JP2018112454A - Inner surface automatic inspection device of pipe material and automatic inspection method of pipe inner surface - Google Patents
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Abstract
Description
本発明は、管材の内面検査に用いる自動検査装置及び管材内面の自動検査方法に関する。 The present invention relates to an automatic inspection apparatus and an automatic inspection method for an inner surface of a pipe material used for an inner surface inspection of a pipe material.
様々な用途に多様な管材が使われているが、特に、その内面傷が管材の信頼性に大きく影響する管材では、依然として目視検査が行われている。しかし、グローバル化の進展に伴い、生産性の向上が急務となっており、様々な多様な管材において、この目視検査の自動化に対するニーズは極めて大きい。 Various pipe materials are used for various applications, but visual inspection is still performed especially for pipe materials whose inner surface flaws greatly affect the reliability of the pipe material. However, with the progress of globalization, improvement in productivity has become an urgent need, and the need for automation of this visual inspection is extremely great in various diverse pipe materials.
本願発明者等は、上記ニーズに対応した管材自動検査装置を、特許文献１に開示している。 The inventors of the present application have disclosed an automatic pipe material inspection apparatus corresponding to the above needs in Patent Document 1.
特許文献１に開示した技術は、管材の一方にカメラと可動焦点型ズームレンズを取り付け、その反対側に拡散光源を設置し、管材正面から管材内面画像をズームし、ピントを変えながら複数枚撮影して画像取得すると共に、それ等の画像を統合した統合画像を作成し、それを画像解析して良否判定するものである。長尺管材の端から管材の中央までを、管材の両端から順次繰り返して２回、画像検査する構成としている。 The technique disclosed in Patent Document 1 has a camera and a movable focus type zoom lens attached to one of the tubes, a diffused light source is installed on the opposite side, and the inner surface image of the tube is zoomed from the front of the tube, and multiple images are shot while changing the focus. Thus, an image is acquired, and an integrated image obtained by integrating these images is created, and the quality is determined by image analysis. From the end of the long tubular material to the center of the tubular material, the image is inspected twice in order from both ends of the tubular material.
すなわち、特許文献１に開示した管材自動検査装置における検査方法は、焦点を連続変化させて得られた複数枚の管材の内面観察画像を一枚の統合画像に合成し、その後、その統合画像を、傷検出解析手段で画像解析して合否判定検査するものである In other words, the inspection method in the automatic tube inspection apparatus disclosed in Patent Document 1 combines the inner surface observation images of a plurality of tubes obtained by continuously changing the focus into one integrated image, and then the integrated image is The image is analyzed by the flaw detection analysis means and the pass / fail judgment inspection is performed.
しかしながら、特許文献１に開示した管材内面の自動検査装置は、図６に示すように、管材正面から管材内面画像をズームし、ピントや光学条件を変えながら複数枚撮影して画像取得したのち、それらの画像を統合した統合画像を作成し、それを画像解析して良否判定するものである。 However, the automatic inspection device for the inner surface of the pipe disclosed in Patent Document 1, as shown in FIG. 6, zooms the tube inner surface image from the front of the pipe, acquires a plurality of images while changing the focus and optical conditions, An integrated image obtained by integrating these images is created, and the image is analyzed to determine whether it is acceptable.
そのため、かかる自動検査装置では、複数枚の管材内面観察画像を撮影する際に、ズームレンズ移動やカメラ及び光学条件の設定に時間が掛かるため、複数枚の画像撮影後に、統合画像に合成し画像解析する従来の手法では、検査時間の高速化に限界があった。 Therefore, in such an automatic inspection device, when taking a plurality of tube inner surface observation images, it takes time to set the zoom lens and to set the camera and optical conditions. The conventional method of analysis has a limit in speeding up the inspection time.
本発明は、かかる不都合に鑑みてなされたもので、その主な目的は、管材の開口端部側から、焦点を可変にしながら管材の内面画像を複数枚撮影して、管材内面を自動検査する装置において、検査時間の高速化を図ることにある。 The present invention has been made in view of such inconveniences, and its main object is to automatically inspect the inner surface of the pipe material by photographing a plurality of inner surface images of the tube material while changing the focus from the opening end side of the tube material. The purpose of the apparatus is to increase the inspection time.
