-symmetric. The upper ends of the first and second side surfaces are joined by an end seal portion E. The left and right ends of the first and second side surfaces are continuous. The outer surfaces of the first and second side faces are substantially opposite to each other. The outer surface of the first side surface is the front surface of the tube T. The outer surface of the second side surface is the back surface of the tube T.
　図３は、本実施形態による制御システムが導入される充填機Ｐの一例を示す概略図である。
　充填機Ｐは、歯磨き剤などの内容物をチューブＴに充填するとともに充填後のチューブＴの開口部をヒートシールするための生産ラインである。
　充填機Ｐの中央にはレーストラック形状のテーブルが設置される。このテーブルの周囲に多数設置された筒形のチューブホルダーが整列状態でテーブルの円周方向に水平移動自在に設けられている。これらのチューブホルダーは、テーブルの周面に沿って設けられた搬送機構（不図示）によりテーブルの周囲を周回移動するように構成されている。 FIG. 3 is a schematic diagram illustrating an example of a filling machine P into which the control system according to the present embodiment is introduced.
The filling machine P is a production line for filling the tube T with contents such as a dentifrice and heat-sealing the opening of the tube T after filling.
In the center of the filling machine P, a racetrack-shaped table is installed. A number of cylindrical tube holders installed around the table are provided in an aligned state so as to be horizontally movable in the circumferential direction of the table. These tube holders are configured to move around the table by a transport mechanism (not shown) provided along the peripheral surface of the table.
　チューブＴは、充填機Ｐの供給部１０１からチューブホルダーへ供給され、テーブルの周面に沿って排出部１１２まで移動する。まず、供給部１０１において、新しいチューブＴがそれらのキャップＣ側を下に向けて開口された状態でチューブホルダーに供給される。次に、チューブ挿入部１０２が、チューブＴをチューブホルダーに押し付けて挿入することにより、チューブＴをチューブホルダーに固定する。次に、キャップ確認部１０３が、センサによりチューブＴにキャップＣが装着されていることを確認する。次に、異物除去部１０４が、チューブＴ内にクリーンエアを吹き付けることにより、チューブＴ内の異物を除去する。そして、煉充填部１０５が、チューブＴに内容物を充填する。 The tube T is supplied from the supply unit 101 of the filling machine P to the tube holder, and moves to the discharge unit 112 along the peripheral surface of the table. First, in the supply part 101, the new tube T is supplied to a tube holder in the state opened with those cap C side facing down. Next, the tube insertion unit 102 fixes the tube T to the tube holder by inserting the tube T against the tube holder. Next, the cap confirmation unit 103 confirms that the cap C is attached to the tube T by the sensor. Next, the foreign matter removing unit 104 removes foreign matter in the tube T by blowing clean air into the tube T. Then, the brick filling unit 105 fills the tube T with the contents.
　次に、マーク位置合せ部１０６が、カラーセンサによりチューブＴのマークＩを検出し、マークＩが予め設定された所定方向を向くようにチューブＴを位置合せする。次に、品種確認部１０７が、カメラによりチューブＴの品種を確認する。そして、ヒートシール部１０８が、チューブＴの開口部を熱溶融して圧着することによりヒートシールする。次に、包装ロット刻印部１０９が、エンドシール部Ｅに包装ロットを刻印する。そして、外観検査部１１０が、チューブＴのデザインの位置を検査する。次に、Ｒカッター部１１１が、エンドシール部Ｅの端部をカットする。最後に、排出部１１２が、ダンパー式コンベア１１３によりチューブＴを後工程に排出する。 Next, the mark alignment unit 106 detects the mark I of the tube T by the color sensor, and aligns the tube T so that the mark I faces a predetermined direction set in advance. Next, the product type confirmation unit 107 confirms the product type of the tube T using a camera. And the heat seal part 108 heat-seals by heat-melting and crimping | bonding the opening part of the tube T. FIG. Next, the packaging lot marking unit 109 marks the packaging lot on the end seal portion E. Then, the appearance inspection unit 110 inspects the design position of the tube T. Next, the R cutter part 111 cuts the end part of the end seal part E. Finally, the discharge unit 112 discharges the tube T to the subsequent process by the damper type conveyor 113.
　図４は、本実施形態による制御システムの構成を示す概略図である。
　制御システムは、充填機Ｐ内の外観検査部１１０においてチューブＴのデザインの位置を検査する。制御システムは、照明１と、反射板２と、カメラ（撮像部）３と、画像処理装置４と、シーケンサ５とを含んで構成される。照明１、反射板２、及び、カメラ３は、充填機Ｐ内の外観検査部１１０に設置される。照明１は、充填機Ｐ内を流れるチューブＴの裏面及び反射板に光を照射する。反射板（反射部材）２は、照明１からの光をチューブＴの正面に反射する。カメラ３は、チューブＴの正面を撮像して画像を生成し、生成した画像を画像処理装置４に出力する。以下、照明１と、反射板２と、カメラ３とから構成されるシステムを照明システムと称する。照明システムの詳細な構成は後述する。 FIG. 4 is a schematic diagram showing the configuration of the control system according to the present embodiment.
The control system inspects the design position of the tube T in the appearance inspection unit 110 in the filling machine P. The control system includes an illumination 1, a reflector 2, a camera (imaging unit) 3, an image processing device 4, and a sequencer 5. The illumination 1, the reflector 2, and the camera 3 are installed in the appearance inspection unit 110 in the filling machine P. The illumination 1 irradiates light to the back surface of the tube T flowing through the filling machine P and the reflector. The reflection plate (reflection member) 2 reflects light from the illumination 1 to the front surface of the tube T. The camera 3 captures the front side of the tube T to generate an image, and outputs the generated image to the image processing device 4. Hereinafter, a system composed of the illumination 1, the reflector 2, and the camera 3 is referred to as an illumination system. The detailed configuration of the illumination system will be described later.
