WO2015151392A1 - 接合状態判定方法及び成型装置 - Google Patents
接合状態判定方法及び成型装置 Download PDFInfo
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- WO2015151392A1 WO2015151392A1 PCT/JP2015/000789 JP2015000789W WO2015151392A1 WO 2015151392 A1 WO2015151392 A1 WO 2015151392A1 JP 2015000789 W JP2015000789 W JP 2015000789W WO 2015151392 A1 WO2015151392 A1 WO 2015151392A1
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- Prior art keywords
- belt
- joint
- shaped member
- imaging data
- data
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- 0 CCCC(*)(C(CC)CO)[N-]CC Chemical compound CCCC(*)(C(CC)CO)[N-]CC 0.000 description 1
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D30/00—Producing pneumatic or solid tyres or parts thereof
- B29D30/0061—Accessories, details or auxiliary operations not otherwise provided for
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D30/00—Producing pneumatic or solid tyres or parts thereof
- B29D30/06—Pneumatic tyres or parts thereof (e.g. produced by casting, moulding, compression moulding, injection moulding, centrifugal casting)
- B29D30/08—Building tyres
- B29D30/20—Building tyres by the flat-tyre method, i.e. building on cylindrical drums
- B29D30/30—Applying the layers; Guiding or stretching the layers during application
- B29D30/3007—Applying the layers; Guiding or stretching the layers during application by feeding a sheet perpendicular to the drum axis and joining the ends to form an annular element
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M17/00—Testing of vehicles
- G01M17/007—Wheeled or endless-tracked vehicles
- G01M17/02—Tyres
-
- 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
-
- 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
- G01N21/8851—Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges
-
- 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
- G01N21/95—Investigating the presence of flaws or contamination characterised by the material or shape of the object to be examined
- G01N21/952—Inspecting the exterior surface of cylindrical bodies or wires
-
- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T7/00—Image analysis
- G06T7/0002—Inspection of images, e.g. flaw detection
- G06T7/0004—Industrial image inspection
-
- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T7/00—Image analysis
- G06T7/50—Depth or shape recovery
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D30/00—Producing pneumatic or solid tyres or parts thereof
- B29D30/0061—Accessories, details or auxiliary operations not otherwise provided for
- B29D2030/0066—Tyre quality control during manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D30/00—Producing pneumatic or solid tyres or parts thereof
- B29D30/06—Pneumatic tyres or parts thereof (e.g. produced by casting, moulding, compression moulding, injection moulding, centrifugal casting)
- B29D30/08—Building tyres
- B29D30/20—Building tyres by the flat-tyre method, i.e. building on cylindrical drums
- B29D30/30—Applying the layers; Guiding or stretching the layers during application
- B29D2030/3064—Details, accessories and auxiliary operations not otherwise provided for
-
- 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
- G01N2201/062—LED's
Definitions
- the present invention relates to a method for determining a joining state when a belt-like member is wound on a molding drum, both longitudinal ends of the belt-like member are joined to each other, and the belt-like member is molded into a cylindrical shape, and the method It is related with the molding apparatus which performs.
- the belt-shaped member when a member such as a tread of a tire is molded, the belt-shaped member is formed in a cylindrical shape by winding the belt-shaped member on a molding drum and joining the both longitudinal ends of the belt-shaped member.
- the thickness of the molded member becomes uneven.
- a malfunction occurs.
- the dimensions of the manufactured tire may become out of specification, or the surface properties of the tire may deteriorate and the appearance may be impaired.
- the position of the start and end of the band-shaped member is obtained using a two-dimensional laser displacement sensor or the like, depending on the arrangement of the sensor and the shape of the end of the band-shaped member, the sensor is connected to the joint between the longitudinal ends of the band-shaped member. In some cases, it was impossible to determine a bonding state such as a bonding failure.
- the present invention has been made in order to solve such problems of the prior art, and the object of the invention is to wrap a band-shaped member on a molding drum, and to connect both ends in the longitudinal direction.
- a joining state determination method capable of reliably determining the joining state between the longitudinal ends of the belt-like member, and molding capable of performing the method A device is provided.
- a member tip image data acquisition step for acquiring the member tip portion imaging data of the band-shaped member with respect to the end portion wound first, and after joining both longitudinal ends of the band-shaped member, the member joint of the band-shaped member
- a member joint part imaging data acquisition step for acquiring part imaging data, and the acquired member tip part imaging data based on the acquired member joint part imaging data.