本発明に係る管材の内面自動検査装置は、管材の一方の開口端部側に配置する光源と、管材の他方の開口端部側に配置する焦点可動型ズームレンズを有する撮像手段とを備え、焦点可動型ズームレンズの焦点を可変しながら管材の内面を複数回撮影する際に、一枚の画像を撮影した後、焦点可動型ズームレンズの焦点を次の位置に移動開始すると同時に、撮影した画像で焦点の合った範囲を並列に画像処理し、合否判定検査することを特徴とする。 An inner surface automatic inspection apparatus for a tube according to the present invention includes a light source disposed on one opening end side of the tube, and an imaging unit having a focus movable zoom lens disposed on the other opening end side of the tube, When shooting the inner surface of the tube multiple times while changing the focus of the movable focus zoom lens, after taking a single image, the focus of the movable focus zoom lens started to move to the next position and shot simultaneously It is characterized in that a focused range in the image is subjected to image processing in parallel and a pass / fail judgment inspection is performed.
ある好適な実施形態において、画像撮影後、焦点可動型ズームレンズの焦点を次の位置に移動開始する時点で、前の撮影画像の画像処理による合否判定検査が終了しなかった場合に、次の撮影画像を一時退避画像ファイルとして保存し、前の撮影画像の画像処理による合否判定検査が終了したのちに、保存された一時退避画像ファイルの撮像画像の画像処理による合否判定検査を開始するか、あるいは、前の撮影画像の画像処理による合否判定検査と並列して、次の撮影画像の画像処理を開始する。 In a preferred embodiment, when the focus determination of the previous captured image is not completed at the time when the focus of the movable focusable zoom lens starts moving to the next position after the image is captured, Whether the captured image is saved as a temporarily saved image file, and after the pass / fail judgment inspection by the image processing of the previous photographed image is completed, the pass / fail judgment inspection by the image processing of the captured image of the saved temporarily saved image file is started, Alternatively, image processing of the next photographed image is started in parallel with the pass / fail judgment inspection by image processing of the previous photographed image.
ある好適な実施形態において、撮影した画像の画像処理で不良と判定された場合、その画像以降の画像撮影を中止して、次の管材の検査に移るようにアルゴリズムを設定する。 In a preferred embodiment, when it is determined that the image processing of the captured image is defective, the image capturing after the image is stopped and the algorithm is set so that the next pipe material inspection is started.
ある好適な実施形態において、焦点可動型ズームレンズの焦点を可変しながら管材の内面画像を複数枚撮影する際に、ズームレンズの移動を止めず連続的に動かしながら、同時に撮影条件を連続的に可変して撮影し、得られた連続的な画像から複数枚の画像を選別し、選別した画像毎に、その画像の焦点が合った範囲を並列に画像処理し、合否判定検査する。 In a preferred embodiment, when shooting a plurality of inner surface images of a tube while changing the focus of a movable focus zoom lens, the shooting conditions are continuously changed while continuously moving without stopping the movement of the zoom lens. A plurality of images are selected from the obtained continuous images, and a range in which the images are in focus is processed in parallel for each selected image, and a pass / fail judgment inspection is performed.
本発明に係る管材内面の自動検査方法は、管材の開口端部側から、焦点を可変にしながら管材の内面画像を複数枚撮影して、管材内面を自動検査する方法であって、一枚の画像を撮影した後、焦点を次の位置に移動開始すると同時に、撮影した画像で焦点の合った範囲を並列に画像処理し、合否判定検査することを特徴とする。 An automatic inspection method for an inner surface of a pipe material according to the present invention is a method for automatically inspecting an inner surface of a pipe material by taking a plurality of inner surface images of the pipe material from the opening end side of the pipe material while changing the focus. After the image is taken, the focus is started to move to the next position, and at the same time, the in-focus range of the taken image is processed in parallel, and a pass / fail judgment inspection is performed.