　画像処理装置４は、カメラ３から入力された画像に基づいてチューブＴにおけるデザインの左右のずれを検出する。そして、画像処理装置４は、検出結果に基づいてチューブＴの良品又は不良品を判定し、判定結果をシーケンサ５に出力する。シーケンサ５は、入力された判定結果に基づき、充填機Ｐ内を流れるチューブＴ夫々の良品又は不良品を判定し、各チューブＴにステータス情報（良品又は不良品）付与して記憶する。そして、シーケンサ５は、各チューブＴのステータス情報に基づいてダンパー式コンベア１１３へ動作指示を出力する。例えば、シーケンサ５は、チューブＴが良品である場合には、チューブＴを生産ラインの後工程（第１の方向）に排出する動作指示をダンパー式コンベア１１３に出力する。一方、シーケンサ５は、チューブＴが不良品である場合には、チューブＴを生産ラインの系外（第２の方向）に排出する動作指示をダンパー式コンベア１１３に出力する。 The image processing device 4 detects a left / right shift of the design in the tube T based on the image input from the camera 3. Then, the image processing device 4 determines whether the tube T is good or defective based on the detection result, and outputs the determination result to the sequencer 5. The sequencer 5 determines whether each tube T flowing through the filling machine P is non-defective or defective based on the input determination result, and assigns status information (non-defective or defective) to each tube T and stores it. Then, the sequencer 5 outputs an operation instruction to the damper type conveyor 113 based on the status information of each tube T. For example, when the tube T is a non-defective product, the sequencer 5 outputs an operation instruction for discharging the tube T to a post-process (first direction) on the production line to the damper conveyor 113. On the other hand, when the tube T is a defective product, the sequencer 5 outputs an operation instruction for discharging the tube T out of the production line (second direction) to the damper conveyor 113.
　図５は、本実施形態による検査システムの機能構成を示すブロック図である。
　検査システムは、上述した制御システムにおいて用いられ、チューブＴの良品又は不良品を判定するシステムである。検査システムは、照明システムと、画像処理装置４と、入力部６と、照明制御部７と、表示部８とを含んで構成される。照明システムの詳細な構成は後述する。 FIG. 5 is a block diagram showing a functional configuration of the inspection system according to the present embodiment.
The inspection system is a system that is used in the above-described control system and determines whether the tube T is a non-defective product or a defective product. The inspection system includes an illumination system, an image processing device 4, an input unit 6, an illumination control unit 7, and a display unit 8. The detailed configuration of the illumination system will be described later.
　入力部６は、照明１の照度を制御する制御値の入力を受け付ける。照明制御部７は、入力部６により入力された制御値に基づいて、照明１の照度を制御する。具体的には、照明制御部７は、例えば、照明１への供給電圧又は電流を変化させることにより、照明１の照度を制御する。表示部８は、カメラ３が撮像した画像を表示する。この構成により、作業者は、検査を実施する際に、表示部８に表示された画像を確認しながら、入力部６により照明１の照度を設定することができる。これにより、被検査物であるチューブＴの大きさや形状、デザインに応じて照明１の照度を調整することができる。 The input unit 6 receives an input of a control value that controls the illuminance of the illumination 1. The illumination control unit 7 controls the illuminance of the illumination 1 based on the control value input by the input unit 6. Specifically, the illumination control unit 7 controls the illuminance of the illumination 1 by, for example, changing the supply voltage or current to the illumination 1. The display unit 8 displays an image captured by the camera 3. With this configuration, the operator can set the illuminance of the illumination 1 by the input unit 6 while confirming the image displayed on the display unit 8 when performing the inspection. Thereby, the illumination intensity of the illumination 1 can be adjusted according to the magnitude | size, shape, and design of the tube T which is a to-be-inspected object.
　カメラ３の撮像した画像に基づいてチューブＴの良品又は不良品を判定する画像処理装置４は、画像入力部４０１と、エッジ検出部４０２と、ウィンドウ決定部４０３と、ずれ検出部４０４と、判定部４０５と、判定結果出力部４０６とを含んで構成される。画像処理装置４は、チューブＴのマークＩの位置に基づいてチューブＴの良品又は不良品を判定する。画像入力部４０１は、カメラ３から画像の入力を受け付け、入力された画像を表示部８とエッジ検出部４０２とに出力する。エッジ検出部４０２は、入力された画像におけるチューブＴの左端のエッジを検出する。ウィンドウ決定部４０３は、エッジ検出部４０２により検出された左端のエッジに基づいて、マークＩが有るべき範囲であるマーク検出ウィンドウを決定する。 An image processing apparatus 4 that determines a non-defective product or a defective product of the tube T based on an image captured by the camera 3 includes an image input unit 401, an edge detection unit 402, a window determination unit 403, a deviation detection unit 404, and a determination. 405 and a determination result output unit 406. The image processing apparatus 4 determines whether the tube T is good or defective based on the position of the mark I on the tube T. The image input unit 401 receives an image input from the camera 3 and outputs the input image to the display unit 8 and the edge detection unit 402. The edge detection unit 402 detects the left edge of the tube T in the input image. The window determination unit 403 determines a mark detection window that is a range where the mark I should be based on the leftmost edge detected by the edge detection unit 402.
