JP2011163955A - Signal acquisition device - Google Patents

Abstract

Information output from an imaging device and information output from a sensor can be stored and used in association with each other.
A camera control unit 11 to which an image signal is input from a camera 2 and a sensor signal processing unit 12 to which a sensor signal is input from sensors 3a to 3c are provided. The camera control unit 11 converts the image signal into image data, and the sensor signal processing unit 12 converts the sensor signal into sensor data. The image data and the sensor data are stored in the image data storage memory 14 and the sensor data storage memory 15 via the digital data control unit 10, respectively. Further, the stored image data and sensor data are read out to the inspection device 4 according to an instruction from the inspection device 4. The image data stored in the image data storage memory 14 and the sensor data stored in the sensor data storage memory 15 are instructed by commands from the inspection apparatus 4.
[Selection] Figure 1

Description

  The present invention relates to a signal capturing device that captures at least one of an analog signal output from a sensor and an image signal output from an imaging device, converts the signal into digital data, and applies the digital data to an external device.

  In general, in the process of manufacturing a product in a factory, by extracting information included in the sound and vibration generated by the product itself, or by extracting information included in a response when a sound wave or vibration is applied to the product, It may be judged whether the product is good or bad and the machine tool is abnormal. For such determination, a sensor (such as a microphone, a vibration pickup, or an acceleration sensor) for detecting sound waves or vibration is used.

Similarly, a technique has also been proposed in which abnormal noise or vibration generated from equipment is detected by a sensor and whether the equipment is normal or abnormal using a neural network (see, for example, Patent Document 1).
JP 2008-96305 A

  By the way, as disclosed in Patent Document 1, in the technique of determining whether the output is normal or abnormal using the output of a sensor such as a microphone, a vibration pickup, or an acceleration sensor, an inspector checks an abnormal part such as a chipped or distorted object. It will be visually inspected. When a visual inspection is performed, the relationship between the appearance abnormality and the sensor output cannot be associated.

  In order to associate appearance abnormality with the output of the sensor, it is also considered to separately capture an image using an imaging device and store the sensor signal output from the sensor together with the image signal. A separate signal handling device is required. Therefore, it is difficult to use in an automatic inspection line. In addition, there is a problem that a device that handles the sensor signal and the image signal separately requires time for synchronization and setting.

  The present invention has been made in view of the above-described reasons, and an object of the present invention is to save the information output from the imaging device and the information output from the sensor and to obtain the signal acquisition that can be used in association with each other. It is in providing a loading device.

  In order to achieve the above-described object, the present invention provides an image input unit that receives an image signal from an imaging device, a sensor input unit that receives a sensor signal from a sensor that outputs an analog signal, and an image signal. Signal conversion means for converting the sensor signals into image data and sensor data, which are digital data, image data storage means for storing image signals, sensor data storage means for storing sensor data, and image data storage means Input / output means capable of outputting stored image data and sensor data stored in the sensor data storage means to an external device and capable of inputting instructions from the external device, and image data stored in the image data storage means And data selection means for selecting sensor data to be stored in the sensor data storage means by an instruction from an external device. And butterflies.

  The data selection means gives from the external device a trigger condition relating to at least one of an image signal inputted to the image input means, a sensor signal inputted to the sensor input means, and an instruction given from the external device through the input / output means. Therefore, it is possible to employ a configuration in which at least one of image data and sensor data is stored when the trigger condition is satisfied.

  In this case, it is desirable that the data selection means has a configuration in which a capture condition that defines a storage range related to at least one of image data and sensor data when the trigger condition is satisfied is instructed by an external device.

  The input / output unit may employ a configuration in which image data read from the image data storage unit to the external device and sensor data read from the sensor data storage unit to the external device are selected by an instruction from the external device.

  In this case, when the sensor data stored in the sensor data storage unit satisfies a predetermined determination condition, the input / output unit displays image data corresponding to a predetermined time range before and after the determination condition is satisfied. It is possible to adopt a configuration that outputs to an external device.

  Alternatively, when the image data stored in the image data storage unit satisfies a predetermined determination condition, the input / output unit outputs sensor data corresponding to a predetermined time range before and after the determination condition is satisfied. A configuration for outputting to an external device may be adopted.

  According to the configuration of the present invention, the information output from the imaging device and the information output from the sensor are stored, and the information to be stored can be instructed from the external device. It becomes possible to use it.

It is a block diagram which shows embodiment. It is operation | movement explanatory drawing same as the above.

  In the embodiment described below, a configuration example in which one camera 2 as an imaging device and a plurality of (three in the illustrated example) sensors 3a to 3c can be connected as shown in FIG. 1 will be described. . The external device is the inspection device 4, and uses the image signal output from the camera 2 and the sensor signals output from the sensors 3a to 3c to inspect the object with respect to various inspection items.

  For example, an inspection device 4 for monitoring the presence or absence of an abnormality in a machine tool as an object is assumed. Examples of the sensors 3a to 3c include a microphone, a vibration pickup, an acceleration sensor, a pressure sensor, a position sensor, a temperature sensor, an optical sensor, and a current sensor that detect sound and vibration. In the inspection device 4, when the outputs of the sensors 3a to 3c indicate abnormality of the machine tool, it is possible to visually inspect the presence / absence and type of the abnormality by the image of the main part of the machine tool. This use is an example and is not intended to limit the use. Further, the number of cameras 2 and the number of sensors 3a to 3c in the illustrated example are merely examples, and are not intended to limit the number.

  In this embodiment, in order to exchange data with the inspection device 4, a digital signal in a format standardized as a camera link is used. Therefore, the camera link conversion unit 16 is provided as an interface for connecting to the inspection apparatus 4. If specifications conforming to the camera link standard are used, communication errors due to noise are less likely to occur, and communication reliability can be ensured. Therefore, communication suitable for industrial use is possible. Further, since an interface compliant with the camera link standard is used, the inspection apparatus 4 can be configured by adding a frame grabber to a general-purpose personal computer.

  However, the specification of communication with the inspection device 4 may be any, and various specifications such as USB (Universal Serial Bus), RS-232C, and RS-485 can be adopted depending on the application. is there. Further, the inspection device 4 may be configured as a dedicated device having a microcomputer.

  The signal line Ls between the inspection apparatus 4 conforms to the camera link standard, and includes a data line for transmitting digital data, a synchronization line for transmitting a synchronization signal of digital data transmitted through the data line, and a clock signal. A clock line for transmission. Further, a control line (UART signal line) for giving an instruction from the inspection apparatus 4 to the signal capturing apparatus 1 is also included in the signal line Ls.

  Video signals output from the camera 2 are input to the camera control unit 11, and analog signals output from the sensors 3 a to 3 c are input to the sensor signal processing unit 12. That is, the camera control unit 11 functions as a one-channel image input means for inputting an image signal from the camera 2 (in FIG. 1, the flow of the image signal or image data is indicated by a solid line connecting the elements). To do. The sensor signal processing unit 12 receives sensor signals that are analog signals from the sensors 3a to 3c (in FIG. 1, the flow of sensor signals or sensor data is indicated by a one-dot chain line connecting elements). Functions as a multi-channel sensor input means.

  Further, the camera 2 can be controlled by giving a control signal from the camera control unit 11 to the camera 2 (in FIG. 1, the flow of the control signal is indicated by a broken line connecting elements). . Specifically, the camera control unit 11 can instruct the visual field (direction and angle of view) of the camera 2 in addition to the activation of the camera 2.

  The image signal output from the camera 2 is a digital signal, and the camera control unit 11 has a function of changing necessary parameters according to the type of the camera (digital output). Therefore, even if the type of the camera 2 is different, an image can be acquired correctly and output as image data. The types of cameras include a double speed camera, a quadruple speed camera, and a screen size (VGA, SVGA, etc.). The parameters changed by the camera control unit 11 include the number of pixel data, the count value of the number of horizontal / vertical lines, the enable signal timing, and the like.

  On the other hand, since the sensor signals output from the sensors 3a to 3c are analog signals, the sensor signal processing unit 12 also has an A / D conversion function for converting the analog signals into digital data. That is, the camera control unit 11 functions as a signal conversion unit that adjusts an image signal and converts the image signal into image data, and the sensor signal processing unit 12 functions as a signal conversion unit that converts the sensor signal into sensor data that is digital data. Function.

  In the sensor signal processing unit 12, the gain for the sensor signal, the pass frequency band or the stop frequency band of the sensor signal, and the sampling frequency of A / D conversion can be adjusted as parameters. These parameters are instructed by a control signal from the sensor data control unit 13. Also, since the sensor signal processing unit 12 is connected to a plurality of channels of the sensors 3a to 3c, the channels of the sensors 3a to 3c that take in the sensor signals can be designated by the control signal. The sensor data control unit 13 will be described later.

  Image data output from the camera control unit 11 is input to the digital data control unit 10. On the other hand, sensor data output from the sensor signal processing unit 12 is input to the digital data control unit 10 through the sensor data control unit 13.