本発明によれば、焦点可動型ズームレンズの焦点を可変しながら管材の内面画像を複数回撮影するに際し、一枚の画像を撮影した後、焦点可動型ズームレンズの焦点を次の位置に移動開始させると同時に、撮影した画像の焦点の合った範囲を並列に画像処理し、合否判定検査するため、検査時間の高速化が可能になる。 According to the present invention, when taking an inner surface image of a tube material a plurality of times while changing the focus of a movable focus zoom lens, the focus of the movable focus zoom lens is moved to the next position after taking a single image. At the same time as the start, since the in-focus range of the photographed image is processed in parallel and the pass / fail judgment inspection is performed, the inspection time can be increased.
また、画像撮影後、焦点可動型ズームレンズの焦点を次の位置に移動開始させる時点で、前に撮影した画像の画像処理による管材の内面の検査が終了しない場合でも、次の撮影画像を一時退避画像ファイルとして保存し、前の撮影画像処理による管材の内面の検査が終了したのちに、一時退避画像ファイルとして保存された次の撮像画像を画像処理により合否判定検査するか、あるいは、前の撮影画像の画像処理と並列に、一時画像ファイルとして保存された次の撮像画像を画像処理して合否判定検査することにより、画像の取りこぼしや画像処理の中断もなく、管材内面の自動検査の継続が可能になる。 In addition, after the image is captured, when the focus of the movable focus zoom lens starts to move to the next position, the next captured image is temporarily stored even if the inspection of the inner surface of the tube by the image processing of the previously captured image is not completed. Save as a saved image file, and after the inspection of the inner surface of the tube material by the previous photographed image processing is completed, the next captured image saved as a temporarily saved image file is checked for pass / fail by image processing, or In parallel with the image processing of the captured image, the next captured image saved as a temporary image file is image-processed to perform pass / fail judgment inspection, so that automatic inspection of the inner surface of the tube material can be continued without image loss or image processing interruption. Is possible.
また、撮影した画像の画像処理で不良と判定された場合、その画像以降の画像撮影を中止し、次の管材の検査に移るようにすれば、一層の高速化を図ることが可能になる。 Further, when it is determined that the image processing of the captured image is defective, it is possible to further increase the speed by stopping the image capturing after that image and moving to the inspection of the next tube material.
あるいは、焦点可動型ズームレンズの焦点を可変しながら管材の内面画像を複数枚撮影する際に、ズームレンズの移動を止めず連続的に動かしながら、同時にアイリスや照明強度等の撮影条件を連続的に可変して撮影し、得られた連続的な画像から複数枚の画像を選別し、選別した画像毎に、その画像の焦点が合った範囲を並列に画像処理し、合否判定検査すれば、より検査時間の高速化が可能になる。 Alternatively, when taking multiple images of the inner surface of the tube while changing the focus of the movable focus zoom lens, the shooting conditions such as iris and illumination intensity are continuously changed while moving the zoom lens continuously without stopping. If you select a plurality of images from the obtained continuous images, perform the image processing in parallel for the selected images in parallel, and perform pass / fail judgment inspection, The inspection time can be further increased.
以下、本発明の実施形態を図面に基づいて詳細に説明する。なお、本発明は、以下の実施形態に限定されるものではない。また、本発明の効果を奏する範囲を逸脱しない範囲で、適宜変更は可能である。 Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In addition, this invention is not limited to the following embodiment. Moreover, it can change suitably in the range which does not deviate from the range which has the effect of this invention.
図１は、本発明の一実施形態における管材の内面自動検査装置の全体の構成を模式的に示した図である。 FIG. 1 is a diagram schematically showing the overall configuration of an automatic inner surface inspection apparatus for pipe material according to an embodiment of the present invention.