　ずれ検出部４０４は、ウィンドウ決定部４０３により決定されたマーク検出ウィンドウにマークＩがあるか否かに基づいて、チューブＴのデザインのずれを検出する。具体的には、ずれ検出部４０４は、マーク検出ウィンドウにおけるマーク色の画素数を計数し、計数した画素数が所定の範囲α内である場合に、マーク検出ウィンドウにマークＩがあると判定する。範囲αの上限値と下限値とは予め設定されている。例えば、範囲αは、マーク検出ウィンドウ内にある画素のうち８０％以上の画素等考えられる。一方、ずれ検出部４０４は、計数した画素数が範囲α外である場合に、マーク検出ウィンドウにマークＩがないと判定し、チューブＴのデザインのずれを検出する。判定部４０５は、ずれ検出部４０４における検出結果に基づき、チューブＴの良品又は不良品を判定する。具体的には、判定部４０５は、デザインのずれが検出されなかった場合にチューブＴを良品と判定し、デザインのずれが検出された場合にチューブＴを不良品と判定する。判定結果出力部４０６は、判定部４０５による判定結果をシーケンサ５に送信する。 The deviation detection unit 404 detects a design deviation of the tube T based on whether or not the mark I is present in the mark detection window determined by the window determination unit 403. Specifically, the deviation detection unit 404 counts the number of pixels of the mark color in the mark detection window, and determines that the mark I is in the mark detection window when the counted number of pixels is within a predetermined range α. . The upper limit value and the lower limit value of the range α are set in advance. For example, the range α may be 80% or more of the pixels within the mark detection window. On the other hand, when the counted number of pixels is out of the range α, the deviation detection unit 404 determines that there is no mark I in the mark detection window, and detects a design deviation of the tube T. The determination unit 405 determines a non-defective product or a defective product of the tube T based on the detection result in the deviation detection unit 404. Specifically, the determination unit 405 determines that the tube T is a non-defective product when a design shift is not detected, and determines that the tube T is a defective product when a design shift is detected. The determination result output unit 406 transmits the determination result by the determination unit 405 to the sequencer 5.
　図６は、本実施形態による照明システムの設置位置を示す概略図である。
　図６において、チューブＴの正面が向いている方向を前方と定義する。また、チューブＴの裏面が向いている方向を後方と定義する。
　照明システムは、照明１と、反射板２と、カメラ３とを含んで構成される。照明システムは、充填機Ｐ内の外観検査部１１０に設置される。照明１と反射板２との間にチューブＴを配置する。 FIG. 6 is a schematic diagram showing the installation position of the illumination system according to the present embodiment.
In FIG. 6, the direction in which the front of the tube T is facing is defined as the front. Moreover, the direction in which the back surface of the tube T faces is defined as the back.
The illumination system includes an illumination 1, a reflection plate 2, and a camera 3. The illumination system is installed in the appearance inspection unit 110 in the filling machine P. A tube T is disposed between the illumination 1 and the reflector 2.
　照明１は、ＬＥＤ（Light Emitting Diode）等の面光源であり、その光の色は白色である。照明１の横幅（又は縦幅）は、少なくともチューブＴの横幅より大きい。照明１の縦幅（又は横幅）は、少なくともマークＩの縦幅より大きい。照明１は、充填機Ｐ内の限られたスペース（例えば、奥行き３５ｍｍ～９５ｍｍ）に設置される。このため、照明１として薄型（例えば、厚さ約８ｍｍ）の照明を用いるのが好ましい。
　照明１は、その発光部を前方に向けて、チューブＴより後方の位置に設置される。また、照明１は、反射板２と、充填機Ｐ内を流れるチューブＴの裏面とを照射するよう設置される。ここで、照明１は、チューブＴの裏面を、少なくともマークＩ下部より上方にあるチューブＴの左右両端を含んで照射するよう設置される。 The illumination 1 is a surface light source such as an LED (Light Emitting Diode), and the color of the light is white. The horizontal width (or vertical width) of the illumination 1 is at least larger than the horizontal width of the tube T. The vertical width (or horizontal width) of the illumination 1 is at least larger than the vertical width of the mark I. The illumination 1 is installed in a limited space (for example, a depth of 35 mm to 95 mm) in the filling machine P. For this reason, it is preferable to use a thin (for example, about 8 mm thick) illumination as the illumination 1.
The illuminator 1 is installed at a position behind the tube T with its light emitting part facing forward. Moreover, the illumination 1 is installed so that the reflecting plate 2 and the back surface of the tube T flowing through the filling machine P may be irradiated. Here, the illumination 1 is installed so as to irradiate the back surface of the tube T including at least the left and right ends of the tube T above the lower part of the mark I.
　反射板２は、光を反射する板である。反射板２の反射面の材質はポリテトラフルオロエチレンである。ポリテトラフルオロエチレンは、鏡等に比べて光の拡散率が大きい。また、反射板２の色がチューブＴに映り込まないように、反射板２の反射面の色は白色が好ましい。
　反射板２は、照明１から照射される光をチューブＴのマークＩ周囲に反射するように、その反射面を後方に向けて、チューブＴより前方の位置に設置される。光源（照明１）における光の照射方向（水平方向）に対する反射板２の反射面の角度はθである。角度θは、３０度から６０度であり、好ましくは４０度から５０度であり、より好ましくは４５度である。 The reflecting plate 2 is a plate that reflects light. The material of the reflecting surface of the reflecting plate 2 is polytetrafluoroethylene. Polytetrafluoroethylene has a higher light diffusivity than a mirror or the like. Further, the color of the reflecting surface of the reflecting plate 2 is preferably white so that the color of the reflecting plate 2 does not appear in the tube T.
The reflecting plate 2 is installed at a position in front of the tube T with its reflecting surface facing rearward so that the light emitted from the illumination 1 is reflected around the mark I of the tube T. The angle of the reflecting surface of the reflecting plate 2 with respect to the light irradiation direction (horizontal direction) in the light source (illumination 1) is θ. The angle θ is 30 degrees to 60 degrees, preferably 40 degrees to 50 degrees, and more preferably 45 degrees.