  Connected to the digital data control unit 10 are an image data storage memory 14 as image data storage means for storing image data, and a sensor data storage memory 15 as sensor data storage means for storing sensor data. The digital data control unit 10 stores and reads image data in the image data storage memory 14, and stores and reads sensor data in the sensor data storage memory 15.

  Further, a camera link conversion unit 16 is connected to the digital data control unit 10. The image data read from the image data storage memory 14 and the sensor data read from the sensor data storage memory 15 are transferred to the inspection apparatus 4 through the camera link conversion unit 16.

  The digital data control unit 10 has a function of selecting image data stored in the image data storage memory 14 and sensor data stored in the sensor data storage memory 15. The digital data control unit 10 has a function of selecting image data to be read from the image data storage memory 14 and transferred to the inspection apparatus 4 and sensor data to be read from the sensor storage memory 15 and transferred to the inspection apparatus 4. Prepare.

  Data to be stored or read from the image data storage memory 14 and the sensor data storage memory 15 is specified by a command notified from the inspection device 4 through the camera link conversion unit 16. That is, the signal capturing device 1 includes a command communication control unit 17 that receives a command instructed from the inspection device 4, and the command communication control unit 17 decodes the instruction content by the command, and the digital data control unit 10 and sensor data control Notification to the unit 13. The command communication control unit 17 also has a function of returning responses from the digital data control unit 10 and the sensor data control unit 13 to the inspection device 4.

  As described above, the digital data control unit 10, the sensor data control unit 13, and the command communication control unit 17 include the image data and the sensor that store and read the image data storage memory 14 and the sensor data storage memory 15. It functions as data selection means for selecting data.

  As described above, the sensor data control unit 13 has a function of setting the parameters described above for the sensor signal processing unit 12 and a function of passing the sensor data received from the sensor signal processing unit 12 to the digital data control unit 10. . Further, the sensor data control unit 13 has a function of determining whether or not the sensor signal includes prescribed information.

  The information included in the sensor signal is information indicating whether or not a specific attribute (some simple ON / OFF) of the sensor signal such as the amplitude of the sensor signal and the frequency component of the specific frequency satisfies a specified condition. That is. For example, the sensor data control unit 13 designates a size range for the amplitude and frequency components, and determines that it includes prescribed information when included in the designated range. When the sensor data control unit 13 determines that the prescribed information is included in the sensor signal, the sensor data control unit 13 sets a flag and notifies the digital data control unit 10 of the setting of the flag.

  Conditions are set for the sensor data control unit 13 from the inspection device 4. That is, when a condition is specified for the digital data control unit 10 from the inspection device 4 via the camera link 16 and the command communication control unit 17, the digital data control unit 10 sets a condition for the sensor data control unit 13. Do.

  Similarly, conditions can be set for the camera control unit 11 by designation from the inspection apparatus 4. The camera control unit 11 sets a flag when the condition is satisfied, and the digital data control unit 10 sets the flag. Notify the setting. The conditions for setting the flag by the camera control unit 11 are defined with respect to attributes in the image such as the average luminance of the image signal and the average luminance of a specific area of the image. When a color camera is used as the camera 2, color attributes (hue, saturation, brightness) for the image signal are set, and the number of pixels having a specific color attribute is set as a flag setting condition. Can be used.

  In the digital data control unit 10, at least one of a flag input from the camera control unit 11 and the sensor data control unit 13 and an instruction from the inspection device 4 is used as a trigger condition, and image data, sensor data, Decide when to save. The instruction from the inspection device 4 is normally given to the digital data control unit 10 through the camera link conversion unit 16 and the command communication control unit 17, but may be given from the inspection device 4 to the digital data control unit 10 as an external signal. .

  As described above, the trigger condition uses at least one of flag setting by the camera control unit 11, flag setting by the sensor data control unit 13, and an instruction from the inspection apparatus 4. When combining a plurality of types, their logical sum or logical product may be used. For example, the trigger condition may be that the setting of the flag is notified from the sensor data control unit 13 in the time zone designated by the inspection device 4.

  By the way, the digital data control unit 10 defines the range for storing the image data in the image data storage memory 14 and the range for storing the sensor data in the sensor data storage memory 15 as capture conditions. The capture condition is a range to be stored when the trigger condition is satisfied, and is set for at least one of image data and sensor data. In short, it defines which range is to be stored for image data and sensor data at the timing specified by the trigger condition. The capture condition defines a period for storing image data and sensor data, using the time point when the trigger condition is satisfied as a reference.

  That is, the saving start time in the capture condition is as follows: when the trigger condition is satisfied, when the trigger condition is satisfied, a certain time (for example, several seconds), and when the trigger condition is satisfied for a certain time (for example, several seconds) ) It is possible to select a later time point. In addition, the saving end point in the capture condition is defined as a time point after a certain time from when the trigger condition is satisfied, a time point when a predetermined condition is satisfied for at least one of image data and sensor data after starting saving, etc. can do. The capture condition is specified from the inspection device 4 through the camera link conversion unit 16 and the command communication control unit 17 in the same manner as the trigger condition.

  By setting the trigger condition and the capture condition in the digital data control unit 10, the image signal (image data) and the sensor signal (sensor data) are associated with only a range necessary for the inspection by the inspection apparatus 4. Can be saved. In other words, necessary information can be stored while suppressing an increase in the storage capacity of the image data storage memory 14 and the sensor data storage memory 15.

  For example, when the trigger condition is satisfied when the amplitude of the sensor signal is equal to or greater than a threshold value, the image data and the sensor data are stored in the image data storage memory 14 and the sensor data storage memory 15 respectively when the trigger condition is satisfied. be able to. In addition, the trigger condition is that the amplitude of the sensor signal is equal to or greater than the threshold value and the average luminance of one screen of the image signal is equal to or greater than the threshold value (that is, the logical product of the flags of the camera control unit 11 and the sensor data control unit 13). It is good also as establishment of. Alternatively, the trigger condition may be that an external signal (trigger signal) is input from the inspection device 4 (or that a specific command is input from the inspection device 4).

  The digital data control unit 10 not only predefines the storage range of the image data and the sensor data based on the trigger condition and the capture condition, but also stores the stored image data and sensor data in accordance with an instruction from the inspection apparatus 4. Select the range to be read out. That is, the inspection apparatus 4 instructs the digital data control unit 10 as the information necessary for the inspection, the range of the image data read from the image data storage memory 14 and the sensor data read from the sensor data storage memory 15. be able to. An instruction from the inspection device 4 to the digital data control unit 10 is made through the camera link conversion unit 16 and the command communication control unit 17.

  The range specified by the inspection apparatus 4 to the digital data control unit 10 is, for example, specified to read out all of the image data stored in the image data storage memory 14 and the sensor data stored in the sensor data storage memory 15. can do. Alternatively, it may be specified that sensor data is used only as a trigger condition and only image data stored in the image data storage memory 14 is read out.

  Further, only the range designated for both the image data and the sensor data may be read. Furthermore, when an abnormality is detected by data used for inspection, the setting may be made to read data that is not used for inspection. For example, it is possible to set a condition so that only sensor data is used for checking whether there is an abnormality in an object, and image data is read for confirmation when an abnormality is detected.

  Furthermore, the image data before and after the time point when the amplitude of the sensor data (difference between the maximum value and the minimum value within a predetermined period) becomes equal to or more than a predetermined threshold value can be read. In this example, the amplitude of sensor data is used as a determination condition. When the sensor data stored in the sensor data storage memory 15 satisfies the determination condition, the digital data control unit 10 outputs the image data in a predetermined time range before and after the determination condition is satisfied to the image data storage memory 14. To the inspection device 4. The time range may be set according to the storage capacity of the image data storage memory 14.

  When the image data stored in the image data storage memory 14 satisfies a predetermined determination condition, the digital data control unit 10 stores sensor data in a predetermined time range before and after the determination condition is satisfied. The data may be output from the memory 15 to the inspection device 4.

  As described above, the digital data control unit 10, the camera link conversion unit 16, and the command communication control unit 17 can output image data and sensor data to the inspection device 4, and an instruction from the inspection device 4 is input. Since it is possible, it functions as an input / output means. Moreover, the main part of the signal capture device 1 is configured using an FPGA (Field Programmable Gate Array).

  The operations of the signal capturing device 1 described above are briefly shown in FIG. The right column of FIG. 2 shows commands from the inspection apparatus 4, and the left column shows image data and sensor data. First, the activation check is performed on the signal capturing device 1 from the inspection device 4 (S1), and further, according to a command from the inspection device 4, the digital data control unit 10, the camera control unit 11, and the sensor signal processing unit 12 are performed. Then, parameters and conditions for the sensor data control unit 13 are set (S2). This condition includes a trigger condition, a capture condition, and a determination condition. After such setting for inspection is performed, a command for instructing start of signal acquisition is input (S3).

  In response to this command, capturing of the image signal from the camera 2 and the sensor signals from the sensors 3a to 3c is started (S4). Here, according to the set trigger condition, the image data and the sensor data are stored in the image data storage memory 14 and the sensor data storage memory 15 within a range satisfying the capture condition (S6).

  On the other hand, the establishment of the trigger condition is confirmed from the inspection device 4 (S5). That is, it is confirmed whether image data and sensor data are stored. Thereafter, an instruction to read the stored data is issued from the inspection device 4 (S7). At this time, the inspection apparatus 4 also instructs a range (data amount) or determination conditions for reading the stored image data and sensor data. The readout range includes the channels of the sensors 3a to 3c.

  When reading of image data and sensor data is instructed by a command from the inspection apparatus 4, required data is read from the image data storage memory 14 and the sensor data storage memory 15 (S8). Further, the read image data and sensor data are converted into signals compliant with the camera link standard (S9), and the converted signals are transferred to the inspection apparatus 4 (S10).

  The inspection device 4 repeatedly instructs the reading from the signal capturing device 1 until necessary image data and sensor data necessary for the inspection are read out, and then performs necessary inspection using these data. . Thereafter, the operation after the inspection setting in step S2, that is, the storage and reading of image data and sensor data are repeated, and necessary inspection is performed. In steps S3 and S7, a command for changing the contents of the inspection setting in step S2 can be given from the inspection apparatus 4.

  By the way, since this embodiment uses a communication protocol compliant with the camera link standard, a command from the inspection apparatus 4 is performed by UART communication. That is, the command is transmitted in the following format. Here, the command for the inspection setting in step S2 will be described as an example.

  A header (STX) and a footer (ETX) are added to the beginning and end of the command, respectively, and a setting processing command and setting data (contents of conditions to be set) are specified between the header and the footer. . For example, if only two sensors 3a and 3b among the three sensors 3a to 3c are used, the setting data includes the content that the sensors 3a and 3b are used. The number of sensors is specified by a setting process command. That is, a command of the form [STX, setting processing command (0x10 = 2), setting data (0x31 = use), setting data (0x31), setting data (0x30 = not use), ETX] is used. The same format may be adopted for other commands.

DESCRIPTION OF SYMBOLS 1 Signal capture device 2 Camera 3a-3c Sensor 4 Inspection apparatus 10 Digital data control part (data selection means, input / output means)
11 Camera control unit (image input means, signal conversion means)
12 Sensor signal processing unit (sensor input means, signal conversion means)
13 Sensor data control unit (data selection means)
14 Image data storage memory (image data storage means)
15 Sensor data storage memory (sensor data storage means)
16 Camera link converter (input / output means)
17 Command communication control unit (data selection means)

Claims (6)

  Image input means for inputting an image signal from the imaging apparatus, sensor input means for receiving a sensor signal from a sensor that outputs an analog signal, and image data and sensor that are digital data of the image signal and the sensor signal, respectively Signal conversion means for converting to data, image data storage means for storing image signals, sensor data storage means for storing sensor data, image data stored in the image data storage means, and sensor data storage means Input / output means capable of outputting stored sensor data to an external device and capable of inputting instructions from the external device, image data stored in the image data storage means, and storage in the sensor data storage means Data selection means for selecting sensor data according to an instruction from the external device Write apparatus.   The data selection means includes a trigger condition relating to at least one of an image signal input to the image input means, a sensor signal input to the sensor input means, and an instruction given from the external device through the input / output means. The signal capturing device according to claim 1, wherein at least one of image data and sensor data is stored when a trigger condition is satisfied.   3. The data selection unit according to claim 2, wherein the external device is instructed by a capture condition that defines a storage range for at least one of image data and sensor data when a trigger condition is satisfied. Signal capture device.   The input / output unit selects image data to be read from the image data storage unit to the external device and sensor data to be read from the sensor data storage unit to the external device according to an instruction from the external device. Item 4. The signal capturing device according to any one of Items 1 to 3.   When the sensor data stored in the sensor data storage unit satisfies a predetermined determination condition, the input / output unit outputs image data corresponding to a predetermined time range before and after the determination condition is satisfied. The signal capturing device according to claim 4, wherein the signal capturing device outputs the signal to the external device.   When the image data stored in the image data storage unit satisfies a predetermined determination condition, the input / output unit outputs sensor data corresponding to a predetermined time range before and after the determination condition is satisfied. The signal capturing device according to claim 4, wherein the signal capturing device outputs the signal to the external device.

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