図１に示すように、本実施形態における管材の内面自動検査装置は、未検査の管材１０を乗せる管材投入ユニット２、管材検査ステージ搬送・固定ユニット３、管材１０の一方の開口端部側に配置され、管材１０を撮影するためのカメラ・レンズ・ユニット（撮像手段）１、管材１０の他方の開口端部側に配置され、管材１０の内面を照射する光源ユニット（光源）５、検査済みの管材１０を乗せる管材ストッカ・ユニット４、それらを制御するコンピュータ（画像処理手段）１５で構成される。 As shown in FIG. 1, the automatic inner surface inspection device for a pipe material in this embodiment is provided on a tube material input unit 2 for placing an uninspected tube material 10, a tube material inspection stage conveying / fixing unit 3, and one opening end side of the tube material 10. A camera lens unit (imaging means) 1 for photographing the tube material 10, a light source unit (light source) 5 that is disposed on the other opening end side of the tube material 10 and illuminates the inner surface of the tube material 10, inspected The pipe stocker unit 4 on which the pipe 10 is placed, and a computer (image processing means) 15 for controlling them.
また、カメラ・レンズ・ユニット１と管材１０のカメラ側端の一部を管材１０の種類に応じた遮光箱で覆うことにより、外光の影響を除外している。 Further, the camera-lens unit 1 and a part of the camera-side end of the tube material 10 are covered with a light shielding box corresponding to the type of the tube material 10, thereby eliminating the influence of external light.
本発明の管材の内面自動検査装置では、図２に示すように、管材１０とカメラ１３を、管材１０、カメラ１３、拡散光源がそれぞれ平行になるように配置し、管材１０の中心軸とカメラ１３の光軸を一致させる必要がある。そのため光軸調整手段を備えている。 In the automatic inner surface inspection apparatus for pipes according to the present invention, as shown in FIG. 2, the pipe 10 and the camera 13 are arranged so that the pipe 10, the camera 13, and the diffused light source are parallel to each other. It is necessary to match the 13 optical axes. Therefore, an optical axis adjusting means is provided.
図３に、管材１０とカメラ・レンズ・ユニット１、光源ユニット５の関係を示す。カメラ・レンズ・ユニット１は、ズームレンズ１１、接写リング１２、カメラ１３、遮光手段１７で構成される。接写リング１２は近接撮影により管材１０の内面を明瞭に撮影できるようにする。ズームレンズ１１，接写リング１２、カメラ１３は、遮光手段１７によって、外光を遮断する。 FIG. 3 shows the relationship between the tube material 10, the camera lens unit 1, and the light source unit 5. The camera lens unit 1 includes a zoom lens 11, a close-up ring 12, a camera 13, and a light shielding means 17. The close-up ring 12 makes it possible to clearly photograph the inner surface of the tube material 10 by close-up photography. The zoom lens 11, the close-up ring 12, and the camera 13 block outside light by the light blocking means 17.
光源ユニット５は、図４（ａ）、（ｂ）に示すように、拡散光源１４、集光手段１９で構成される。拡散光源１４からの拡散光１４０は、集光手段１９によって、対象となる管材１０の直径以上の範囲の平行光に調整された平行光１４１に変換され、管材１０へ導かれる。 As shown in FIGS. 4A and 4B, the light source unit 5 includes a diffused light source 14 and a condensing means 19. The diffused light 140 from the diffused light source 14 is converted into parallel light 141 adjusted to parallel light in a range equal to or larger than the diameter of the target tube material 10 by the condensing means 19 and guided to the tube material 10.
様々な口径の管材１０に応じ、拡散光源１４、集光手段１９を変更することにより、最適な光を得ることができる。口径ａの管材１０の場合は、図４（ａ）のように、拡散光源１４、集光手段１９を使用し、口径ｂの管材１０の場合は、図４（ｂ）のように、異なる形状の拡散光源１４、集光手段１９を使用する。それぞれにおいて、拡散光源１４からの拡散光１４０が、集光手段１９によって、その管材１０に最適な平行光１４１に変換される。 Optimum light can be obtained by changing the diffusing light source 14 and the light condensing means 19 according to the tube material 10 having various diameters. In the case of the tube material 10 having the caliber a, the diffused light source 14 and the condensing means 19 are used as shown in FIG. 4A, and in the case of the tube material 10 having the caliber b, the shapes are different as shown in FIG. Diffusing light source 14 and condensing means 19 are used. In each case, the diffused light 140 from the diffused light source 14 is converted into parallel light 141 optimal for the tube material 10 by the condensing means 19.