　カメラ３は、ＣＣＤ（Charge Coupled Device Image Sensor）カメラである。
　カメラ３は、その光学系を後方に向けて、チューブＴより前方の位置に設置される。また、カメラ３は、充填機Ｐ内を流れるチューブＴの正面を、少なくともマークＩとチューブＴの左右両端とを含んで撮像できるよう設置される。 The camera 3 is a CCD (Charge Coupled Device Image Sensor) camera.
The camera 3 is installed at a position in front of the tube T with its optical system facing rearward. Moreover, the camera 3 is installed so that the front surface of the tube T flowing through the filling machine P can be imaged including at least the mark I and the left and right ends of the tube T.
　照明１、反射板２及びカメラ３の高さ並びに反射板２の角度θは調整可能である。これにより、被検査物であるチューブＴの大きさや形状、デザインに応じて照明１、反射板２及びカメラ３の位置を調整することができる。 The height of the illumination 1, the reflector 2 and the camera 3, and the angle θ of the reflector 2 can be adjusted. Thereby, the position of the illumination 1, the reflecting plate 2, and the camera 3 can be adjusted according to the magnitude | size, shape, and design of the tube T which is a test object.
　図６には、高さ１４０ｍｍ（符号ｈ）のチューブＴに対する照明１と反射板２とカメラ３の設置位置の一例が示されている。照明１は、チューブＴの中心から５５ｍｍ（符号ｉ）後方であって、高さ１１２ｍｍ（符号ｊ）の位置に設置される。すなわち、照明１は、チューブＴの背面側に配置される。照明１の上端は、チューブＴよりも上方に位置する。照明１の下端は、マークＩよりも下方に位置する。反射板２は、照明１から１００ｍｍ（符号ｋ）前方の位置に角度θ＝４５度で設置される。すなわち、反射板２は、チューブＴの第１面側であってチューブＴよりも上方に配置される。反射板２は、チューブＴの第１面と対向するように、照明１の光の照射方向に対して傾斜している。また、カメラ３は、チューブＴの中心から１３０ｍｍ（符号ｌ）前方であって、反射板２の下部から６５ｍｍ（符号ｍ）前方の位置に設置される。 FIG. 6 shows an example of the installation positions of the illumination 1, the reflector 2, and the camera 3 with respect to the tube T having a height of 140 mm (symbol h). The illumination 1 is installed 55 mm (symbol i) behind the center of the tube T and at a height of 112 mm (symbol j). That is, the illumination 1 is arranged on the back side of the tube T. The upper end of the illumination 1 is located above the tube T. The lower end of the illumination 1 is located below the mark I. The reflector 2 is installed at an angle θ = 45 degrees at a position 100 mm (symbol k) ahead of the illumination 1. That is, the reflecting plate 2 is disposed on the first surface side of the tube T and above the tube T. The reflecting plate 2 is inclined with respect to the light irradiation direction of the illumination 1 so as to face the first surface of the tube T. The camera 3 is installed 130 mm (symbol 1) in front of the center of the tube T and 65 mm (symbol m) in front of the lower part of the reflector 2.
　充填機Ｐは、チューブＴを２個セットにして各工程を行う。このため、この照明システムを横に２つ並べ、２個のチューブＴを略同時に撮像して検査してもよい。この場合、照明１の横幅を大きくして、１つの照明１で２個のチューブＴを照射できるようにしてもよい。 The filling machine P performs each process by setting two tubes T. Therefore, two illumination systems may be arranged side by side, and the two tubes T may be imaged and inspected substantially simultaneously. In this case, the lateral width of the illumination 1 may be increased so that the two tubes T can be irradiated with one illumination 1.
　図７は、本実施形態による照明システムにより撮像された画像である。
　図７に示すように、照明１がチューブＴの裏面を照射しているため、マークＩ下部より上方にあるチューブＴの左右両端が鮮明に撮像される。すなわち、図７に示すように、カメラ３が撮像した画像においては、マークＩ下部より上方にあるチューブＴの左右両端の背景に照明１（すなわち、照明１からの直接的な照射光）が写っている。このため、チューブＴの左右両端を良好に検出することができる。また、反射板２により照明１の光を拡散させてマークＩに照射しているため、ハレーションを防いでマークＩを鮮明に撮像することができる。 FIG. 7 is an image captured by the illumination system according to the present embodiment.
As shown in FIG. 7, since the illumination 1 irradiates the back surface of the tube T, the left and right ends of the tube T above the lower part of the mark I are clearly imaged. That is, as shown in FIG. 7, in the image captured by the camera 3, the illumination 1 (that is, the direct irradiation light from the illumination 1) is reflected in the background of the left and right ends of the tube T above the lower part of the mark I. ing. For this reason, the right and left ends of the tube T can be detected well. Further, since the light of the illumination 1 is diffused by the reflector 2 and applied to the mark I, halation can be prevented and the mark I can be imaged clearly.
　次に、画像処理装置４が、上述した照明システムにより撮像された画像から、チューブＴのデザインのずれを検出する処理について説明する。
　図８Ａ～８Ｄは、本実施形態による画像処理装置４における良否判定処理の説明図である。
　まず、画像入力部４０１が、カメラ３から画像を取得する（図８Ａ参照）。次に、エッジ検出部４０２が、予め設定してある所定の範囲である検査ウィンドウＷにおいて、左から右へ走査し、色の変化が最も大きい箇所をチューブエッジＧとして検出する（図８Ｂ参照）。次に、ウィンドウ決定部４０３が、チューブエッジＧを基点として、マーク検出ウィンドウＭを決定する（図８Ｃ，図８Ｄ参照）。具体的には、ウィンドウ決定部４０３は、チューブエッジＧから所定画素分右にある領域をマーク検出ウィンドウＭに設定する。 Next, a process in which the image processing device 4 detects a design deviation of the tube T from an image captured by the above-described illumination system will be described.
8A to 8D are explanatory diagrams of pass / fail judgment processing in the image processing apparatus 4 according to the present embodiment.
First, the image input unit 401 acquires an image from the camera 3 (see FIG. 8A). Next, the edge detection unit 402 scans from the left to the right in the inspection window W which is a predetermined range set in advance, and detects a portion having the largest color change as the tube edge G (see FIG. 8B). . Next, the window determining unit 403 determines the mark detection window M using the tube edge G as a base point (see FIGS. 8C and 8D). Specifically, the window determination unit 403 sets an area that is a predetermined pixel to the right of the tube edge G as the mark detection window M.
　次に、ずれ検出部４０４が、マーク検出ウィンドウＭ内でマーク色の画素を計数する。
　ずれ検出部４０４は、計数した画素数が範囲α内である場合にチューブＴのデザインにずれがないことを検出する（図８Ｃ参照）。一方、ずれ検出部４０４は、計数した画素数が範囲α外である場合にチューブＴのデザインにずれがあることを検出する（図８Ｄ）。最後に、判定部４０５が、デザインにずれがないチューブＴを良品と判定し、デザインにずれがあるチューブＴを不良品と判定する。例えば、図８Ｃに示すチューブＴの場合、マーク検出ウィンドウＭの位置にマークＩが存在するため、マーク色の画素数は範囲α内である。このため、画像処理装置４は、図８Ｃに示すチューブＴを良品と判定する。一方、図８Ｄに示すチューブＴの場合、マーク検出ウィンドウＭの位置にマークＩが存在しないため、マーク色の画素数は「０」であり、範囲α外である。このため、画像処理装置４は、図８Ｄに示すチューブＴを不良品と判定する。 Next, the deviation detection unit 404 counts the mark color pixels in the mark detection window M.
The deviation detection unit 404 detects that there is no deviation in the design of the tube T when the counted number of pixels is within the range α (see FIG. 8C). On the other hand, the deviation detection unit 404 detects that there is a deviation in the design of the tube T when the counted number of pixels is outside the range α (FIG. 8D). Finally, the determination unit 405 determines that the tube T without design deviation is a non-defective product, and determines that the tube T with design deviation is a defective product. For example, in the case of the tube T shown in FIG. 8C, since the mark I exists at the position of the mark detection window M, the number of pixels of the mark color is within the range α. For this reason, the image processing apparatus 4 determines that the tube T shown in FIG. 8C is a non-defective product. On the other hand, in the case of the tube T shown in FIG. 8D, since the mark I does not exist at the position of the mark detection window M, the number of pixels of the mark color is “0” and out of the range α. For this reason, the image processing apparatus 4 determines that the tube T illustrated in FIG. 8D is a defective product.
　次に、図９を参照して、画像処理装置３による良否判定処理について説明する。図９は、本実施形態による良否判定処理の手順を示すフローチャートである。
　まず、エッジ検出部４０２が、カメラ３から取得した画像において、検査ウィンドウＷを左から右へ走査し、色の変化が最も大きい箇所をチューブエッジＧとして検出する（ステップＳ１０１）。次に、ウィンドウ決定部４０３が、チューブエッジＧを基点として、マーク検出ウィンドウＭを決定する（ステップＳ１０２）。次に、ずれ検出部４０４が、マーク検出ウィンドウＭにおけるマーク色の画素数を計数する（ステップＳ１０３）。そして、ずれ検出部４０４は、計数したマーク色の画素数が範囲α内（画素数が所定の閾値内）であるか否かを判定する（ステップＳ１０４）。計数した画素数が範囲α内である場合（ステップＳ１０４：Ｙｅｓ）、判定部４０５は、チューブＴが良品（ＯＫ）であると判定し（ステップＳ１０５）、処理を終了する。一方、計数した画素数が範囲α内でない場合（ステップＳ１０４：Ｎｏ）に、判定部４０５は、チューブＴが不良品（ＮＧ）であると判定し（ステップＳ１０６）、処理を終了する。 Next, with reference to FIG. 9, the quality determination process by the image processing apparatus 3 will be described. FIG. 9 is a flowchart showing a procedure of pass / fail judgment processing according to the present embodiment.
First, the edge detection unit 402 scans the inspection window W from the left to the right in the image acquired from the camera 3, and detects a portion having the largest color change as the tube edge G (step S101). Next, the window determination unit 403 determines the mark detection window M using the tube edge G as a base point (step S102). Next, the deviation detection unit 404 counts the number of pixels of the mark color in the mark detection window M (step S103). Then, the deviation detection unit 404 determines whether or not the counted number of pixels of the mark color is within the range α (the number of pixels is within a predetermined threshold) (step S104). When the counted number of pixels is within the range α (step S104: Yes), the determination unit 405 determines that the tube T is a non-defective product (OK) (step S105), and ends the process. On the other hand, when the counted number of pixels is not within the range α (step S104: No), the determination unit 405 determines that the tube T is a defective product (NG) (step S106), and ends the process.
　次に、本実施形態による照明システムによる撮像結果と、チューブＴを直接照射した場合の撮像結果とを比較する。
　図１０Ａ～１０Ｃは、本実施形態による照明システムにおけるカメラ３の撮像結果を示す。図１０Ａは、上述した照明システムの配置で反射板２の材質をポリテトラフルオロエチレンとした場合の撮像結果である。図１０Ｂは、上述した照明システムの配置で反射板２を鏡とした場合の撮像結果である。比較のため、図１０Ｃに、照明１からチューブＴの正面を直接照射した場合の撮像結果を示す。 Next, the imaging result by the illumination system according to the present embodiment is compared with the imaging result when the tube T is directly irradiated.
10A to 10C show the imaging results of the camera 3 in the illumination system according to the present embodiment. FIG. 10A shows an imaging result when the reflector 2 is made of polytetrafluoroethylene in the above-described illumination system arrangement. FIG. 10B is an imaging result when the reflector 2 is a mirror in the arrangement of the illumination system described above. For comparison, FIG. 10C shows an imaging result when the front surface of the tube T is directly irradiated from the illumination 1.
　図１０Ｃに示すように、チューブＴの正面を直接照射して撮像すると、エンドシール部Ｅにおいてハレーションが発生するため、マークＩが消え、更に、チューブＴのチューブエッジＧがかすむ。このため、チューブＴを直接照射すると、画像処理によりマークＩを検出することができなかった。これに対して、図１０Ｂに示すように、照明システムにおいて鏡を反射板２に用いた場合には、直接照射した場合と比べるとハレーションを抑制することができるため、マークＩを撮像することができる。しかしながら、鏡はポリテトラフルオロエチレンに比べて光の拡散率が低いため、ハレーションが残り、図示するようにマークＩの色がかすむ場合や他の色（例えば、青）がマーク色に写る場合がある。このため、反射板２に鏡を用いた場合には、マークＩの検出率が低下する。これらに対して、図１０Ａに示すように、本実施形態による照明システムにおいてポリテトラフルオロエチレンを反射板２に用いた場合には、ハレーションを防ぎ、マークＩ及びチューブエッジＧを鮮明に撮像することができる。このため、この撮像画像に基づいて検査をした場合には良好な結果が得られた。これにより、上述した照明システムの配置で反射板２をポリテトラフルオロエチレンとした場合には、画像処理によりマークＩをより精度良く検出することができる。 As shown in FIG. 10C, when imaging is performed by directly irradiating the front surface of the tube T, halation occurs at the end seal portion E, so that the mark I disappears and the tube edge G of the tube T becomes hazy. For this reason, when the tube T was directly irradiated, the mark I could not be detected by image processing. On the other hand, as shown in FIG. 10B, when a mirror is used for the reflecting plate 2 in the illumination system, halation can be suppressed as compared with the case of direct irradiation. it can. However, since the mirror has a lower light diffusivity than polytetrafluoroethylene, halation remains, and as shown in the figure, the color of the mark I may be blurred, or other colors (for example, blue) may appear in the mark color. is there. For this reason, when a mirror is used for the reflecting plate 2, the detection rate of the mark I decreases. On the other hand, as shown in FIG. 10A, when polytetrafluoroethylene is used for the reflector 2 in the illumination system according to the present embodiment, halation is prevented and the mark I and the tube edge G are imaged clearly. Can do. For this reason, a good result was obtained when the inspection was performed based on the captured image. Thereby, when the reflector 2 is made of polytetrafluoroethylene in the arrangement of the illumination system described above, the mark I can be detected with higher accuracy by image processing.
　図１１は、本実施形態による検査システムの実験結果を示す。
　図１１に示す表において、チューブ品質は、目視により良品又は不良品を判定した結果を示す。検査機判定は、検査システムによる良品（ＯＫ）又は不良品（ＮＧ）の判定結果を示す。図１１に示すように、検査システムによる判定結果は、目視による判定結果と全て一致する。このように、本実施形態による検査システムは、従来のように目視した場合の検査品質を維持することができる。 FIG. 11 shows the experimental results of the inspection system according to the present embodiment.
In the table | surface shown in FIG. 11, tube quality shows the result of having determined the quality goods or inferior goods by visual observation. The inspection machine determination indicates a determination result of a non-defective product (OK) or a defective product (NG) by the inspection system. As shown in FIG. 11, the determination results obtained by the inspection system all match the visual determination results. Thus, the inspection system according to the present embodiment can maintain the inspection quality when visually observed as in the conventional case.
　図１２は、本実施形態によるチューブＴ位置における照度変化を示すグラフである。
　このグラフにおいて、横軸は光源が発する光の強さ（照度）を制御する制御値（単位はツマミボリューム（Ｖｏｌ（Ｖｏｌｕｍｅ）））である。縦軸はチューブＴ位置における照度（単位はルクス（Ｌｘ））である。
　図１２に示す線２０１は、チューブＴの正面を照明１で直接照射した場合の照度変化を示す。線２０２は、本実施形態による照明システムにおいて反射板２に鏡を用いた場合の照度変化を示す。線２０３は、本実施形態による照明システムにおいて反射板にポリテトラフルオロエチレンを用いた場合の照度変化を示す。
　図１２に示すように、本実施形態による照明システムを用いた場合におけるチューブＴの照度は、制御値に対して略直線的に緩やかに変化する。このため、チューブＴのデザインや形状に応じて照度をより細かく調整することができる。一方、チューブＴの正面を直接照射した場合の照度は、制御値に対して変化が不安定であり、照度の調整が困難である。
　また、反射板２にポリテトラフルオロエチレンを用いた場合の照度は、反射板２に鏡を用いた場合に比べてより穏やかに変化する。これは、ポリテトラフルオロエチレンが鏡に比べて光の拡散率が大きいためである。このため、反射板２にポリテトラフルオロエチレンを用いた方が、鏡を用いた場合に比べてハレーションがより起きにくい。 FIG. 12 is a graph showing a change in illuminance at the tube T position according to the present embodiment.
In this graph, the horizontal axis represents a control value (unit: knob volume (Vol)) for controlling the intensity (illuminance) of light emitted from the light source. The vertical axis represents the illuminance at the tube T position (unit: lux (Lx)).
A line 201 illustrated in FIG. 12 indicates a change in illuminance when the front surface of the tube T is directly irradiated with the illumination 1. A line 202 indicates a change in illuminance when a mirror is used for the reflector 2 in the illumination system according to the present embodiment. A line 203 indicates a change in illuminance when polytetrafluoroethylene is used for the reflector in the illumination system according to the present embodiment.
As shown in FIG. 12, the illuminance of the tube T when the illumination system according to the present embodiment is used changes gently in a substantially linear manner with respect to the control value. For this reason, illumination intensity can be adjusted more finely according to the design and shape of the tube T. On the other hand, the illuminance when the front surface of the tube T is irradiated directly is unstable with respect to the control value, and it is difficult to adjust the illuminance.
Further, the illuminance when polytetrafluoroethylene is used for the reflecting plate 2 changes more gently than when a mirror is used for the reflecting plate 2. This is because polytetrafluoroethylene has a higher light diffusion rate than a mirror. For this reason, halation is less likely to occur when polytetrafluoroethylene is used for the reflector 2 than when a mirror is used.
　このように、本実施形態によれば、裏面からチューブＴを照明１で照射し、照明１から照射される光を反射板２でチューブＴの正面に反射する。このため、チューブＴ表面に光沢がある場合であっても、塵や塵の混入を防ぐためにカバーされた充填機Ｐ内で、ハレーションを防いでチューブＴのマークＩをより鮮明に撮像することができる。これにより、生産ライン上で精度良くチューブＴの良品又は不良品を判定することができる。
　また、入力部６、照明制御部７及び表示部８を備えることにより、検査を行う作業者は、撮像された画像を確認しながら、チューブＴのデザインや形状に応じて照明１の照度を微調整することができる。また、反射板２をポリテトラフルオロエチレンとしたことにより、照明１の光が拡散されて反射されるため、より細かくチューブＴの正面に反射される光の照度を調整することができる。 Thus, according to this embodiment, the tube T is irradiated from the back surface with the illumination 1, and the light irradiated from the illumination 1 is reflected to the front surface of the tube T by the reflection plate 2. For this reason, even when the surface of the tube T is glossy, the mark I on the tube T can be imaged more clearly by preventing halation in the filling machine P that is covered to prevent dust and dust from entering. it can. Thereby, the non-defective product or the defective product of the tube T can be accurately determined on the production line.
In addition, by providing the input unit 6, the illumination control unit 7, and the display unit 8, an operator who performs the inspection can reduce the illuminance of the illumination 1 according to the design and shape of the tube T while checking the captured image. Can be adjusted. Further, since the reflector 2 is made of polytetrafluoroethylene, the light of the illumination 1 is diffused and reflected, so that the illuminance of the light reflected on the front surface of the tube T can be adjusted more finely.
　図９に示す各ステップを実現するためのプログラムをコンピュータ読み取り可能な記録媒体に記録して、この記録媒体に記録されたプログラムをコンピュータシステムに読み込ませ、実行することにより、チューブＴの良品又は不良品を判定する処理を行ってもよい。ここでいう「コンピュータシステム」とは、ＯＳや周辺機器等のハードウェアを含むものであってもよい。
　「コンピュータ読み取り可能な記録媒体」とは、フレキシブルディスク、光磁気ディスク、ＲＯＭ、フラッシュメモリ等の書き込み可能な不揮発性メモリ、ＣＤ－ＲＯＭ等の可搬媒体、コンピュータシステムに内蔵されるハードディスク等の記憶装置のことをいう。 A program for realizing each step shown in FIG. 9 is recorded on a computer-readable recording medium, and the program recorded on the recording medium is read into a computer system and executed. You may perform the process which determines a non-defective product. Here, the “computer system” may include an OS and hardware such as peripheral devices.
“Computer-readable recording medium” means a flexible disk, a magneto-optical disk, a ROM, a writable nonvolatile memory such as a flash memory, a portable medium such as a CD-ROM, and a storage such as a hard disk built in a computer system. Refers to the device.
　「コンピュータ読み取り可能な記録媒体」とは、インターネット等のネットワークや電話回線等の通信回線を介してプログラムが送信された場合のサーバやクライアントとなるコンピュータシステム内部の揮発性メモリ（例えばＤＲＡＭ（Dynamic Random Access Memory））のように、一定時間プログラムを保持しているものも含むものとする。
　上記プログラムは、このプログラムを記憶装置等に格納したコンピュータシステムから、伝送媒体を介して、あるいは、伝送媒体中の伝送波により他のコンピュータシステムに伝送されてもよい。プログラムを伝送する「伝送媒体」は、インターネット等のネットワーク（通信網）や電話回線等の通信回線（通信線）のように情報を伝送する機能を有する媒体のことをいう。
　上記プログラムは、前述した機能の一部を実現するためのものであっても良い。
　前述した機能をコンピュータシステムにすでに記録されているプログラムとの組み合わせで実現できるもの、いわゆる差分ファイル（差分プログラム）であっても良い。 “Computer-readable recording medium” refers to a volatile memory (for example, DRAM (Dynamic Random) in a computer system that becomes a server or client when a program is transmitted via a network such as the Internet or a communication line such as a telephone line. Access Memory)) is also included, which holds a program for a certain period of time.
The program may be transmitted from a computer system storing the program in a storage device or the like to another computer system via a transmission medium or by a transmission wave in the transmission medium. A “transmission medium” for transmitting a program refers to a medium having a function of transmitting information, such as a network (communication network) such as the Internet or a communication line (communication line) such as a telephone line.
The program may be for realizing a part of the functions described above.
What can implement | achieve the function mentioned above in combination with the program already recorded on the computer system, and what is called a difference file (difference program) may be sufficient.
