JP6035116B2 - Circular product inspection apparatus and method - Google Patents
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- JP6035116B2 JP6035116B2 JP2012246046A JP2012246046A JP6035116B2 JP 6035116 B2 JP6035116 B2 JP 6035116B2 JP 2012246046 A JP2012246046 A JP 2012246046A JP 2012246046 A JP2012246046 A JP 2012246046A JP 6035116 B2 JP6035116 B2 JP 6035116B2
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- 238000007689 inspection Methods 0.000 title claims description 47
- 238000000034 method Methods 0.000 title claims description 19
- 238000003384 imaging method Methods 0.000 claims description 17
- 238000005286 illumination Methods 0.000 claims description 15
- 238000012545 processing Methods 0.000 claims description 14
- 238000005259 measurement Methods 0.000 description 7
- 238000012937 correction Methods 0.000 description 3
- 230000007547 defect Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 230000003287 optical effect Effects 0.000 description 2
- PXFBZOLANLWPMH-UHFFFAOYSA-N 16-Epiaffinine Natural products C1C(C2=CC=CC=C2N2)=C2C(=O)CC2C(=CC)CN(C)C1C2CO PXFBZOLANLWPMH-UHFFFAOYSA-N 0.000 description 1
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 238000004512 die casting Methods 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 238000013507 mapping Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 230000003252 repetitive effect Effects 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
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Description
本発明は画像処理により製品の良否を検査する装置及び方法に関し、特に略円盤状の円形状製品の検査に係る。 The present invention relates to an apparatus and method for inspecting the quality of a product by image processing, and more particularly to inspection of a substantially disc-shaped circular product.
円筒形状容器，円筒体の製品を外観検査する方法として特許文献１，２が公知である。
特許文献１は円筒形状容器の側面１回転分の画像を検査画像として、ブロック毎に設定してある領域内でテンプレートマッチングを行って位置補正をする検査方法を開示する。
特許文献２は円筒体の側面画像を平坦に展開した変換画像にするとともに回転を複数回繰り返した合成画像を基準画像とするものである。
上記いずれの公報に開示する検査方法も対象製品を回転させて検査画像を取り込むものではあるが、検査に用いる基準画像を平準化しており、必ずしも個々の製品の検査精度が高いものではない。
特許文献３は円板状の対象物を回転させ、１回転分の画像データを複数の順次画像データとして一旦メモリ１８に記憶格納し、基準となる硬貨の１番目の画像データと上記検査画像データと順次比較することで両硬貨の回転角度を対応させる技術を開示する。
しかし、表面状態像をリニアセンサにて電気信号に変換する撮像範囲を集光レンズにて取り込んでデータに基づいているために検査精度が充分に高いものではない。
Patent Documents 1 and 2 are known as methods for inspecting the appearance of cylindrical containers and cylindrical products.
Patent Document 1 discloses an inspection method in which an image corresponding to one rotation of a side surface of a cylindrical container is used as an inspection image and template matching is performed within a region set for each block to perform position correction.
In Patent Document 2, a side image of a cylindrical body is converted into a flattened converted image, and a combined image obtained by repeating rotation a plurality of times is used as a reference image.
Although the inspection methods disclosed in any of the above publications rotate the target product to capture the inspection image, the reference image used for the inspection is leveled, and the inspection accuracy of each product is not necessarily high.
In Patent Document 3, a disk-shaped object is rotated, and image data for one rotation is temporarily stored and stored in the memory 18 as a plurality of sequential image data, and the first image data of a reference coin and the inspection image data described above are stored. And a technique for making the rotation angles of both coins correspond to each other by sequentially comparing them.
However, since the imaging range for converting the surface state image into an electrical signal by the linear sensor is taken in by the condenser lens and based on the data, the inspection accuracy is not sufficiently high.
本発明は検査精度が高く、作業性に優れた円形状製品の検査装置及びその方法の提供を目的とする。 It is an object of the present invention to provide a circular product inspection apparatus and method with high inspection accuracy and excellent workability.