- the first pattern matching step for calculating the matching rate representing the degree of coincidence of the member tip portion registration data registered based on the data, and the matching rate calculated in the first pattern matching step are predetermined values.
- the joining state determination method of the present invention it is possible to reliably determine the joining state between the longitudinal ends of the belt-shaped member, and according to the molding apparatus of the present invention, the method can be performed. .
- a molding apparatus 1 according to an embodiment of the present invention illustrated in FIG. 1 includes a molding drum 2 around which a belt-like member 21 such as a tread or a belt of a tire is wound, and when the belt-like member 21 is wound around the molding drum 2.
- End of the belt-shaped member 21 imaging data, which is an image of the end of the belt-shaped member 21 that is first wound around the molding drum 2, and the winding of the belt-shaped member 21 around the molding drum 2.
- the molding drum 2 is formed in a columnar shape or a cylindrical shape, and is rotated around the central axis Cr by a driving means such as a servo motor.
- the imaging means 3 includes at least a member tip portion (longitudinal end portion 21 of the strip-like member shown in FIG. 4) and a member joint portion (both end portions 21a in the longitudinal direction of the strip-like member) arranged on the molding drum 2. , 21b between the vicinity).
- the imaging means 3 can be constituted by a so-called image sensor that converts light and darkness of light emitted from an imaging object into an electrical signal, such as a CCD camera. Further, the image pickup means 3 is fixed in a posture in which the image pickup direction faces the molding drum 2 while being separated from the molding drum 2.
- joining state determination means 4 member tip portion master data described later and joint crack shape registration data are stored.
- the joining state determination unit 4 is connected to the imaging unit 3.
- the joining state determination unit 4 determines the joining state between the longitudinal ends of the strip member using the information, the member tip portion imaging data and the member joint portion imaging data of the strip member captured by the imaging unit 3. To do.
- the joining state determination means 4 can be configured by a computer system or other hardware that can execute program instructions, such as a personal computer.
- the connection between the joining state determination unit 4 and the imaging unit 3 can be a wired connection or a wireless connection.
- the molding apparatus 1 includes a control unit.
- the control unit controls the rotation of the molding drum 2 and gives an imaging instruction to the imaging unit 3.
- a control means can be comprised by what is called a controller which performs operation control according to a program, such as a programmable logic controller (PLC), for example.
- PLC programmable logic controller
- the molding apparatus 1 of this embodiment also includes a light source 11 composed of LEDs or the like.
- the light source 11 provides appropriate brightness for the imaging unit 3 to image the belt-like member 21. By providing the light source 11, the imaging unit 3 can perform imaging without being affected by ambient brightness.
- the molding apparatus 1 when the molding apparatus 1 according to this embodiment of the present invention winds the belt-like member 21 on the molding drum 2 and joins the longitudinal ends of the belt-like member 21 to each other, the joining state is determined.
- An embodiment of the joining state determination method of the invention will be described in detail with reference to the flowcharts of FIGS. 2A and 2B.
- a member tip portion master data registration step Prior to winding the belt-shaped member 21 on the molding drum 2, in this embodiment, as a member tip portion master data registration step, at least before a first pattern matching step described later (this embodiment will be described later).
- a belt-shaped member sample Prior to the member tip detection step, for example, a belt-shaped member sample that is the same type as the belt-shaped member 21 (for example, a tread when the belt-shaped member 21 is a tread), the same size, and a similar processed member.
- the member tip master data A of the belt-like member including the member tip master image of FIG. 3 and the position information of the member tip reference position Pa in the member tip master image shown in FIG. 3 is registered (step S101).
- FIG. 1 As shown in FIG.
- the band-shaped member sample 101 is arranged on the molding drum 2, and the region including the member tip portion reference position Pa and the member tip portion of the band-shaped member sample 101 by the imaging unit 3.
- the member tip portion master data A is created by imaging the (virtual region surrounded by a two-dot chain line).
- the member tip portion reference position Pa is one end in the width direction of the cut surface of the band-shaped member 21. Then, the position of the member tip portion reference position Pa in the member tip portion master data A is obtained.