　以上、図面を参照してこの発明の一実施形態について詳しく説明してきたが、具体的な構成は上述のものに限られることはなく、この発明の要旨を逸脱しない範囲内において様々な設計変更等をすることが可能である。
　例えば、本実施形態では、反射板２の反射面の材質をポリテトラフルオロエチレンとしたが、これに限られない。拡散率の大きい材質であれば、例えば、ポリプロピレンやポリエチレン等の他の材質を反射板２に用いてもよい。
　また、本実施形態では、照明１をＬＥＤとしたが、これに限られない。例えば、照明１は、蛍光灯やハロゲンランプ等他の光源を用いてもよい。 As described above, the embodiment of the present invention has been described in detail with reference to the drawings. However, the specific configuration is not limited to the above, and various design changes and the like can be made without departing from the scope of the present invention. It is possible to
For example, in this embodiment, although the material of the reflective surface of the reflecting plate 2 is polytetrafluoroethylene, it is not limited to this. As long as the material has a high diffusivity, other materials such as polypropylene and polyethylene may be used for the reflector 2.
In the present embodiment, the illumination 1 is an LED, but is not limited thereto. For example, the illumination 1 may use another light source such as a fluorescent lamp or a halogen lamp.
　本発明は、照明システム、検査システム及び制御システムに適用することができる。 The present invention can be applied to lighting systems, inspection systems, and control systems.
　１      照明
　２   反射板
　３   カメラ
　４   画像処理装置
　５   シーケンサ
　６   入力部
　７   照明制御部
　８   表示部
　４０１      画像入力部
　４０２      エッジ検出部
　４０３      ウィンドウ決定部
　４０４      ずれ検出部
　４０５      判定部
　４０６      判定結果出力部
　Ｔ   チューブ（被検査物） DESCRIPTION OF SYMBOLS 1 Illumination 2 Reflector 3 Camera 4 Image processing apparatus 5 Sequencer 6 Input part 7 Illumination control part 8 Display part 401 Image input part 402 Edge detection part 403 Window determination part 404 Deviation detection part 405 Determination part 406 Determination result output part T Tube ( Inspected)

Claims (5)

  1. 　マークの印刷された被検査物のうち前記マークのある面であって前記マーク周囲に光沢のある第１の面を撮像し、撮像した画像に基づいて前記被検査物のデザインの位置を検査する検査システムにおいて用いられる照明システムであって、
    　前記被検査物の前記第１の面の背面側に配置され、前記被検査物よりも上方に位置する上端と前記マークよりも下方に位置する下端とを有し、光を照射する照明と、
    　前記被検査物の前記第１面側であって前記被検査物よりも上方に配置され、前記被検査物の第１面と対向するように前記照明の光の照射方向に対して傾斜し、前記照明からの光を反射する反射部材とを備え、
    　前記照明は、前記被検査物のうち前記第１の面の背面に光を直接的に照射するとともに、前記反射部材を介して、前記被検査物の前記第１面に光を間接的に照射する照明システム。     Of the inspected object on which the mark is printed, the surface having the mark and the first glossy surface around the mark are imaged, and the design position of the inspected object is inspected based on the captured image. An illumination system used in an inspection system,
    An illumination that is disposed on the back side of the first surface of the object to be inspected, has an upper end located above the object to be inspected, and a lower end located below the mark, and emits light;
    The first surface side of the inspection object is located above the inspection object, and is inclined with respect to the illumination direction of the illumination light so as to face the first surface of the inspection object, A reflective member that reflects light from the illumination,
    The illumination directly irradiates light to the back surface of the first surface of the inspection object and indirectly irradiates light to the first surface of the inspection object via the reflection member. Lighting system.
  2. 　前記反射部材に対して前記照明とは反対側に配置され、前記被検査物の第１の面を撮像することにより、少なくとも前記マークと前記被検査物の左右両端と含む画像を得る撮像部
    　をさらに備える請求項１に記載の照明システム。     An imaging unit that is arranged on the opposite side of the illumination with respect to the reflecting member and obtains an image including at least the mark and the left and right ends of the inspection object by imaging the first surface of the inspection object. The lighting system according to claim 1, further comprising:
  3. 　前記反射部材の反射面の材質はポリテトラフルオロエチレンである
    　請求項１又は２に記載の照明システム。     The illumination system according to claim 1, wherein a material of a reflection surface of the reflection member is polytetrafluoroethylene.
  4. 　請求項１乃至３のいずれか一項に記載の照明システムを用いて前記被検査物のデザインの位置を検出する検査システムであって、
    　前記被検査物のうち前記第１の面を撮像する撮像部と、
    　前記撮像部により撮像された画像において、前記マークの有るべき範囲を決定する決定部と、
    　前記決定部により決定された範囲における前記マークの有無に基づいて前記被検査物のデザインの位置を検出する検出部と、
    　を備える検査システム。     An inspection system that detects the position of the design of the object to be inspected using the illumination system according to claim 1,
    An imaging unit for imaging the first surface of the inspection object;
    A determination unit for determining a range of the mark in the image captured by the imaging unit;
    A detection unit that detects the position of the design of the inspection object based on the presence or absence of the mark in the range determined by the determination unit;
    An inspection system comprising:
  5. 　請求項４に記載の検査システムを用いて生産ラインを流れる被検査物の良品又は不良品を判定する制御システムであって、
    　前記検出部による検出結果に基づいて、前記生産ラインを流れる被検査物夫々の良品又は不良品を判定する制御部
    　を備える制御システム。     A control system for determining a non-defective product or a defective product of an inspection object flowing through a production line using the inspection system according to claim 4,
    A control system comprising: a control unit that determines a non-defective product or a defective product of each inspection object flowing through the production line based on a detection result by the detection unit.
PCT/JP2012/063732 2011-05-30 2012-05-29 Lighting system, inspection system and control system WO2012165419A1 (en)

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