本発明は、円形状製品を検査するための検査装置であって、前記円形状製品を回転可能に載置するための回転治具と、前記円形状製品は回転方向に沿って繰り返しパターンからなる複数のスリットを有し、前記円形状製品を一方から照らすためのコリメート照明手段と、前記円形状製品のスリットからの透過光による検査画像を取り込むためのテレセントリックレンズを用いた撮像手段とを備え、前記回転治具にて円形状製品を回転させながら、前記撮像手段にて取得した検査画像をマスター画像と照合する照合手段を有し、前記照合手段は、繰り返しパターンのマッチング処理手段を有することを特徴とする。
ここでコリメート照明手段とは、照らす光の方向を平行光化したものをいう。
また、テレセントリックレンズとは、主光線が焦点を通るように配列された光学系をいい、主光線が光軸に対して平行なレンズ、つまり画角が０°となるレンズをいう。
The present invention is an inspection apparatus for inspecting a circular products, and rotation jig for rotatably mounting the circular product, the circular product of a repeating pattern along the rotational direction A plurality of slits, collimating illumination means for illuminating the circular product from one side, and imaging means using a telecentric lens for capturing an inspection image by transmitted light from the slit of the circular product while rotating the circular product by the rotating jig, the inspection image obtained by the imaging means have a collation means for collating the master image, before Symbol matching means comprises a matching processing means repeating pattern It is characterized by that.
Here, the collimating illumination means refers to a collimated light direction.
The telecentric lens refers to an optical system arranged so that the principal ray passes through the focal point, and refers to a lens in which the principal ray is parallel to the optical axis, that is, a lens having an angle of view of 0 °.
本発明の検査対象となる製品は、略円盤状の外形を有する円形状製品全般に適用できるが、特に円形状製品を中心廻りに回転させた場合に回転方向に沿って繰り返しパターンを有し、パターン毎に製品検査するのに有用である。 The product to be inspected according to the present invention can be applied to all circular products having a substantially disk-shaped outer shape, but has a repeated pattern along the rotation direction when the circular product is rotated around the center, Useful for product inspection for each pattern.
また、本発明に係る検査方法は、円形状製品を検査するための検査方法であって、前記円形状製品を回転可能に載置するための回転治具と、前記円形状製品は回転方向に沿って繰り返しパターンからなる複数のスリットを有し、前記円形状製品を一方から照らすためのコリメート照明手段と、前記円形状製品のスリットからの透過光による検査画像を取り込むためのテレセントリックレンズを用いた撮像手段とを備え、前記回転治具にて円形状製品を回転させながら前記撮像手段を用いて当該円形状製品の検査画像を帯状に展開取得するステップと、帯状に展開したマスター画像に、検査基準位置をパターンマッチング処理により基準合せするステップと、前記検査画像とマスター画像とを照合するステップとを、有することを特徴とする。 Moreover, inspection査方method according to the present invention is an inspection method for inspecting a circular products, and rotation jig for rotatably mounting the circular product, the circular product rotation a plurality of slits of a repeating pattern along the direction, and the collimating illumination means for illuminating said circular product from one, a telecentric lens for capturing an inspection image by transmitted light from the circular product of the slit And using the imaging means to develop and obtain an inspection image of the circular product in a band shape while rotating the circular product with the rotating jig, and to obtain a master image developed in a belt shape. And a step of matching the inspection reference position by pattern matching processing and a step of collating the inspection image with the master image.
本発明において対象製品が複数の型番からなる等、複数の製品群が存在する場合には予め、対象商品に附されている印字、該印等をカメラで読取り、製品の種別を特定するのが好ましい。 In the present invention, when there are a plurality of product groups, for example, the target product is composed of a plurality of model numbers, the print attached to the target product, the mark, etc. are read with the camera in advance to specify the type of the product. preferable.
製品の良否の検査において傾向に特徴がある部位で領域分けをし、それぞれで良否判定のためのしきい値を設定すると高精度で安定性が向上する。 Stability is improved with high accuracy by dividing a region into regions having characteristic features in the quality inspection of products and setting threshold values for determining quality.
本発明に係る検査装置及び方法は、円形状製品の検査画像及び基準画像（マスター画像）を取り込む際にコリメート照明手段とテレセントリックレンズ系の撮像手段を用いたので、撮像時に深さ方向に画像歪みが生じにくく、検査精度が高い。 Since the inspection apparatus and method according to the present invention uses the collimating illumination unit and the imaging unit of the telecentric lens system when capturing the inspection image and the reference image (master image) of the circular product, the image distortion in the depth direction during imaging is performed. Is less likely to occur and the inspection accuracy is high.
図１に本発明に係る検査装置１０の構成例を示す。
検査対象となる円形状のワーク１を載置し、回転制御する回転治具１１を有する。
ワーク１を照明するコリメート照明１２を有し、ワーク１の１回転分の外観をテレセントリックレンズ１３を介して撮像するラインセンサカメラ１４を有する。
本発明はワーク１の画像を取り込む際に、ラインセンサカメラ１４を用いて直接光のみ取り込むようにし、太陽光等の外乱光を防ぐとともにコリメート照明手段とテレセントリックレンズ系の撮像手段の組み合せを用いてワークの形状の周囲からの廻り込み光を防ぎ、深度の高い画像を得ることができる。
本実施例ではワークの大きさ等により複数の品番を有するので、リング照明１５にてワーク１を照らし、ワーク１の中央よりに刻印した文字を読み取るフレームカメラ１６を備えた構成例になっている。
ワーク１から取得した画像データに基づいて、品番及び製品の良否を判定するための照合手段としての画像処理手段１７を有する。
FIG. 1 shows a configuration example of an inspection apparatus 10 according to the present invention.
A circular workpiece 1 to be inspected is placed, and a rotation jig 11 that controls rotation is provided.
A collimating illumination 12 that illuminates the workpiece 1 is provided, and a line sensor camera 14 that images the appearance of the workpiece 1 for one rotation through a telecentric lens 13 is provided.
In the present invention, when the image of the workpiece 1 is captured, only the direct light is captured using the line sensor camera 14, and disturbance light such as sunlight is prevented and a combination of the collimating illumination unit and the imaging unit of the telecentric lens system is used. It is possible to prevent sneak light from the periphery of the workpiece shape and obtain an image with a high depth.
In the present embodiment, since there are a plurality of product numbers depending on the size of the workpiece, the configuration is provided with a frame camera 16 that illuminates the workpiece 1 with the ring illumination 15 and reads characters engraved from the center of the workpiece 1. .
Based on the image data acquired from the workpiece 1, the image processing means 17 is provided as a collating means for determining the product number and the quality of the product.
本実施例で検査対象とした製品の外観を図２に示す。
この製品は車両のオートマチックトランスミッションに使用されているトルクコンバーター用の部品であるステーターホイールである。
ステーターホイールは回転体であり、回転廻りに沿って概ね等間隔に複数のブレード３Ａ，３Ｂ，３Ｃ，・・・が配置され、その間に複数のスリット３ａ，３ｂ，３ｃ，・・・が形成されている。
本発明に係る検査対象品は円形状の製品全般に適用できるが、このようなステーターホイールのように周廻りにブレード等が繰り返し有するものに特に適している。
本実施例におけるステーターホイールは、アルミニウム合金を用いたダイカスト鋳造にて製造されるものであり、鋳造時のバリ残りや欠肉の有無をマスター画像と照合判定する。
FIG. 2 shows the appearance of a product to be inspected in this example.
This product is a stator wheel that is a component for torque converters used in vehicle automatic transmissions.
The stator wheel is a rotating body, and a plurality of blades 3A, 3B, 3C,... Are arranged at approximately equal intervals along the rotation, and a plurality of slits 3a, 3b, 3c,. ing.
The product to be inspected according to the present invention can be applied to all circular products, but is particularly suitable for such a stator wheel having blades repeatedly around its circumference.
The stator wheel in the present embodiment is manufactured by die casting using an aluminum alloy, and the presence or absence of burrs remaining at the time of casting or the presence or absence of thinning is checked against the master image.
図３に図１に示した検査装置を用いたフロー図を示す。
検査を行うために、検査対象物（ステーターホイール）が回転治具１１にセットされる（＃１）。
図示されていない測定開始ボタンが操作されると測定が開始される（＃２）。
まず、フレームカメラ１６の撮像位置まで移動し（＃３）、リング照明１５がＯＮされフレームカメラ１６によって検査対象物の刻印部の撮影を実施する（＃４）。
刻印部撮影画像にてあらかじめ準備しておく刻印部マスター画像を用いてパターンマッチング処理を実施して、セットされた測定対象物の刻印から測定対象物の品番を判別する（＃５）。
刻印部の画像処理後にリング照明１５をＯＦＦし、結果より刻印部が読取り可の場合（＃６Ｙｅｓ分岐）は次の処理へ、刻印部の読取りが不可の場合（＃６分岐Ｎｏ）は読取不可フラグをＯＮする（＃７）。
刻印部の処理が終了したら、ラインセンサカメラ１４を撮像位置まで動作させる（＃８）。
動作完了後にコリメート照明１２をＯＮし回転治具１１を回転させて検査対象部位の撮像を実施する（＃９）。
撮像完了後にコリメート照明１２をＯＦＦする。
撮像実施後、読取不可フラグがＯＮの場合（＃１０分岐Ｎｏ）、取得した画像とマスター画像を用いて品番判別処理を実施する（＃１１）。
品番判別処理（＃１１）終了後、もしくは読取フラグ（＃１０分岐Ｙｅｓ）の場合は対応する品番のマスター画像を読み出す（＃１２）。
測定対処物はダイカスト素形材であるため、繰り返しパターン毎（ブレード毎）に固体差が発生する傾向がある。
従って、本システムにおいては測定対象物の繰り返しパターン一つに対して一つのマスター画像を保有させる。
また、測定対象物は丸物であるため装置へのセット姿勢が毎回異なる。
測定対象物のセット姿勢を毎回固定することでも対応可能であるが、作業性悪化の要因となることより、マスター画像内と撮影画像撮内の繰り返しパターンを用いて撮像ズレ量を算出して撮影画像上にてセット姿勢補正処理を実施する（＃１３）。
本実施例の場合は具体例を段落（００１５）に示す。
セット姿勢の補正処理実施後にマスター画像と照合（＃１４）し判定処理を実施するが、測定対象物の形状特性により判定領域を分割して、それぞれの領域においてバリ，欠肉に対するしきい値処理（＃１５）を実施する。
本実施例では、図５，６に示す。
しきい値処理を実施後に総合判定を実施（＃１６）し、欠陥未検査（＃１７分岐Ｙｅｓ）の場合は処理を終了し、欠陥を検出（＃１７分岐Ｎｏ）した場合は欠陥部をモニタ上にマッピング（＃１８）後に処理を終了する。
FIG. 3 shows a flow diagram using the inspection apparatus shown in FIG.
In order to perform the inspection, the inspection object (stator wheel) is set on the rotating jig 11 (# 1).
When a measurement start button (not shown) is operated, measurement is started (# 2).
First, it moves to the imaging position of the frame camera 16 (# 3), the ring illumination 15 is turned on, and the frame camera 16 performs imaging of the marking portion of the inspection object (# 4).
Pattern matching processing is performed using a stamped portion master image prepared in advance in the stamped portion photographed image, and the product number of the measured object is determined from the set marking of the measured object (# 5).
The ring illumination 15 is turned off after image processing of the stamped portion, and if the stamped portion can be read from the result (# 6 Yes branch), the process proceeds to the next processing, and if the stamped portion cannot be read (# 6 branch No), it cannot be read. The flag is turned on (# 7).
When the process of the marking part is completed, the line sensor camera 14 is moved to the imaging position (# 8).
After the operation is completed, the collimated illumination 12 is turned on and the rotating jig 11 is rotated to image the inspection target part (# 9).
The collimating illumination 12 is turned off after completion of imaging.
If the unreadable flag is ON after image capturing (# 10 branch No), product number discrimination processing is performed using the acquired image and master image (# 11).
After completion of the product number discrimination process (# 11) or in the case of a reading flag (# 10 branch Yes), the master image of the corresponding product number is read (# 12).
Since the measurement object is a die-cast material, there is a tendency for a solid difference to occur for each repeated pattern (for each blade).
Therefore, in this system, one master image is held for one repetitive pattern of the measurement object.
Moreover, since the measurement object is a round object, the setting posture to the apparatus is different every time.
It is possible to cope by fixing the set posture of the measurement object every time, but because it becomes a factor of workability deterioration, shooting is performed by calculating the amount of imaging deviation using the repeating pattern in the master image and in the captured image. A set posture correction process is performed on the image (# 13).
In this embodiment, a specific example is shown in paragraph (0015).
After executing the set posture correction process, the master image is collated (# 14) and the determination process is performed. The determination area is divided according to the shape characteristic of the measurement object, and threshold processing for burrs and lacking in each area is performed. (# 15) is performed.
This embodiment is shown in FIGS.
Comprehensive judgment is performed after threshold processing (# 16). If the defect is not inspected (# 17 branch Yes), the process is terminated. If a defect is detected (# 17 branch No), the defective portion is monitored. The process ends after mapping up (# 18).
上記のフロー図に基づいてステーターホイールを検査する場合、マスター画像をブレード３Ａ，３Ｂ，３Ｃ，・・・に対応したスリット部３ａ，３ｂ，３ｃ，・・・毎に準備し、透過光の検査画像をブレード間のスリット部毎に取り込むことで各ブレードのパターンマッチング処理し、検査画像のブレードとマスター画像のブレードを対応させる。
これにより、検査対象製品を回転治具１１に載置する際にワーク１の載置角度を合せる必要がない。
When inspecting the stator wheel based on the above flow diagram, a master image is prepared for each of the slit portions 3a, 3b, 3c,... Corresponding to the blades 3A, 3B, 3C,. The image is captured for each slit between the blades to perform pattern matching processing of each blade, and the blade of the inspection image and the blade of the master image are associated with each other.
This eliminates the need to match the placement angle of the workpiece 1 when placing the inspection target product on the rotating jig 11.
本実施例に係るステーターホイールの場合に円形状の中心に中心孔４を有し、外周よりに複数のブレード３Ａ，３Ｂ，３Ｃ，・・・を有するとともにブレードの端部をリング状に連結した外形が円形状のリング部２を有している。
そこで、回転治具１１にワークをセットした後に撮像する際に各ブレードの半径方向の中心（重心）とリング部２との間の各寸法を計測し、この寸法（差分座標）を用いてアフィン変換することでワークの中心ずれを補正してもよい。
In the case of the stator wheel according to the present embodiment, the center hole 4 is provided at the center of the circular shape, the blades 3A, 3B, 3C,... The ring portion 2 has a circular outer shape.
Therefore, when imaging after setting the work on the rotating jig 11, each dimension between the center (center of gravity) in the radial direction of each blade and the ring portion 2 is measured, and using this dimension (difference coordinate), the affine is measured. The center deviation of the workpiece may be corrected by conversion.
ブレード部のバリ残り及び欠肉を判定するのに図４に示すようにブレード部間のスリット部から透過した光より、ブレード部の外形形状の検査画像の特徴的な領域に分けて、しきい値を定めた。
図５は、スリット部の上側と下側に表れるブレードの外形（部位Ａ）のバリ残り、欠肉の判定しきい値を定めた例を示す。
図６は、スリット部の半径方向両側に表れる部位Ｂのバリ残り、欠肉の判定しきい値を定めた例を示す。
In order to determine the remaining burr and thinness of the blade, the threshold is divided into the characteristic areas of the inspection image of the outer shape of the blade from the light transmitted from the slit between the blades as shown in FIG. A value was set.
FIG. 5 shows an example in which determination thresholds for remaining burr and lack of thickness on the outer shape (part A) of the blade appearing on the upper side and the lower side of the slit portion are shown.
FIG. 6 shows an example in which determination thresholds for remaining burr and lack of thickness of the portion B appearing on both sides in the radial direction of the slit portion are set.
１ ワーク
１０ 検査装置
１１ 回転治具
１２ コリメート照明
１３ テレセントリックレンズ
１４ ラインセンサカメラ
１５ リング照明
１６ フレームカメラ
１７ 画像処理手段
DESCRIPTION OF SYMBOLS 1 Work 10 Inspection apparatus 11 Rotating jig 12 Collimated illumination 13 Telecentric lens 14 Line sensor camera 15 Ring illumination 16 Frame camera 17 Image processing means
Claims (2)
前記円形状製品を回転可能に載置するための回転治具と、
前記円形状製品は回転方向に沿って繰り返しパターンからなる複数のスリットを有し、
前記円形状製品を一方から照らすためのコリメート照明手段と、
前記円形状製品のスリットからの透過光による検査画像を取り込むためのテレセントリックレンズを用いた撮像手段とを備え、
前記回転治具にて円形状製品を回転させながら、前記撮像手段にて取得した検査画像をマスター画像と照合する照合手段を有し、
前記照合手段は、繰り返しパターンのマッチング処理手段を有することを特徴とする円形状製品の検査装置。 An inspection apparatus for inspecting a circular product,
A rotating jig for rotatably mounting the circular product;
The circular product has a plurality of slits consisting of a repeating pattern along the rotation direction,
Collimated illumination means for illuminating the circular product from one side ;
An imaging means using a telecentric lens for capturing an inspection image by transmitted light from the slit of the circular product ,
While rotating the circular product by the rotating jig, it has a collation means for collating the test image acquired with the master image by the imaging means,
Before SL collating means, the inspection apparatus of the circle shaped article characterized by having a matching processing means repeating pattern.
前記円形状製品を回転可能に載置するための回転治具と、
前記円形状製品は回転方向に沿って繰り返しパターンからなる複数のスリットを有し、
前記円形状製品を一方から照らすためのコリメート照明手段と、
前記円形状製品のスリットからの透過光による検査画像を取り込むためのテレセントリックレンズを用いた撮像手段とを備え、
前記回転治具にて円形状製品を回転させながら前記撮像手段を用いて当該円形状製品の検査画像を帯状に展開取得するステップと、
帯状に展開したマスター画像に、検査基準位置をパターンマッチング処理により基準合せするステップと、前記検査画像とマスター画像とを照合するステップとを、有することを特徴とする円形状製品の検査方法。 An inspection method for inspecting a circular product,
A rotating jig for rotatably mounting the circular product;
The circular product has a plurality of slits consisting of a repeating pattern along the rotation direction,
Collimated illumination means for illuminating the circular product from one side ;
An imaging means using a telecentric lens for capturing an inspection image by transmitted light from the slit of the circular product ,
Obtaining an inspection image of the circular product in a strip shape using the imaging means while rotating the circular product with the rotating jig;
An inspection method for a circular product, comprising: a step of matching an inspection reference position to a master image developed in a band shape by pattern matching processing; and a step of comparing the inspection image with the master image.
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