- the member tip portion master data A created as described above is stored in the joining state determination means 4.
- the band-shaped member in a state in which a joint cracking defect is generated in which a gap is generated in at least a part between the longitudinal ends 21a and 21b of the band-shaped member.
- a joint crack shape registration data registration step of registering one or more joint crack shape registration data B, which is an image of at least a part of the joint portion of the member, is performed (step S102). Details of this step will be described later.
- the longitudinal end portion (member tip portion) 21a of the strip-shaped member 21 to be molded is disposed on the molding drum 2 of the molding apparatus 1, and winding of the strip-shaped member 21 is started (step S201).
- the longitudinal end 21a of the belt-like member 21 moves in the circumferential direction of the molding drum 2 (counterclockwise in FIGS. 4A to 4D) as the molding drum 2 rotates.
- the imaging means 3 is used as the member tip imaging data acquisition step of this embodiment.
- step S202 Captures and acquires the member tip image data C of the belt-like member 21 (step S202).
- the control means generates an imaging trigger so that imaging can be automated.
- the belt-like member 21 is wound while the molding drum 2 is rotated, and after the winding is finished (step S203), as shown in FIG. 4C, both longitudinal ends of the belt-like member 21, that is, both longitudinal ends 21a and 21b. They are joined together (step S204).
- the imaging means 3 captures and acquires the member joint part imaging data D of the belt-like member 21 (step S205). Again, imaging can be automated in the same manner as in step S202.
- the joining state determination means 4 of the molding apparatus 1 determines the joining state between the longitudinal ends of the belt-shaped member.
- the member tip portion detection step of this embodiment it is determined whether or not a member tip portion equivalent to the member tip portion of the registered member tip portion master data A can be detected in the acquired member tip portion imaging data C ( Step S301).
- the detection of the member front end can be performed by performing pattern matching on the member front end master data A for the member front end imaging data C. More specifically, both the images are subjected to pattern matching while relatively moving the member tip portion master data A and the member tip portion imaging data C.
- pattern matching can be performed by using, for example, a gray-scale correlation coefficient as a matching rate.
- tip part detection process is after the member front-end
- the threshold value can be appropriately set according to the purpose.
- the member tip portion detection step when the member tip portion equivalent to the member tip portion of the member tip portion master data A can be detected in the acquired member tip portion imaging data C, that is, for example, in the above pattern matching, If the matching rate exceeds or exceeds a predetermined threshold, the process proceeds to the member tip registration data registration step.
- the image of the member tip in the member tip imaging data C is registered as member tip registration data C1 (step S302).
- the shape of the belt-like member 21 generally changes depending on the outside air temperature or the like.
- the member tip registration data C1 based on the member tip image data C imaged at the time of molding is used to determine the joining state of the longitudinal ends of the belt-like member. By doing so, the joining state can be determined stably without being influenced by the change in the shape of the belt-like member due to the change in the outside air temperature.
- the joint boundary which is an image of the member tip portion including the member tip portion reference position Pc, from the member tip portion registration data C1.
- the copy registration data E is acquired (step S303).
- the joint boundary portion registration data E is an image of an area narrower than the member tip portion registration data C1, and specifically, for example, in the figure, starting from the member tip portion reference position Pc of the member tip portion registration data C1.
- the joint boundary registration data E is created by extracting a portion having a certain width (for example, the number of pixels corresponding to 1 mm) in the left-right direction of the image (direction substantially coincident with the longitudinal direction of the band-shaped member 21).
- the first pattern matching step and the first joining state determination step of this embodiment it is confirmed whether or not it is possible to detect the member tip portion in the member joint portion imaging data D corresponding to the member tip portion registration data C1.
- the pattern is obtained by using the member tip portion registration data C1 registered based on the acquired member tip portion imaging data C for the acquired member joint portion imaging data D. Matching is performed, and a matching rate indicating the degree of coincidence of the member tip portion registration data C1 with respect to the member joint portion imaging data D is calculated (step S304).
- the pattern matching method is the same as that exemplified in the description of the above-described member tip end detection step (step S301) except that the image to be used is different, and thus detailed description thereof is omitted.
- the first bonding state determination step it is determined whether the matching rate calculated in the first pattern matching step is equal to or less than a predetermined threshold value (50% in this embodiment) (step S305).
- a predetermined threshold value 50% in this embodiment
- a gap is generated in at least a part between the one end portion 21a and the other end portion 21b in the longitudinal direction of the band-shaped member 21 (the joint crack failure is caused).
- the joint crack failure is caused.
- There is a risk of occurrence of a misalignment or a misalignment (a joining state in which the one end 21a and the other end 21b of the strip member 21 are shifted in the width direction of the strip member 21).
- the matching rate calculated in the first pattern matching step is equal to or less than a predetermined threshold value, as shown in FIG. 6B, one end 21a in the longitudinal direction of the band-shaped member 21 is replaced with the other end 21b.
- the joining state determination unit 4 determines that the longitudinal ends of the belt-like member 21 are normally joined to each other, and ends the process. be able to.
- the threshold value “below” is used as the criterion for determining that both ends in the longitudinal direction of the band-shaped member 21 are normally joined in step S305. This point can also be applied to determination criteria in step S307 and step S309 described later. However, whether the threshold value is “below” or “less than” is determined unambiguously in design (either alternatively or exclusively).
- the maximum value of the matching rate that is determined to be normally joined is determined, and whether the matching rate calculated in the first pattern matching process is equal to or less than this maximum value (threshold value). Assume that it is decided to determine whether or not. In this case, it is not changed to determine whether or not the matching rate is “less than the threshold value” thereafter.
- the threshold value is 50% in the above embodiment, for example. However, the threshold value can be set as appropriate according to the purpose, and the same applies to steps S307 and S309 described later.
- the joining state between the longitudinal ends of the belt-like member can be reliably determined.
- the length of the band-shaped member is not affected even when the tip of the member is detected in the first pattern matching step and the first joining state determination step, that is, when the matching rate exceeds a predetermined threshold value. Since both ends in the direction may be normally joined, joint failure such as joint crack failure does not necessarily occur. Therefore, it is preferable to implement the 2nd joining state determination process mentioned later from a viewpoint which determines the joining state of the longitudinal direction both ends of a strip
- step S307 it is determined whether the matching rate calculated in the second pattern matching step is equal to or lower than a predetermined threshold value (50% in this embodiment) (step S307).
- a predetermined threshold value 50% in this embodiment
- the joining state determination means 4 determines that the longitudinal ends of the band-shaped member 21 are normally joined to each other and ends the process. it can.
- the bonding state of the belt-shaped member can be more reliably determined by the first bonding state determination step and the second bonding state determination step, but it is strictly determined that the bonding is defective only by these steps. I can't do it.
- the joint crack shape registration data registration step is performed in advance (step S102 in FIG. 2A).
- one or more images of at least a part of the joint portion of the belt-like member in a state where the joint crack failure has occurred among the joint failures are given in advance to the joint state determination means 4 as joint crack shape registration data B.
- Joint crack shape registration data B For example, ten types of shapes and shade patterns as shown in FIG. 7 are registered as joint crack shapes.
- black indicates the color of the upper surface of the band-shaped member 21
- white indicates the color of the surface of the molding drum 2
- hatched lines indicate the color of the cut surface of the band-shaped member 21.
- the third pattern matching step at least one of the registered joint crack shape registration data B or an image equivalent thereto (hereinafter referred to as the target joint portion imaging data D acquired) , Collectively referred to as “joint crack shape registration data, etc.”), and a matching rate representing the degree of coincidence of the joint crack shape registration data, etc., based on the member joint portion imaging data D Calculate (step S308). Furthermore, in the third joining state determination step, one of the one or more matching rates calculated in the third pattern matching step, that is, any one of the member joint portion imaging data D and the joint crack shape registration data, etc. It is determined whether the matching rate is equal to or less than a predetermined threshold (step S309).
- any of the matching rates exceeds a predetermined threshold value, it is determined that a joint crack failure has occurred, and the process ends.
- a predetermined threshold value it is determined that the longitudinal ends of the belt-like member 21 are normally joined to each other, and the process ends.
- the joint crack shape registration data is enlarged / reduced in the longitudinal direction and / or the width direction of the belt-like member, for example, in the range of 0.5 to 1.5 times, and / or the image is, for example, ⁇ 10 ° to By rotating within the range of + 10 °, one or more new images can be created, which can be similar to the joint crack image.
- a matching ratio representing at least one coincidence degree of a new image that is a joint fracture image or an image equivalent thereto is calculated with reference to the member joint portion imaging data.
- a plurality of images can be created by combining a plurality of joint crack shape registration data, a plurality of enlargement / reduction ratios, and a plurality of rotation angles, and at least one of the images and a member
- pattern matching with the joint imaging data D even if the number of joint crack shape registration data is limited, it is possible to determine various types of joint crack failures, improving the determination capability and robustness It is possible to secure sex. Thereby, the joining state of the longitudinal direction both ends of a strip
- 1 molding apparatus
- 2 molding drum
- 3 imaging means
- 4 joining state determination means
- 11 light source
- 21 strip member
- 101 strip member sample
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Abstract
Description
このような接合不良を検出するためには、帯状部材の始端及び終端の位置を正確に求める必要がある。ここで特許文献1では、2次元レーザー変位センサを用いて帯状部材の始端及び終端の位置を求めている。
図1に例示する、本発明の一実施形態に係る成型装置1は、タイヤのトレッドやベルト等の帯状部材21が巻き付けられる成型ドラム2と、当該帯状部材21を成型ドラム2に巻き付ける際の、帯状部材21の長手方向両端部のうち成型ドラム2に最初に巻き付けられた端部の画像である部材先端部撮像データ、及び、帯状部材21の成型ドラム2への巻き付けを終了し、その長手方向両端部同士を接合した際の、接合部付近の画像である部材ジョイント部撮像データを撮像により取得する撮像手段3と、帯状部材の長手方向両端部同士の接合の状態を判定する接合状態判定手段4とを具える。
また、撮像手段3は、成型ドラム2から離隔して、撮像方向が成型ドラム2を向いた姿勢で固定される。
光源11は、撮像手段3が帯状部材21を撮像するために適切な明るさを提供する。光源11を設けることで、撮像手段3は、周囲の明るさに影響されずに撮像を行うことができる。
この実施形態では、図3に示すように、例えば成型ドラム2上に、帯状部材サンプル101を配置し、撮像手段3によって帯状部材サンプル101の、部材先端部基準位置Pa及び部材先端部を含む領域(二点鎖線で囲まれた仮想領域)を撮像することで、部材先端部マスタデータAを作成する。この実施形態では、部材先端部基準位置Paを、帯状部材21の切断面の幅方向一端としている。そして、部材先端部マスタデータA中の部材先端部基準位置Paの位置を求める。以上のように作成された部材先端部マスタデータAは、接合状態判定手段4に格納される。
帯状部材21を成型ドラム2に巻き付け開始した後、成型ドラム2の回転とともに、帯状部材21の長手方向一端部21aは、成型ドラム2の周方向(図4A-図4Dでは反時計回り)に移動し、帯状部材21の長手方向両端部同士を接合する前、この実施形態では、図4Bのように撮像位置まで達した際に、本実施形態の部材先端部撮像データ取得工程として、撮像手段3が帯状部材21の部材先端部撮像データCを撮像し取得する(ステップS202)。ここで、帯状部材21の長手方向一端部21aが撮像位置に到達した際に、制御手段が撮像トリガを発生させることで、撮像を自動化させることができる。
その後、成型ドラム2を回転させながら帯状部材21を巻き付けてゆき、巻き終えた(ステップS203)後、図4Cのように、帯状部材21の長手方向両端部同士、すなわち長手方向両端部21a、21b同士を接合する(ステップS204)。
帯状部材21の長手方向両端部同士を接合した後、この実施形態では、成型ドラム2をさらに回転させ、図4Dのように帯状部材21の接合部が撮像位置まで達した際に、この実施形態の部材ジョイント部撮像データ取得工程として、撮像手段3が帯状部材21の部材ジョイント部撮像データDを撮像し取得する(ステップS205)。ここでも上記ステップS202の場合と同様にして、撮像を自動化することができる。
本実施形態の部材先端部検出工程では、取得された部材先端部撮像データC中に、登録された部材先端部マスタデータAの部材先端部と同等の部材先端部を検出できるか判定を行う(ステップS301)。この部材先端部の検出は、部材先端部撮像データCを対象に、部材先端部マスタデータAでパターンマッチングを行うことで実施することができる。より具体的には、部材先端部マスタデータAと部材先端部撮像データCとを相対移動させながら、両画像をパターンマッチングさせる。なお、パターンマッチングは、例えば濃淡値の相関係数をマッチング率として用いることで行うことができる。
このような部材先端部検出工程を含むことで、上述した部材先端部撮像データ取得工程で、部材先端部撮像データCが適切に取得されていない場合を除外することができる。
ここで、部材先端部撮像データC中に、部材先端部マスタデータAの部材先端部と同等の部材先端部を検出できなかった場合、具体的には例えば、上記のパターンマッチングにおいて、登録された部材先端部マスタデータAを基準とした、取得された部材先端部撮像データCとの一致度を示すマッチング率が所定のしきい値以下の場合又は当該しきい値未満である場合には、異常値を制御手段に出力して処理を終了することができる。
なお、この部材先端部検出工程は、上述した部材先端部撮像データ取得工程(ステップS202)の後であれば、部材ジョイント部撮像データ取得工程(ステップS205)よりも前に行うこともできる。また前記しきい値は、目的に応じて適宜設定することができる。
部材先端部検出工程で、取得された部材先端部撮像データC中に、部材先端部マスタデータAの部材先端部と同等の部材先端部を検出できた場合、すなわち例えば、上記のパターンマッチングにおいて、マッチング率が所定のしきい値を超え又はそれ以上であった場合には、部材先端部登録データ登録工程に進む。
部材先端部登録データ登録工程では、部材先端部撮像データC中の部材先端部の画像を、部材先端部登録データC1として登録する(ステップS302)。
なお、部材先端部撮像データCが適切に取得されることが、十分確実に保証できる場合等には、部材先端部検出工程を行わず、撮像された部材先端部撮像データC中の部材先端部の画像を、そのまま部材先端部登録データC1として登録して、以降の工程を行うこともできる。
そして、第1の接合状態判定工程では、上記の第1のパターンマッチング工程において算出されたマッチング率が、所定のしきい値(この実施形態では50%)以下かを判定する(ステップS305)。マッチング率が所定のしきい値を超える場合には、帯状部材の長手方向両端部同士が、正常に接合されている場合と、接合不良が生じている場合とを含んでいるので、好ましくは、以降の工程で、そのいずれであるか、さらに確認を進める。ここで、上記しきい値を超える場合は、図6Aに示すように、帯状部材21の長手方向の一端部21aと他端部21bとの間の少なくとも一部に隙間が発生(ジョイント割れ不良が発生)しているおそれや、段ずれ(帯状部材21の一端部21aと他端部21bとが、帯状部材21の幅方向にずれた接合状態)が発生しているおそれがある。
一方、上記第1のパターンマッチング工程において算出されたマッチング率が所定のしきい値以下の場合には、図6Bに示すように、帯状部材21の長手方向の一端部21aが、他端部21bに十分にラップされた(覆われた)状態であると判断でき、接合状態判定手段4は、帯状部材21の長手方向両端部同士が正常に接合されていると判定して、処理を終了することができる。
なお、ステップS305における、帯状部材21の長手方向両端部同士が正常に接合されていると判定する判定基準を、上記の実施形態では、しきい値「以下」としたが、しきい値「未満」とすることもでき、この点は、後述するステップS307及びステップS309の判定基準でも同様である。ただし、しきい値「以下」とするか、しきい値「未満」とするかは、設計上一義的に(二者択一で、排他的に)決まるものである。例えば、ある制御において、正常に接合されている状態と判定するマッチング率の最大値を決めて、第1のパターンマッチング工程において算出されるマッチング率がこの最大値(しきい値)「以下」かどうかを判定すると決めた場合を想定する。この場合には、その後にマッチング率がしきい値「未満」かどうかを判定するように変更されることはない。また、しきい値は、上記の実施形態では、例えば50%としたが、目的に応じ適宜設定することができ、後述のステップS307及びステップS309でも同様である。