図５に示す模式図に従い、本発明の管材の内面自動検査装置の動作について説明する。 The operation of the pipe inner surface automatic inspection apparatus of the present invention will be described with reference to the schematic diagram shown in FIG.
まず、管材１０を、管材１０のＡ端側がズームレンズ１１側に位置するように、管材投入ユニット２より第１検査台に載せ、光源ユニット５により管材１０の内面を照射する。 First, the tube material 10 is placed on the first inspection table from the tube material charging unit 2 so that the A end side of the tube material 10 is positioned on the zoom lens 11 side, and the inner surface of the tube material 10 is irradiated by the light source unit 5.
次に、ズームレンズ１１のズーム値と、拡散光源１４の強度を変更しながら、複数枚管材１０の内面画像を撮影し、管材１０の中央部までズームし、画像の撮影毎に、その時点のズームレンズのズーム値により決まる焦点の合っている部分の画像を切り出し、その画像内の不良判定を行う。この動作を、複数枚の画像取得毎に行うが、本発明はこの手順に関する。 Next, while changing the zoom value of the zoom lens 11 and the intensity of the diffusing light source 14, the inner surface image of the plurality of tube materials 10 is taken and zoomed to the center of the tube material 10. An in-focus image determined by the zoom value of the zoom lens is cut out, and a defect is determined in the image. This operation is performed every time a plurality of images are acquired, and the present invention relates to this procedure.
図６に、従来の管材の内面自動検査（撮影〜不良判定）の手順を示す。従来の管材の内面自動検査装置では、複数枚（図６では６枚）の画像撮影後、それ等の画像合成後に画像処理を行い、合否判定検査を実施する。 FIG. 6 shows a procedure for conventional automatic inner surface inspection (imaging to defect determination) of a pipe material. In a conventional automatic inner surface inspection apparatus for pipe materials, after a plurality of images (six images in FIG. 6) are taken, image processing is performed after combining the images, and a pass / fail judgment inspection is performed.
図７に、本発明の管材の内面自動検査における自動検査（撮影〜不良判定）の手順１を示す。手順１では、焦点可動型ズームレンズ１１の焦点を可変しながら管材１０の内面画像を複数枚撮影する際に、一枚の画像を撮影した後、焦点可動型ズームレンズ１１の焦点を次の位置に移動開始すると同時に、撮影した画像で焦点の合った範囲を並列に画像処理し、合否判定検査する。本発明では、各画像の撮影終了毎に合否判定検査を実施するため、全体の検査時間短縮が可能になる。 In FIG. 7, the procedure 1 of the automatic test | inspection (photographing-defect determination) in the inner surface automatic test | inspection of the pipe material of this invention is shown. In the procedure 1, when a plurality of inner surface images of the tube material 10 are captured while changing the focus of the movable focus zoom lens 11, after one image is captured, the focus of the focus movable zoom lens 11 is set to the next position. At the same time as the movement starts, the in-focus range of the captured image is image-processed in parallel, and pass / fail judgment inspection is performed. In the present invention, since the pass / fail judgment inspection is performed every time the photographing of each image is completed, the entire inspection time can be shortened.
なお、本発明において、撮影した画像の画像処理、及び合否判定は、例えば、以下の手順で行うことができる。 In the present invention, image processing of a captured image and pass / fail determination can be performed, for example, by the following procedure.
すなわち、撮影した画像を、管材の内面に生じた傷の特徴に応じた周知の画像処置手法を用いて行う。例えば、背景差分法を用いて画像処理を行う場合、撮影した画像に対して、微細なノイズ除去のための弱フィルタ、及び背景画像作成のための強フィルタによる処理を行い、求めた差分画像をある閾値で二値化する。そして、二値化した画像を、例えば、ラベリング処理により、最大の傷部分を抽出し、その面積値を別途準備した判定規格値と比較して、合否判定する。 That is, the photographed image is performed by using a well-known image treatment technique according to the characteristics of the scratch generated on the inner surface of the tube material. For example, when performing image processing using the background subtraction method, the captured image is subjected to processing by a weak filter for fine noise removal and a strong filter for background image creation, and the obtained difference image is obtained. Binarize with a certain threshold. Then, the binarized image is subjected to pass / fail judgment by, for example, extracting the largest scratched part by labeling processing and comparing the area value with a separately prepared judgment standard value.
図８は、不良判定時間が撮影間隔よりも長くなった場合の手順２を示す。手順２では、撮影１の結果の不良判定１の時間が、次の撮影２の時刻に終了しなかった場合は、撮影２の結果を一時ファイルに保管（ファイル保存２）する。不良判定１が終了した後、保管したファイル保存２を用いて、不良判定２に移る。撮影３以降も、不良判定が終了しない場合は、同様にファイル保存を繰り返し、同様に次の不良判定を待機する。 FIG. 8 shows the procedure 2 when the defect determination time is longer than the shooting interval. In the procedure 2, if the time of the failure determination 1 of the result of the shooting 1 does not end at the time of the next shooting 2, the result of the shooting 2 is stored in a temporary file (file save 2). After the defect determination 1 is completed, the process proceeds to the defect determination 2 using the stored file storage 2. If the defect determination does not end after shooting 3, the file storage is repeated in the same manner, and the next defect determination is similarly awaited.
すなわち、手順２では、画像撮影後、焦点可動型ズームレンズ１１の焦点を次の位置に移動開始する時点で、前の撮影画像の画像処理による合否判定検査が終了しなかった場合に、次の撮影画像を一時退避画像ファイルとして保存し、前の撮影画像の画像処理による合否判定検査が終了したのちに、保存された一時退避画像ファイルの撮像画像の画像処理による合否判定検査を開始するか、あるいは、前の撮影画像の画像処理による合否判定検査と並列して、次の撮影画像の画像処理を開始する。これにより、画像の取りこぼしや画像処理の中断もなく、管材内面の自動検査の継続が可能になる。 That is, in the procedure 2, when the pass / fail judgment inspection by the image processing of the previous photographed image is not completed at the time when the focus of the movable movable zoom lens 11 starts to move to the next position after the image is photographed, Whether the captured image is saved as a temporarily saved image file, and after the pass / fail judgment inspection by the image processing of the previous photographed image is completed, the pass / fail judgment inspection by the image processing of the captured image of the saved temporarily saved image file is started, Alternatively, image processing of the next photographed image is started in parallel with the pass / fail judgment inspection by image processing of the previous photographed image. As a result, it is possible to continue the automatic inspection of the inner surface of the tube material without missing the image or interrupting the image processing.
図９は、不良判定時間が撮影間隔よりも長くなった場合の手順３を示す。手順３では、画像処理による合否判定検査を並列処理する場合を示す。不良判定時間が次の撮影時間まで終了する、終了しないに関わらず、それぞれの撮影に対する不良判定を独立した処理で行う。そのため、不良判定時間の長短にかかわらず、全体の検査時間の短縮が可能になる。 FIG. 9 shows the procedure 3 when the defect determination time is longer than the shooting interval. Procedure 3 shows a case where the pass / fail judgment inspection by image processing is performed in parallel. Regardless of whether or not the defect determination time ends until the next shooting time, the defect determination for each shooting is performed by independent processing. Therefore, the overall inspection time can be shortened regardless of the length of the defect determination time.
また、撮影した画像の画像処理で不良と判定された場合、その画像以降の画像撮影を中止し、次の管材の検査に移るようにすれば、一層の高速化を図ることが可能になる。 Further, when it is determined that the image processing of the captured image is defective, it is possible to further increase the speed by stopping the image capturing after that image and moving to the inspection of the next tube material.
また、焦点可動型ズームレンズ１１の焦点を可変しながら管材１０の内面画像を複数枚撮影する際に、ズームレンズ１１の移動を止めず連続的に動かしながら、同時にアイリスや照明強度等の撮影条件を連続的に可変して撮影し、得られた連続的な画像から複数枚の画像を選別し、選別した画像毎に、その画像の焦点が合った範囲を並列に画像処理し、合否判定検査すれば、より検査時間の高速化が可能になる。 Further, when a plurality of inner surface images of the tube material 10 are photographed while changing the focus of the movable focus zoom lens 11, the photographing conditions such as iris and illumination intensity are simultaneously moved while continuously moving the zoom lens 11 without stopping. The image is processed continuously, and multiple images are selected from the obtained continuous images. For each selected image, the in-focus range of the image is processed in parallel, and pass / fail judgment inspection is performed. If so, the inspection time can be further increased.
なお、本実施形態において、ズームレンズ１１の「移動を止めず連続的」に動かしながら撮影するとは、ズームレンズ１１の移動中に撮影した画像にぶれが生じる場合、撮影中、ズームレンズ１１の動作を一旦停止する動作も含むものである。勿論、ズームレンズ１１の移動に伴う画像のぶれが許容でくる場合には、ズームレンズ１１の動作を一旦停止する必要はない。 In the present embodiment, shooting while moving the zoom lens 11 “continuously without stopping the movement” means that when the image taken while the zoom lens 11 moves is blurred, the operation of the zoom lens 11 during shooting is performed. The operation of temporarily stopping the operation is also included. Of course, when the image blur due to the movement of the zoom lens 11 is allowed, it is not necessary to temporarily stop the operation of the zoom lens 11.
以上の処理を、管材１０を第２検査台に移し、反対側（Ｂ端）からも同様に行い、全域に対し検査する。 The above processing is performed by moving the tube material 10 to the second inspection table and performing the same process from the opposite side (B end) to inspect the entire area.
図５に示した管材の内面自動検査装置の実施例について説明する。 An embodiment of the pipe inner surface automatic inspection apparatus shown in FIG. 5 will be described.
管材１０は、長さ４．０ｍ、内径２０〜５０ｍｍ、の樹脂パイプである。なお、本管材の内面自動検査装置が検査対象とする管材は、鋼管、塩ビ、プラスチック、樹脂、ゴムなど、円筒形であれば何でも対応が可能である。 The tube material 10 is a resin pipe having a length of 4.0 m and an inner diameter of 20 to 50 mm. The pipe material to be inspected by the automatic inner surface inspection apparatus for the main pipe material can be anything as long as it is cylindrical, such as a steel pipe, polyvinyl chloride, plastic, resin, rubber, or the like.
本実施例では、管材を保持しておくストッカ・ユニットとして、未検査用の管材投入ユニット２、検査済用の管材ストッカ・ユニット４を備える。管材ストッカ・ユニット４は良品ストッカーＳ１、不良ストッカーＳ２を備え、良品ストッカーＳ１と不良ストッカーＳ２は設置高さが異なるようにしてある。 In this embodiment, an uninspected tube material input unit 2 and an inspected tube material stocker unit 4 are provided as stocker units for holding the tube material. Tubing stocker unit 4 is good stocker S 1, includes a defect stocker S 2, good stocker S 1 defective stocker S 2 are are the installation height is different.
本実施例の自動検査装置に使用した光学機材は次の通りである。ズームレンズ１１は、焦点距離８〜１３６ｍｍ、最大口径比１：１．６、ズーム比１７倍、包括角度４３．６°×３３．４°から２．７°×２．２°、絞りＦ１．６〜Ｃｌｏｓｅのものを用いた。また、接写リング１２は、厚さ１．５ｍｍ、カメラ１３はＣＭＯＳカメラで、最大解像度６４８×４８８〜２５９２×１９４４、ピクセルサイズ２．２μｍ×２．２μｍ〜７．４μｍ×７．４μｍのものを用いた。 The optical equipment used in the automatic inspection apparatus of this example is as follows. The zoom lens 11 has a focal length of 8 to 136 mm, a maximum aperture ratio of 1: 1.6, a zoom ratio of 17 times, a comprehensive angle of 43.6 ° × 33.4 ° to 2.7 ° × 2.2 °, an aperture F1. 6-Close was used. The close-up ring 12 has a thickness of 1.5 mm, the camera 13 is a CMOS camera, and has a maximum resolution of 648 × 488 to 2592 × 1944 and a pixel size of 2.2 μm × 2.2 μm to 7.4 μm × 7.4 μm. Using.
また、拡散光源１４には、白色ＬