WO2016152485A1 - 検査装置 - Google Patents
検査装置 Download PDFInfo
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- WO2016152485A1 WO2016152485A1 PCT/JP2016/057024 JP2016057024W WO2016152485A1 WO 2016152485 A1 WO2016152485 A1 WO 2016152485A1 JP 2016057024 W JP2016057024 W JP 2016057024W WO 2016152485 A1 WO2016152485 A1 WO 2016152485A1
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- LRWMFNBMOYQFRV-UHFFFAOYSA-N C(C1)C2C1C1=CC2C1 Chemical compound C(C1)C2C1C1=CC2C1 LRWMFNBMOYQFRV-UHFFFAOYSA-N 0.000 description 1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N23/00—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00
- G01N23/02—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by transmitting the radiation through the material
- G01N23/06—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by transmitting the radiation through the material and measuring the absorption
- G01N23/083—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by transmitting the radiation through the material and measuring the absorption the radiation being X-rays
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N23/00—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00
- G01N23/02—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by transmitting the radiation through the material
- G01N23/06—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by transmitting the radiation through the material and measuring the absorption
- G01N23/10—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by transmitting the radiation through the material and measuring the absorption the material being confined in a container, e.g. in a luggage X-ray scanners
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2223/00—Investigating materials by wave or particle radiation
- G01N2223/10—Different kinds of radiation or particles
- G01N2223/101—Different kinds of radiation or particles electromagnetic radiation
- G01N2223/1016—X-ray
Definitions
- One aspect of the present invention relates to an inspection apparatus, and more particularly, to an inspection apparatus that inspects a defect in the contents of a product.
- an inspection apparatus described in Patent Document 1 includes an X-ray source that emits X-rays, an X-ray light receiving unit that receives the irradiated X-rays, and an inspection unit that inspects an article based on the received X-rays.
- the inspection unit performs image processing on the image based on the received X-rays to inspect the article.
- the transmittance of light (X-rays) in a plurality of articles is substantially the same. Therefore, in a conventional inspection apparatus, a threshold value used for image processing (used for binarization of an image) is set to be constant.
- the inspection target may be a product including a plurality of types of articles. In such a product, the light transmittance of each product may differ from product to product. In this case, in an inspection using a fixed threshold value, appropriate image processing is not performed on each article. For this reason, there is a possibility that a defect inspection of a product including a plurality of types of articles cannot be properly performed by the same method as the conventional one.
- an object of one aspect of the present invention is to provide an inspection apparatus capable of performing a defect inspection of a product including a plurality of types of articles.
- An inspection apparatus detects a light irradiation unit that irradiates a product including a plurality of types of articles and the articles are arranged at different positions, and transmitted light of the light irradiated to the product.
- An inspection apparatus comprising: a detection unit; an image generation unit that generates an image based on transmitted light; and an inspection unit that inspects a defect in the product based on the image; and a position in the product for each of a plurality of types of articles.
- a plurality of article areas set in association with each other and a storage unit that stores a threshold value set for each article area, and the inspection unit identifies the article area based on the image, and Each of the article regions is inspected based on the threshold value set to, and the presence / absence of a defect in the product is determined based on the inspection result.
- the storage unit stores a plurality of article areas set in association with positions in a product and a threshold value set for each article area.
- the inspection unit identifies the article region from the image and inspects each of the article regions based on a threshold set for each article region.
- the inspection apparatus can be inspected. Therefore, for example, the inspection device can inspect the presence or absence of a missing item in the product, or the abnormality of the shape (breaking crack).
- the inspection apparatus can perform a defect inspection of a product including a plurality of types of articles.
- the apparatus includes a threshold setting unit that sets a threshold for each article region, the threshold setting unit sets a binarization threshold for binarizing the article region for each article region, and the inspection unit includes: Each article region may be binarized based on the binarization threshold, and the article may be inspected based on the binarized binarized article region. By binarizing the article region, the inspection apparatus can clarify the article region. Therefore, the inspection apparatus can more appropriately inspect the article.
- the threshold setting unit sets a determination threshold for determining the presence / absence of an article for each article region, and the inspection unit determines at least one of the shape, area, or perimeter of the binarized article region.
- the presence / absence of the article may be determined based on the threshold value.
- the inspection apparatus can accurately determine the presence or absence of an article.
- the inspection device can inspect a missing item in the product.
- the image processing apparatus includes a region setting unit that sets a reference position in an image and sets an article region including each article according to a positional relationship with the reference position, and the inspection unit acquires the reference position from the image,
- the article region may be specified based on the position.
- the product may include a container that stores a plurality of types of articles, and the region setting unit may set each article region by setting a reference position in the container. Since the shape of the container is less likely to change compared to the shape of the article, it is easily acquired from the image. Therefore, by setting the reference position in the container, the inspection unit can acquire the reference position quickly and reliably. Thereby, the inspection unit can acquire the article region more quickly and reliably. As a result, the inspection performance can be improved.
- the area setting unit may set each article area by setting a reference position for an article having the largest area among a plurality of types of articles.
- the reference position can be set for a portion that can be reliably acquired from an image.
- the region setting unit extracts a region estimated to include an article from an image, and when there is a portion where a difference in values based on the transmittance of transmitted light is a predetermined value or more in one region, It may be determined that there are a plurality of different types of articles in the area, and each of the plurality of portions may be set as an article area. When some of the plurality of articles are arranged in contact (overlapping) with each other, the plurality of articles in contact appear as one region in the image. In this case, there is a possibility that one article region is set even though there are a plurality of articles.
- the region setting unit detects a portion in which a difference in values based on the transmittance of transmitted light is greater than or equal to a predetermined value in one region estimated to include an article. Thereby, even if one area appears in the image, the area setting unit can recognize it as a plurality of articles. Therefore, the area setting unit can appropriately set the article area.
- FIG. 1 is a perspective view of an X-ray inspection apparatus according to an embodiment of the present invention.
- FIG. 2A is a diagram illustrating an internal configuration of the X-ray inspection apparatus.
- FIG. 2B is a diagram showing a profile of the transmitted X-ray in FIG.
- FIG. 3 is a block diagram of the X-ray inspection apparatus of FIG.
- FIG. 4A shows an X-ray transmission image.
- FIG. 4B is a diagram showing a binarized image obtained by binarizing an X-ray transmission image.
- FIG. 5 is a flowchart illustrating processing for presetting defect inspection by the control unit.
- (A) of FIG. 6 is a figure which shows an example of a container.
- FIG. 6B is a diagram schematically showing the article.
- FIG. 7 is a diagram illustrating a reference position, an article area, and a binarized article area.
- FIG. 8 is a flowchart showing a defect inspection process by the control unit.
- FIG. 9A shows an X-ray transmission image.
- FIG. 9B is a diagram showing a binarized image obtained by binarizing an X-ray transmission image.
- FIG. 10 is a diagram illustrating a reference position, an article area, and a binarized article area.
- FIG. 11 is a flowchart illustrating processing for presetting defect inspection by the control unit.
- (A) of FIG. 12 is a figure for demonstrating an estimation area
- (B) of FIG. 12 is a figure which shows an example of the brightness
- FIG. 13 is a figure which shows an example of the number of pixels with respect to the brightness
- FIG. 13B is a diagram illustrating an example of the cumulative number of pixels with respect to the luminance of transmitted X-rays of the article.
- the X-ray inspection apparatus (inspection apparatus) 10 is an apparatus that performs a defect inspection of an article C in a product G in a production line of the product G, for example.
- the product G to be inspected includes a plurality of types of articles C and a container B (container) that stores the plurality of types of articles C.
- the articles C are arranged at different positions. Examples of the product G include lunch boxes, continuously packaged foods (for example, different materials or different tastes), confectionary assortment, assortment of parts such as screws, assemblies (tools, tableware), and the like.
- the defect in the product G includes the presence / absence of a shortage of the product C, an abnormal shape (cracked chip), or the like.
- the container is not limited to the box-shaped container B.
- the container may be variously shaped containers, bags, packaging boxes, or the like. In the present embodiment, as an example, a case will be described in which the product G is a lunch box containing food as a plurality of types of articles C.
- the X-ray inspection apparatus 10 emits X-rays (light) to the product G that is continuously transported along the transport direction a.
- the X-ray inspection apparatus 10 generates an image of the product G based on the transmittance of X-ray transmitted light (hereinafter referred to as transmitted X-ray) that has passed through the product G.
- transmitted X-ray X-ray transmitted light
- the X-ray inspection apparatus 10 includes an apparatus main body 11, a conveyor 12, an X-ray source (light irradiation unit) 13, an X-ray detection unit (detection unit) 14, a monitor 20, and a control unit 30 (see FIG. 3). And including.
- the conveyor 12, the X-ray source 13, the X-ray detection unit 14, and the control unit 30 are accommodated in the apparatus main body 11.
- the apparatus main body 11 includes an inspection room 11a formed in a box shape.
- a carry-in port 11c through which the product G passes is provided on the upstream side wall 11b in the carrying direction a.
- a carry-out port 11e through which the product G passes is provided on the downstream side wall 11d in the conveyance direction a.
- Each of the carry-in entrance 11c and the carry-out exit 11e is provided with an X-ray shielding curtain (not shown).
- the X-ray shielding screen prevents scattered X-rays from leaking out of the examination room 11a.
- a general flat belt conveyor is used as the conveyor 12. Both ends of the conveyor 12 protrude from the carry-in port 11c and the carry-out port 11e of the inspection room 11a.
- the conveyor 12 receives the product G before inspection from a carry-in conveyor (not shown) on the upstream side in the transport direction a.
- the conveyor 12 carries the commodity G into the inspection room 11a from the carry-in entrance 11c.
- the conveyor 12 carries the product G out of the inspection room 11a from the carry-out port 11e.
- the conveyor 12 delivers the inspected product G to a carry-out conveyor (not shown) on the downstream side in the transport direction a.
- the delivery conveyor may be provided with a function for distributing the products G.
- the X-ray source 13 is disposed above the examination room 11 a in the apparatus main body 11.
- the X-ray source 13 forms an X-ray irradiation region X via a slit mechanism (not shown) or the like.
- the X-ray source 13 irradiates the product G carried into the examination room 11a with X-rays.
- the X-ray source 13 is electrically connected to the control unit 30.
- the X-ray detection unit 14 is disposed below the examination room 11 a in the apparatus main body 11 so as to face the X-ray source 13.
- the X-ray detection unit 14 has a line sensor composed of a plurality of pixels arranged in a line in the width direction of the transport direction a (the direction perpendicular to the transport direction a and the vertical direction).
- the X-ray detection unit 14 detects transmitted X-rays transmitted through the product G and ambient X-rays irradiated around the product G.
- the transmitted X-rays and the surrounding X-rays detected by the X-ray detection unit 14 are simply referred to as detected X-rays.
- the X-ray detection unit 14 is electrically connected to the control unit 30.
- the X-ray detection unit 14 acquires a detection signal at a predetermined timing when the product G passes through the X-ray irradiation region X.
- the X-ray detection unit 14 outputs an electrical signal related to the detection signal to the control unit 30.
- the monitor 20 is provided above the front surface of the apparatus body 11 (see FIG. 1).
- the monitor 20 is a display unit on which, for example, the operation status of the X-ray inspection apparatus 10, an X-ray transmission image of the product G, an inspection result, and the like are displayed.
- the monitor 20 has a touch panel function.
- the monitor 20 performs display for input operation.
- the input operation includes various setting operations.
- the monitor 20 is electrically connected to the control unit 30.
- the monitor 20 transmits operation information related to the input operation to the control unit 30.
- the control unit 30 includes a CPU [Central Processing Unit], a ROM [Read Only Memory], a RAM [Random Access Memory], and the like.
- the control unit 30 controls the processing related to the defect inspection in the product G in an integrated manner.
- the control unit 30 includes an image generation unit 31, an area setting unit 32, a threshold setting unit 33, a storage unit 34, and an inspection unit 35.
- the image generation unit 31, the region setting unit 32, the threshold setting unit 33, and the inspection unit 35 are executed as programs in the CPU (processor) of the control unit 30.
- the storage unit 34 is, for example, an HDD [Hard Disk Disk Drive].
- the image generation unit 31 generates an X-ray transmission image of the product G based on the detected X-rays including the transmission X-rays irradiated on the product G.
- the X-ray transmission image is a two-dimensional image in which the brightness (brightness) of detected X-rays corresponding to the X-ray transmittance in the product G is expressed by color shading (for example, gray scale).
- the image generation unit 31 generates an X-ray transmission image based on a detected X-ray luminance profile PR1 as shown in FIG.
- FIG. 2B as an example, a profile PR1 of a commodity GX in which a single article C is accommodated in a container B is shown.
- the profile PR1 is a graph showing the luminance of the detected X-ray at each point in the detection range where the X-ray detection unit 14 detects X-rays.
- the profile PR1 here is a two-dimensional graph.
- the horizontal axis indicates the position of each detection point (for example, each pixel of the line sensor) arranged along the direction intersecting the conveyor 12 in the detection range of the X-ray detection unit 14.
- the vertical axis indicates the luminance of the detected X-ray according to the transmittance at each detection point.
- the portion where only the container B exists (the X-ray is the container) than the transmittance of the portion where the product GX does not exist (the portion where the X-ray does not pass the product GX)
- the transmittance of the portion that transmits only B is smaller.
- the transmittance of the portion where the container B and the article C exist (the portion where X-rays pass through the container B and the article C) is smaller than the transmittance of the portion where only the container B exists. Therefore, the brightness of the detected X-rays decreases in the order of the part where the product GX is not present, the part where only the container B is present, the part where the container B and the article C are present.
- the image generation unit 31 is arranged in the order of the part where the product GX does not exist, the part where only the container B exists, the part where the container B and the article C exist, according to the luminance of the detected X-rays.
- An X-ray transmission image in which the darkness of the color is expressed (darkness is dark) is generated.
- the region setting unit 32 sets the reference position P 0 in the X-ray transmission image J 1 (see (a) and (b) of FIG. 4) generated by the image generation unit 31.
- Region setting unit 32 sets the article area A k by the positional relationship between the reference position P 0.
- the article area A k is an area set to include each article C k .
- the position in the product G is associated with the article region A k for each of a plurality of types of articles C k .
- Position in commodity G are relative position, for example with respect to the reference position P 0.
- “k” in the article C k and the article area A k is a natural number. In the article C k and the article area A k , when “k” is the same, it indicates that the article C k and the article area A k correspond to each other. The same applies to the following description.
- the region setting unit 32 binarizes the X-ray transmission image J 1 (see FIG. 4A) generated by the image generation unit 31 with a threshold L 0 .
- the area setting unit 32 generates a binarized image JB 1 as shown in FIG.
- the threshold value L 0 is set so that, for example, the outer shape of the container B and all of the plurality of types of articles C k are extracted.
- the area setting unit 32 receives an input operation to the monitor 20 by the operator of the X-ray inspection apparatus 10.
- the area setting unit 32 sets the reference position P 0 according to the input operation. Reference position P 0 is set as the coordinate information (0,0).
- the area setting unit 32 sets a rectangle including the article C k according to the input operation, and sets the rectangle as the article area A k (see FIG. 7).
- Region setting unit 32 for all of the articles C k, sets the article area A k.
- the article region A k is set as coordinate information of two points located on the diagonal of the rectangle with the reference position P 0 as a reference.
- the area setting unit 32 stores the set reference position P 0 and each article area Ak in the storage unit 34.
- the threshold setting unit 33 sets a threshold for each article region Ak .
- Threshold setting unit 33 sets a binarization threshold value L k for binarizing the article area A k for each article area A k.
- the binarization threshold L k is, for example, a luminance threshold for performing an appropriate binarization process on each article C k .
- the binarization threshold L k is set according to the X-ray transmittance of each article C k .
- the threshold setting unit 33 accepts an input operation on the monitor 20 by the operator, and sets a binarization threshold L k according to the input operation.
- the threshold setting unit 33 stores the set binarization threshold L k in the storage unit 34.
- the threshold value setting unit 33 sets a determination threshold value S k for determining the presence or absence of the item C k for each item region A k .
- the determination threshold value S k includes at least one of the shape, the area U k, or the perimeter of the binarized article region T k (see FIG. 7).
- the binarized article area T k is an area surrounded by the outer edge of the article C k when each article area A k is binarized with the binarization threshold L k .
- the determination threshold S k is set to the area U k of the binarized article region T k
- the determination threshold S k is set to a value in which a certain allowable error is added to the area U k .
- Threshold setting unit 33 accepts an input operation to the operator of the monitor 20, in response to an input operation to set the determination threshold S k.
- the threshold setting unit 33 stores the set determination threshold Sk in the storage unit 34.
- Storage unit 34 for each of a plurality kinds of articles C k, a plurality of articles regions located in the product G is set in association with A k and, the article area A binarization threshold is set for each k L k And the determination threshold value S k are stored.
- the binarization threshold L k and the determination threshold S k are stored in association with each article region A k .
- the inspection unit 35 inspects the product G for defects based on the X-ray transmission image J 2 generated by the image generation unit 31 (see FIG. 9A). Specifically, the inspection unit 35 identifies the article area A k based on the X-ray transmission image J 2. The inspection unit 35 inspects each of the article regions A k based on the binarization threshold L k and the determination threshold S k set for each article region A k . The inspection unit 35 determines the presence / absence of a defect in the product G based on the inspection result.
- the inspection unit 35 acquires the reference position P 0 from the X-ray transmission image J 2 .
- Checking unit 35 identifies each item area A k based on the reference position P 0.
- the inspection unit 35 performs binarization processing using the binarization threshold L k set for each article region A k for each identified article region A k .
- the inspection unit 35 inspects the presence / absence of the article C k in each binarized binarized article region T k using each determination threshold value S k .
- Checking unit 35 based on the inspection result of the presence or absence of the article C k, it determines the presence or absence of defects of the product G.
- the inspection unit 35 determines that the product G has a defect
- the inspection unit 35 outputs an operation signal to a sorting device (not shown).
- the defect inspection of the product G is an inspection for detecting a shortage or a position shift (a position shift that does not exist at the position where the product C k should be) in the product G, and the like. It is different from inspection.
- the preset for performing the defect inspection of the goods G is demonstrated with reference to FIG.
- the presetting is performed based on an input to the monitor 20 by the operator.
- the control unit 30 displays a setting button for starting pre-setting on the menu screen of the monitor 20.
- the control unit 30 causes the monitor 20 to display text for instructing to place the product GS on the conveyor 12 (for example, “Please place the product on the conveyor”).
- the product GS is a sample product that serves as a basis for defect inspection used for presetting.
- the product GS has the same content as the product G that is the subject of the defect inspection, and has no defect.
- the product GS includes a container B similar to the product G (see FIG. 9A). As shown in FIG. 6A, the container B has a substantially rectangular outer shape in plan view.
- the image generation unit 31 performs an X-ray transmission image J of the product GS based on the detected X-rays including the transmitted X-rays transmitted through the product GS. 1 (see FIG. 4A) is generated (step S10). Then, the area setting unit 32 binarizes the X-ray transmission image J 1 generated by the image generating unit 31 at threshold L 0 (step S11), and as shown in FIG. 4 (b), the binary generating a reduction image JB 1.
- the area setting unit 32 sets the reference position P 0 (step S12). Specifically, the area setting unit 32 displays the binarized image JB 1 on the monitor 20. The area setting unit 32 causes the monitor 20 to display text that prompts the operator to specify the reference position P 0 (for example, “Please specify the reference position”). The operator, in the monitor 20, touch an arbitrary position, specifying the reference position P 0. Here, it is assumed that the operator specifies the reference position P 0 by touching the corner of the container B of the product GS. The area setting unit 32 sets the reference position P 0 when receiving an input operation to the monitor 20 by the operator. The region setting unit 32 stores the set reference position P 0 in the storage unit 34 as coordinate information.
- the area setting unit 32 sets the article area A k (step S13). Specifically, the area setting unit 32, the text to prompt the designation of the article area A k to the operator (e.g., "Please specify the goods area", etc.) is displayed on the monitor 20. The operator, in the monitor 20, touch two points position where the diagonal with including articles C k for any article C k. The area setting unit 32 creates a rectangle having two touched points as diagonal lines. The area setting unit 32 sets the rectangle as the article area Ak . The area setting unit 32 displays the created rectangle on the monitor 20. The area setting unit 32 displays a setting confirmation pop-up (for example, “Do you want to set an article area?”) On the monitor 20. Region setting unit 32, when the "OK" button displayed in the pop-up is pressed by the operator, the coordinates of the two points relative to the reference position P 0, stored as information indicating the article area A k Stored in the unit 34.
- the text to prompt the designation of the article area A k to the operator e.g., "Please
- the region setting unit 32 displays a rectangle having the two points as diagonal lines. create.
- Region setting unit 32 sets the rectangular as an article area A 1.
- the region setting unit 32 creates a rectangle having the two points as diagonal lines.
- Region setting unit 32 sets the rectangular as an article region A 2.
- the article regions A 1 and article regions A 2 regardless the housing portion B 1, is set according to the position of the article C 1 and article C 2.
- the region setting unit 32 receives an operator input for all articles C k .
- the area setting unit 32 sets an article area A k for each article C k .
- the threshold setting unit 33 sets a binarization threshold value L k (step S14). Specifically, the threshold setting unit 33 causes the monitor 20 to display text that prompts the operator to specify the binarization threshold L k (for example, “Please specify the binarization threshold”). The operator touches an arbitrary article C k (article area A k ) on the monitor 20 to select an article C k (article area A k ) for which the binarization threshold L k is designated. When an arbitrary article C k is designated, the threshold setting unit 33 causes the monitor 20 to display an input screen for the binarization threshold L k of the article C k .
- the input screen may have a form in which the operator directly inputs a numerical value, or a form in which a numerical value is input by pressing a ⁇ button.
- an appropriate value (predicted value) of the binarization threshold L k of the article C k acquired based on the X-ray transmission image J 1 may be displayed.
- Threshold setting unit 33 receives the operator input for all of the articles area A k.
- the threshold setting unit 33 sets a binarization threshold L k for each article region A k .
- the threshold setting unit 33 stores the binarization threshold L k in the storage unit 34.
- the threshold setting unit 33 sets the determination threshold S k (step S15).
- the determination threshold S k of the area U k binarization article region T k.
- Threshold setting unit 33 text to encourage the designation of the determination threshold S k to the operator (for example, "Please specify the determination threshold", etc.) is displayed on the monitor 20.
- the operator selects an article C k (article area A k ) for which the determination threshold value S k is designated by touching an arbitrary article C k (article area A k ) on the monitor 20.
- Threshold setting unit 33 when any article C k is designated to display an input screen for determining the threshold S k of the article C k in the monitor 20.
- the input screen may have a form in which the operator directly inputs a numerical value, or a form in which a numerical value is input by pressing a ⁇ button.
- an appropriate value (predicted value) of the determination threshold value S k based on the area U k of the binarized article region T k acquired based on the binarized image JB 1 may be displayed.
- Threshold setting unit 33 receives the operator input for all of the articles area A k.
- the threshold setting unit 33 sets a determination threshold S k for each article region A k .
- Threshold setting unit 33 stores the determined threshold value S k in the storage unit 34.
- control unit 30 in the defect inspection of the product G will be described with reference to FIGS.
- the image generation unit 31 generates an X-ray transmission image J 2 (see FIG. 9A) of the product G based on the detected X-rays including the transmitted X-rays transmitted through the product G. Generate (step S20). Then, the area setting unit 32 binarizes the X-ray image J 2 generated by the image generating unit 31 at threshold L 0 (step S21), and as shown in FIG. 9 (b), the binary Generated image JB 2 is generated.
- the checking unit 35 identifies the article area A k (step S22). Specifically, the inspection unit 35 specifies the corner of the container B in the binarized image JB 2 and sets the corner to the reference position P 0 . Inspecting unit 35, by setting the reference position P 0, it reads the coordinate information of the article area A k in the storage unit 34 are stored. Checking unit 35, based on the reference position P 0 and the coordinate information, as shown in FIG. 10, it identifies all of the articles area A k.
- the inspection unit 35 binarizes the article area A k (step S23). Specifically, the inspection unit 35 reads the binarization threshold value L k stored in the storage unit 34 in association with the article region A k . The inspection unit 35 binarizes the article region A k based on the binarization threshold L k . Thereby, as shown in FIG. 10, a binarized article region T k is created. Then, the inspection unit 35 calculates an area U k of the binarized article region T k (Step S24).
- the inspection unit 35 determines whether or not the area U k is greater than or equal to the determination threshold value S k (step S25). If the inspection unit 35 determines that the area U k is equal to or greater than the determination threshold value S k , the inspection unit 35 determines that the item region A k includes the item C k (step S26). On the other hand, when the inspection unit 35 does not determine that the area U k is greater than or equal to the determination threshold value S k , the inspection unit 35 determines that the article region A k does not include the article C k (step S29).
- the inspection unit 35 does not determine that the area U k is greater than or equal to the determination threshold value S k when the inspection is performed on the article region A 6 .
- Checking unit 35 determines that if it is determined that there is no article C k to the article area A k, there is a defect in the product G (step S30).
- step S ⁇ b> 27 the inspection unit 35 determines whether or not determination has been performed for all article regions Ak. If the inspection unit 35 determines that all the article regions Ak have been determined, the inspection unit 35 determines that there is no defect in the product G (step S28). On the other hand, when the inspection unit 35 does not determine that all the article regions Ak are determined, the process returns to the process of step S22.
- the storage unit 34 has a plurality of article regions A k set in association with positions in the product G, and each of the article regions A k. Is stored as a binarization threshold L k .
- Checking unit 35 identifies the article area A k from X-ray transmission image J 1. Inspection unit 35 inspects each article area A k based on the binarization threshold L k which is set for each the article area A k.
- the article region A k can be inspected based on the binarization threshold L k set for each article region A k
- the article C k includes a plurality of types of articles C k and the articles C k are arranged at different positions. and even product G, can be examined for each article C k. Therefore, the X-ray inspection apparatus 10 can inspect for the presence or absence of a missing item C k in the product G or an abnormality in shape (cracked chip), for example.
- the X-ray inspection apparatus 10 it is possible to perform defect inspection of products G, including a plurality of types of articles C k.
- the X-ray inspection apparatus 10 includes a threshold setting unit 33 that sets a binarization threshold L k for each article region A k .
- Threshold setting unit 33 sets a binarization threshold value L k for binarizing the article area A k for each article area A k.
- the inspection unit 35 binarizes each article region A k based on the binarization threshold L k .
- the inspection unit 35 inspects the article C k based on the binarized binarized article region T k . By binarizing the article region A k , the article region A k can be clarified. Therefore, the inspection of the article C k can be performed more appropriately.
- the threshold setting unit 33 sets a determination threshold S k for determining the presence / absence of the article C k for each article region A k .
- the inspection unit 35 determines the presence / absence of the article C k based on at least one of the shape, the area U k or the peripheral length of the binarized article region T k and the determination threshold value S k . Thereby, the presence or absence of the article C k can be accurately determined, and a lack of the article C k in the product G can be inspected.
- X-ray inspection apparatus 10 includes an area setting unit 32 for setting the article area A k.
- the area setting unit 32 sets the reference position P 0 in the X-ray transmission image.
- the area setting unit 32 includes an area setting unit 32 that sets an article area A k including each article C k according to the positional relationship with the reference position P 0 .
- the inspection unit 35 acquires the reference position P 0 from the X-ray transmission image.
- Checking unit 35 identifies the article area A k based on the reference position P 0. By acquiring the reference position P 0 , the inspection unit 35 can accurately acquire each article region Ak . As a result, the inspection accuracy can be improved.
- the product G comprises a container B for containing a plurality of types of articles C k.
- the area setting unit 32 sets a reference position P 0 for the container B and sets each article area Ak .
- Container B because the change in shape is smaller than that of the article C k, obtained from the X-ray transmission image tends. Therefore, by setting the reference position P 0 in the container B, the inspection unit 35 can acquire the reference position P 0 quickly and reliably. Thereby, the test
- the region setting unit 32 sets the reference position P 0 in the X-ray transmission image J 1 (see FIG. 4A) generated by the image generation unit 31, and each article C according to the positional relationship with the reference position P 0.
- the article region A k including k is automatically set.
- the area setting unit 32 extracts the estimated area Z k suspected of containing an article C k from X-ray transmission image J 1.
- Region setting unit 32 sets automatically the articles area A k based on the estimated area Z k.
- the area setting unit 32 stores the set article area Ak in the storage unit 34.
- the threshold setting unit 33 automatically sets a threshold for each article region Ak . Threshold setting unit 33, a binarization threshold L k for binarizing the article area A k, and the determination threshold S k for determining the presence or absence of the article C k, automatically every article area A k Set.
- the threshold setting unit 33 causes the storage unit 34 to store the set binarization threshold L k and determination threshold S k .
- presetting in the control unit 30 will be described with reference to FIG.
- the presetting is automatically performed by the control unit 30.
- the control unit 30 displays a setting button for starting pre-setting on the menu screen of the monitor 20.
- the control unit 30 causes the monitor 20 to display text for instructing to place the product GS on the conveyor 12 (for example, “Please place the product on the conveyor”).
- the image generation unit 31 performs an X-ray transmission image J of the product GS based on the detected X-rays including the transmitted X-rays transmitted through the product GS. 1 (see FIG. 4A) is generated (step S40). Then, the area setting unit 32 binarizes the X-ray transmission image J 1 generated by the image generating unit 31 at threshold L 0 (step S41), as shown in FIG. 4 (b), the binary generating a reduction image JB 1.
- the area setting unit 32 sets the reference position P 0 (step S42). Specifically, the region setting unit 32 extracts the container B from the binarized image JB 1 . The region setting unit 32 sets a reference position P 0 at one corner of the container B. The region setting unit 32 stores the set reference position P 0 in the storage unit 34 as coordinate information.
- the area setting unit 32 sets an article area Ak .
- the area setting unit 32 sets the estimated area Z k (step S43).
- the estimated area Z k is an area estimated to include the article C k .
- the estimated area Z k is set based on the binarized image JB 1 .
- the region setting unit 32 estimates a portion where regions (black portions in the drawing) are continuous as one article C k .
- Region setting unit 32 sets the region to the estimated area Z k.
- Region setting unit 32 may set the portion surrounded by the region in the envelope L Z1 as the estimated area Z k, it may be set a rectangle containing the region as the estimated area Z k.
- the region setting unit 32 stores the set estimated region Z k in the storage unit 34.
- the area setting unit 32 generates a profile of luminance (gray) in the estimation region Z k (step S44).
- Region setting unit 32, the X-ray transmission image J 1, extracts a portion corresponding to the estimated area Z k.
- the area setting unit 32 generates a luminance profile of the part.
- a profile PR2 is generated. Is done.
- the horizontal axis indicates the position of each detection point in the horizontal direction in the estimation region Z k as shown.
- the vertical axis indicates the average luminance at each detection point.
- the average luminance is a luminance obtained by averaging the luminance at each detection point in the vertical direction in the figure at a certain position in the horizontal direction in the figure.
- the transmittance of the article C 1 is lower than the transmittance of the article C 2
- the luminance of the transmitted X-rays of the article C 1 luminance of the transmitted X-rays of the article C 2 Smaller than. Therefore, the profile PR2, difference in brightness occurs in the article C 1 and the article C 2.
- Region setting unit 32 determines the estimated area Z k, whether or not the difference in brightness exists a predetermined value or more parts (step S45). For example, as illustrated in FIG. 12B, the region setting unit 32 determines whether or not the difference ⁇ X m between the minimum luminance X m1 and the minimum luminance X m2 is equal to or greater than a predetermined value.
- the predetermined value may be, for example, a fixed value set in advance or a value that changes.
- the minimum luminance X m2 is a value that doubles the minimum luminance X m1 .
- Region setting unit 32 when the difference [Delta] X m is equal to or more than the predetermined value, it is determined that a plurality of parts present in the estimation region Z k. Region setting unit 32 sets each of the plurality of partial as an article area A k (step S36). Specifically, the area setting unit 32, for example, as shown in FIG. 12 (b), as the boundary a peak value X T, setting the article area A k. Peak value X T emerges in the case of using the average luminance for each detection point the longitudinal axis of the profile PR2. The area setting unit 32 stores the set article area Ak in the storage unit 34.
- the area setting unit 32 in the estimation region Z k, when the difference in luminance is not determined that there is a predetermined value or more portions sets the estimated area Z k as an article area A k (step S47) .
- the area setting unit 32 stores the set article area Ak in the storage unit 34.
- the threshold setting unit 33 sets a binarization threshold value L k (step S48).
- the threshold setting unit 33 sets the binarization threshold L k based on the relationship between the brightness of the article C k and the number of pixels. Specifically, the histogram threshold setting unit 33, as shown in (a) of FIG. 13, showing the article area A k, the horizontal axis of the transmission X-ray of the article C k luminance, and the vertical axis the number of pixels To get. Based on the histogram, the threshold setting unit 33 sets, as the binarization threshold L k , the luminance L 90 at which the cumulative number (%) of the number of pixels is 90%, for example, as illustrated in FIG. . The threshold value setting unit 33 sets a binarization threshold value L k for each of the article regions A k . The threshold setting unit 33 stores the set binarization threshold L k in the storage unit 34.
- the threshold setting unit 33 sets the determination threshold S k (step S49).
- the threshold value setting unit 33 acquires the area U k of the binarized article region T k from the binarized image JB 1 .
- the threshold setting unit 33 sets a determination threshold S k by adding a certain allowable error or the like to the area U k .
- the threshold setting unit 33 stores the set determination threshold Sk in the storage unit 34.
- the region setting unit 32 extracts the estimated region Z k that is estimated to include the article C k from the binarized image JB 1 .
- the region setting unit 32 has a plurality of different articles C in the estimated region Z k. It is determined that k exists.
- the area setting unit 32 sets each of the plurality of parts as the article area Ak .
- the articles C k in contact with each other are one in the binarized image JB 1 based on the X-ray transmission image J 1 . Appears as an area.
- the article C k which are in contact with each other could be set as one of the articles area A k. Therefore, in one estimated region Z k that is estimated to include the article C k , the articles that are in contact with each other by detecting portions where the luminance difference ⁇ X m based on the transmittance of transmitted X-rays is equal to or greater than a predetermined value.
- the articles C k that are in contact with each other can be regarded as a plurality of articles C k . Therefore, the article region Ak can be set appropriately.
- the inspection apparatus may be another inspection apparatus such as a near infrared inspection apparatus.
- the inspection unit 35 identifies the article area A k from the image, it is possible to examine each item area A k based on a threshold L k which is set for each the article area A k.
- the X-ray inspection apparatus 10 is an apparatus that performs a defect inspection of the article C in the product G (inspection of the presence or absence of the article C or an abnormality in the shape (cracked chipping), etc.). In addition to the defect inspection, the foreign matter inspection on the product G may be performed. In this case, the binarization of the X-ray transmission image can be uniformly performed with a single binarization threshold.
- the reference position P 0 is not limited to the corner of the container B.
- the region setting unit 32 may set the reference position P 0 at the center point or the center of gravity of the specific article C k extracted by binarization.
- the region setting unit 32 may set the reference position P 0 at a point having the highest density (a point having the lowest luminance) in the X-ray transmission image J 1 of the product G.
- the region setting unit 32 may set the reference position P 0 at an arbitrary point outside the container B in the X-ray transmission image J 1 .
- the area setting unit 32 sets the reference position P 0 to the article C k having the largest area among the plurality of types of articles C k, may be set each article regions A k.
- the region setting unit 32 can set the reference position P 0 to the center of gravity of the article C k having the largest area, and set a certain region around the center of gravity as the article region A k .
- Checking unit 35 in each of the article area A k, by comparing the estimated mass of the articles C k, and a determination threshold S k, may be inspected for articles C k.
- the X-ray inspection apparatus 10 can inspect the presence / absence of the article C k based on the estimated mass of the article C k calculated as follows.
- the threshold setting unit 33 sets the reference estimated mass of the article C k included in the article area A k as the determination threshold S k for each article area A k .
- the reference estimated mass is the mass of the article C k in the product GS which is a sample product that is a standard for defect inspection.
- the mass of the article C k in the product GS is a mass in a state where there is no defect.
- the determination threshold value S k may be set to a value in which a certain allowable error is added to the estimated mass of the article C k .
- Threshold setting unit 33 accepts an input operation to the operator of the monitor 20, in response to an input operation to set the determination threshold S k.
- the threshold setting unit 33 stores the set determination threshold Sk in the storage unit 34.
- the inspection unit 35 has functions of a mass estimation curve setting unit and a mass estimation unit.
- the inspection unit 35 is based on the X-ray transmission image J 1 (see FIG. 4A) of the product GS generated by the image generation unit 31 (for example, the X-ray detection unit 14).
- a mass estimation curve for luminance (shading) for each pixel is set based on the following equation (1).
- the inspection unit 35 sets a mass estimation curve for each article region Ak .
- the inspection unit 35 may adjust the mass estimation curve so that the actual total mass of the article C k in the product GS is close to the total estimated mass of the article C k .
- m is the estimated mass of the article
- c coefficient for converting the thickness of the article into mass
- t thickness of the article
- I X-ray brightness when there is no article
- I 0 Brightness of transmitted X-rays of the article
- ⁇ Linear absorption coefficient
- the inspection unit 35 calculates the estimated mass of the article C k using the mass estimation curve set as described above. For example, the inspection unit 35 acquires the reference position P 0 from the X-ray transmission image J 2 Product G, for specifying each item area A k based on the reference position P 0. Checking unit 35, to each of the identified goods area A k, in accordance with the luminance of each unit area (e.g. 1 pixel), and calculates the estimated mass of the articles C k using mass estimated curve for each unit area . The inspection unit 35 calculates the estimated mass of the article C k for all article areas A k .
- Checking unit 35 to each of the identified goods area A k, by using the respective determination thresholds S k, estimated mass of the estimated article C k to determine whether the determination threshold S k or more, the article C k Check for the presence or absence of.
- Checking unit 35 based on the inspection result of the presence or absence of the article C k, it determines the presence or absence of defects of the product G.
- the inspection unit 35 calculates the estimated mass of the article C k using the mass estimation curve set for each article area A k . Therefore, even for products G comprising a plurality of articles C k, it can perform accurate mass estimate.
- the inspection unit 35 determines the presence / absence of the article C k based on the estimated mass of the article C k and the determination threshold value S k . Thereby, the presence or absence of the article C k can be accurately determined, and a lack of the article C k in the product G can be inspected.
- SYMBOLS 10 ... X-ray inspection apparatus (inspection apparatus), 13 ... X-ray source (light irradiation part), 14 ... X-ray detection part (detection part), 31 ... Image generation part, 32 ... Area setting part, 33 ... Threshold setting part , 34 ... storage unit, 35 ... inspection unit, B ... container (container), C k ... article, G ... products, J 1, J 2 ... X-ray transmission image, JB 1, JB 2 ... binarized image, L k ... binarization threshold, P 0 ... reference position, S k ... determination threshold, T k ... binarized article area, U k ... area, Z k ... estimation area.
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Abstract
Description
以下、添付図面を参照して、本発明の一側面の好適な実施形態について詳細に説明する。なお、図面の説明において同一又は相当要素には同一符号を付し、重複する説明は省略する。
図1~図3に示されるように、X線検査装置(検査装置)10は、例えば商品Gの生産ラインにおいて、商品Gにおける物品Cの不良検査を行う装置である。検査対象となる商品Gは、複数種類の物品Cと、複数種類の物品Cを収容する容器B(収容体)と、を含む。この商品Gにおいては、各物品Cが異なる位置に配置されている。商品Gとしては、例えば、弁当、連続包装の食品(例えば材料又は味違い)、菓子折り詰め合わせ、ネジ等の部品の詰め合わせ、又は組物(工具、食器)等が挙げられる。商品Gにおける不良としては、物品Cの欠品の有無、又は形状の異常(割れ欠け)等が含まれる。収容体は、箱型の容器Bに限られない。収容体は、種々の形状の容器、袋体、又は包装箱等であってもよい。本実施形態では、一例として、商品Gが、複数種類の物品Cとして食品が収容された弁当である場合について説明する。
制御部30は、例えば電源が投入されると、モニタ20のメニュー画面に、事前設定を開始させる設定ボタンを表示させる。制御部30は、設定ボタンが操作者により押下されると、商品GSをコンベア12に置くように指示するテキスト(例えば、「商品をコンベアに置いてください」等)をモニタ20に表示させる。商品GSは、事前設定のために用いられる不良検査の基準となるサンプル商品である。具体的には、商品GSは、不良検査の対象である商品Gと同様の内容とされており、不良が無い状態とされている。商品GSは、商品G(図9の(a)参照)と同様の容器Bを含む。容器Bは、図6の(a)に示されるように、平面視で略矩形形状の外形を呈している。容器Bは、複数(ここでは8個)の収容部Bn(n=1~8)を有する。図6の(b)に示されるように、収容部Bnには、物品Ckが収容される。本実施形態では、物品Ckの数が10個である。10個の物品C1~C10は、8個の収容部B1~B8に収容されている。具体的には、収容部B1に、物品C1及び物品C2が収容され、収容部B2に、物品C3及び物品C4が収容されている。
図8に示されるように、画像生成部31は、商品Gを透過した透過X線を含む検出X線に基づいて、商品GのX線透過画像J2(図9の(a)参照)を生成する(ステップS20)。次に、領域設定部32は、画像生成部31によって生成されたX線透過画像J2を閾値L0で二値化し(ステップS21)、図9の(b)に示されるように、二値化画像JB2を生成する。
以上説明したように、本実施形態に係るX線検査装置10では、記憶部34は、商品Gにおける位置が対応付けられて設定された複数の物品領域Ak、及び、当該物品領域Ak毎に設定された二値化閾値Lkを記憶している。検査部35は、X線透過画像J1から上記物品領域Akを特定する。検査部35は、当該物品領域Ak毎に設定された二値化閾値Lkに基づいて物品領域Akのそれぞれを検査する。このように、物品領域Ak毎に設定された二値化閾値Lkに基づいて物品領域Akを検査できるため、複数種類の物品Ckを含み且つ当該物品Ckが異なる位置に配置された商品Gであっても、物品Ck毎に検査を行うことができる。したがって、X線検査装置10では、例えば、商品Gにおける物品Ckの欠品の有無、又は形状の異常(割れ欠け)等を検査できる。このように、X線検査装置10では、複数種類の物品Ckを含む商品Gの不良検査を行うことができる。特に、X線検査装置10では、例えば、容器Bにおける同一の収容部Bnに異種の物品Cが存在したり、容器Bにおける隣接する収容部Bnに跨るように物品Cが存在したりしたとしても、収容部Bnの領域毎に二値化閾値を設定していないため、商品Gの不良検査を行うことができる。
続いて、X線検査装置10の第2実施形態について説明する。第2実施形態に係るX線検査装置10は、領域設定部32において物品領域Ak、及び、閾値設定部33において二値化閾値Lk及び判定閾値Skを自動で設定する点で第1実施形態と異なる。
制御部30は、例えば電源が投入されると、モニタ20のメニュー画面に、事前設定を開始させる設定ボタンを表示させる。制御部30は、設定ボタンが操作者により押下されると、商品GSをコンベア12に置くように指示するテキスト(例えば、「商品をコンベアに置いてください」等)をモニタ20に表示させる。
以上説明したように、本実施形態に係るX線検査装置10では、領域設定部32は、物品Ckを含むと推定される推定領域Zkを二値化画像JB1から抽出する。領域設定部32は、一つの推定領域Zkにおいて透過X線の透過率に基づく輝度の差ΔXmが所定値以上の部分が存在する場合、当該推定領域Zkに種類の異なる複数の物品Ckが存在していると判定する。領域設定部32は、複数の部分のそれぞれを物品領域Akとして設定する。複数の物品Ckの一部が互いに接触して(重なって)配置されている場合、互いに接触している物品Ckは、X線透過画像J1に基づく二値化画像JB1において一つの領域として現れる。この場合、複数の物品Ckが存在しているにも関わらず、互いに接触している物品Ckが一つの物品領域Akとして設定される可能性がある。そこで、物品Ckを含むと推定される一つの推定領域Zkにおいて、透過X線の透過率に基づく輝度の差ΔXmが所定値以上の部分を検出することにより、互いに接触している物品Ckが一つの領域として二値化画像JB1に現れている場合であっても、互いに接触している物品Ckを複数の物品Ckとして捉えることができる。したがって、物品領域Akを適切に設定できる。
上記実施形態では、検査装置がX線検査装置10である場合を例に説明したが、検査装置は、例えば、近赤外線検査装置等の他の検査装置であってもよい。この場合においても、検査部35は、画像から上記物品領域Akを特定し、当該物品領域Ak毎に設定された閾値Lkに基づいて物品領域Akのそれぞれを検査することができる。
=-c/μ×In(I/I0)=-αIn(I/I0) ・・・(1)
ただし、m :物品の推定質量、
c :物品の厚さから質量に変換するための係数、
t :物品の厚さ、
I :物品がないときのX線の輝度、
I0:物品の透過X線の輝度、
μ :線吸収係数
Claims (7)
- 複数種類の物品を含み且つ当該物品が異なる位置に配置された商品に光を照射する光照射部と、前記商品に照射された前記光の透過光を検出する検出部と、前記透過光に基づいて画像を生成する画像生成部と、前記画像に基づいて前記商品における不良を検査する検査部と、を備える検査装置であって、
複数種類の前記物品毎に、前記商品における位置が対応付けられて設定された複数の物品領域、及び、当該物品領域毎に設定された閾値を記憶する記憶部を備え、
前記検査部は、前記画像に基づいて前記物品領域を特定し、当該物品領域毎に設定された前記閾値に基づいて前記物品領域のそれぞれを検査して、当該検査結果に基づいて前記商品における不良の有無を判定する、検査装置。 - 前記閾値を前記物品領域毎に設定する閾値設定部を備え、
前記閾値設定部は、前記物品領域を二値化するための二値化閾値を前記物品領域毎に設定し、
前記検査部は、前記二値化閾値に基づいて各前記物品領域を二値化し、二値化した二値化物品領域に基づいて前記物品を検査する、請求項1に記載の検査装置。 - 前記閾値設定部は、前記物品の有無を判定するための判定閾値を前記物品領域毎に設定し、
前記検査部は、前記二値化物品領域の形状、面積又は周囲長の少なくとも一つと前記判定閾値とに基づいて、前記物品の有無を判定する、請求項2に記載の検査装置。 - 前記画像に基準位置を設定し、当該基準位置との位置関係によって各前記物品を含む前記物品領域を設定する領域設定部を備え、
前記検査部は、前記画像から前記基準位置を取得し、前記基準位置に基づいて前記物品領域を特定する、請求項1~3のいずれか一項に記載の検査装置。 - 前記商品は、複数種類の前記物品を収容する収容体を含み、
前記領域設定部は、前記収容体に前記基準位置を設定して各前記物品領域を設定する、請求項4に記載の検査装置。 - 前記領域設定部は、複数種類の前記物品のうち最も大きい面積を有する前記物品に前記基準位置を設定して、各前記物品領域を設定する、請求項4に記載の検査装置。
- 前記領域設定部は、前記物品を含むと推定される領域を前記画像から抽出し、一つの前記領域において前記透過光の透過率に基づく値の差が所定値以上の部分が存在する場合、当該領域に種類の異なる複数の前記物品が存在していると判定し、複数の前記部分のそれぞれを前記物品領域として設定する、請求項4~6のいずれか一項に記載の検査装置。
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