しかしながら、上記第1のパターンマッチング工程及び第1の接合状態判定工程で、部材先端部が検出された場合、即ち、マッチング率が所定のしきい値を超える場合であっても、帯状部材の長手方向両端部同士が正常に接合されている場合もあるので、必ずしもジョイント割れ不良等の接合不良が発生しているとは限らない。そのため、帯状部材の長手方向両端部同士の接合状態をより確実に判定する観点から、後述する第2の接合状態判定工程を実施することが好ましい。
そして、第2の接合状態判定工程として、第2のパターンマッチング工程において算出された前記マッチング率が、所定のしきい値(この実施形態では50%)以下であるか判定する(ステップS307)。
しきい値を超える場合、帯状部材の長手方向両端部同士が、正常に接合されている場合と、ジョイント割れ不良等の接合不良が生じている場合とを含む。そのため、好ましくは、以降の工程でさらに確認を行う。
一方、マッチング率が所定のしきい値以下の場合には、接合状態判定手段4は、帯状部材21の長手方向両端部同士が正常に接合されていると判定して、処理を終了することができる。
第3の接合状態判定工程を行うために、前述の通り、この実施形態では、あらかじめ、ジョイント割れ形状登録データ登録工程を行う(図2AのステップS102)。この工程では、接合不良のうち、ジョイント割れ不良を生じた状態の、帯状部材の接合部の少なくとも一部の画像を、ジョイント割れ形状登録データBとして、1つ以上、接合状態判定手段4に事前に登録しておく。例えば、図7に示すような10種類の形状及び色合いのパターンをジョイント割れ形状として登録する。なお図7において、黒色は帯状部材21の上面が持つ色を示し、白色は成型ドラム2の表面が持つ色を示し、斜線は帯状部材21の切断面が持つ色を示すものとする。
そして、この実施形態では、第3のパターンマッチング工程として、取得された部材ジョイント部撮像データDを対象に、登録されたジョイント割れ形状登録データB、またはこれと同等の画像の少なくとも1つ(以下、総称して「ジョイント割れ形状登録データ等」ともいう)でパターンマッチングを実施して、当該部材ジョイント部撮像データDを基準とした、当該ジョイント割れ形状登録データ等の一致度を表すマッチング率を算出する(ステップS308)。
さらに、第3の接合状態判定工程では、第3のパターンマッチング工程において算出された1つ以上のマッチング率のいずれか、すなわち、部材ジョイント部撮像データDとジョイント割れ形状登録データ等のいずれかとのマッチング率が、所定のしきい値以下であるかを判定する(ステップS309)。いずれかのマッチング率が所定のしきい値を超える場合には、ジョイント割れ不良が発生していると判定して処理を終了する。逆に、該マッチング率がすべて所定のしきい値以下の場合には、帯状部材21の長手方向両端部同士が正常に接合されていると判定して処理を終了する。
この方法によれば、複数のジョイント割れ形状登録データと、複数の拡縮率と、複数の回転角度とをそれぞれ組み合わせることで、多数の画像を作成することができ、この画像の少なくとも1つと、部材ジョイント部撮像データDとをパターンマッチングすることで、ジョイント割れ形状登録データの数が限られたものであっても、様々な種類のジョイント割れ不良を判定することができ、判定能力の向上やロバスト性の確保をはかることができる。これにより、帯状部材の長手方向両端部同士の接合の状態を、高い精度で判定することができる。
Claims (6)
- 成型ドラム上に帯状部材を巻き付け、前記帯状部材の長手方向両端部同士を接合して、帯状部材を円筒状に成型する際に、前記接合の状態を判定する方法であって、
前記帯状部材を前記成型ドラム上に巻き付け開始した後であって前記帯状部材の長手方向両端部同士を接合する前に、前記帯状部材の長手方向両端部のうち前記成型ドラムに最初に巻き付けられた端部に対する部材先端部撮像データを取得する、部材先端部撮像データ取得工程と、
前記帯状部材の長手方向両端部同士を接合した後に、前記帯状部材の部材ジョイント部撮像データを取得する、部材ジョイント部撮像データ取得工程と、
取得された前記部材ジョイント部撮像データを基準とした、取得された前記部材先端部撮像データに基づいて登録された部材先端部登録データの一致度を表すマッチング率を算出する、第1のパターンマッチング工程と、
前記第1のパターンマッチング工程において算出された前記マッチング率が、所定のしきい値以下又はそれ未満である場合に、前記帯状部材の長手方向両端部同士が正常に接合されていると判定する、第1の接合状態判定工程と、
を含むことを特徴とする、接合状態判定方法。 - 前記第1のパターンマッチング工程の前にあらかじめ、帯状部材サンプルの部材先端部マスタ画像を含む、前記帯状部材の部材先端部マスタデータを登録する、部材先端部マスタデータ登録工程をさらに含み、
取得された前記部材先端部撮像データ中に、登録された前記部材先端部マスタデータの部材先端部と同等の部材先端部が検出できた場合に、該部材先端部の画像を前記部材先端部登録データとして登録する、請求項1に記載の接合状態判定方法。 - 前記部材先端部登録データから、部材先端部基準位置を含む部材先端部の画像であるジョイント境界部登録データを取得する、ジョイント境界部登録データ取得工程と、
前記第1の接合状態判定工程において前記マッチング率が所定のしきい値を超え又はそれ以上であると判定された場合に、取得された前記部材ジョイント部撮像データを基準とした、取得された前記ジョイント境界部登録データの一致度を表すマッチング率を算出する、第2のパターンマッチング工程と、
前記第2のパターンマッチング工程において算出された前記マッチング率が、所定のしきい値以下又はそれ未満である場合に、前記帯状部材の長手方向両端部同士が正常に接合されていると判定する、第2の接合状態判定工程と、
をさらに含む、請求項1又は2に記載の接合状態判定方法。 - あらかじめ、前記接合の状態のうち、帯状部材の長手方向両端部の間の少なくとも一部に隙間が生じるジョイント割れ不良を生じた状態の、前記帯状部材の接合部の少なくとも一部の画像である、ジョイント割れ形状登録データを1つ以上登録する、ジョイント割れ形状登録データ登録工程と、
前記第2の接合状態判定工程において前記マッチング率が所定のしきい値を超え又はそれ以上であると判定された場合に、取得された前記部材ジョイント部撮像データに基づいた、登録された前記ジョイント割れ形状登録データ又はこれと同等の画像の少なくとも1つの一致度を表すマッチング率を算出する、第3のパターンマッチング工程と、
前記第3のパターンマッチング工程において算出されたいずれかの前記マッチング率が、所定のしきい値以下又はそれ未満である場合に、前記帯状部材の長手方向両端部同士が正常に接合されていると判定する、第3の接合状態判定工程と、
をさらに含む、請求項3に記載の接合状態判定方法。 - 前記ジョイント割れ形状登録データと同等の画像が、前記ジョイント割れ形状登録データを拡縮および/または回転させた画像である、請求項4に記載の接合状態判定方法。
- 成型ドラム上に帯状部材を巻き付け、前記帯状部材の長手方向両端部同士を接合して、帯状部材を円筒状に成型する成型装置であって、
前記帯状部材が巻き付けられる前記成型ドラムと、
前記帯状部材の長手方向両端部のうち前記成型ドラムに最初に巻き付けられた端部に対する部材先端部撮像データ、及び、部材ジョイント部撮像データを撮像により取得する撮像手段と、
帯状部材の長手方向両端部同士の接合の状態を判定する接合状態判定手段とを具え、
前記接合状態判定手段は、
前記帯状部材を前記成型ドラム上に巻き付け開始した後であって前記帯状部材の長手方向両端部同士を接合する前に、前記長手方向両端部のうち前記成型ドラムに最初に巻き付けられた端部に対する部材先端部撮像データを取得し、
前記帯状部材の長手方向両端部同士を接合した後に、前記帯状部材の部材ジョイント部撮像データを取得し、
取得された前記部材ジョイント部撮像データを基準とした、取得された前記部材先端部撮像データに基づいて登録された部材先端部登録データの一致度を表すマッチング率を算出し、
前記第1のパターンマッチング工程において算出された前記マッチング率が、所定のしきい値以下又はそれ未満である場合に、帯状部材の長手方向両端部同士が正常に接合されていると判定する、成型装置。
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US20170015075A1 (en) | 2017-01-19 |
EP3128312B1 (en) | 2018-09-05 |
EP3128312A1 (en) | 2017-02-08 |
CN106164654A (zh) | 2016-11-23 |
JPWO2015151392A1 (ja) | 2017-04-13 |
CN106164654B (zh) | 2018-11-20 |
EP3128312A4 (en) | 2017-04-19 |
JP6397895B2 (ja) | 2018-09-26 |
US10076885B2 (en) | 2018-09-18 |
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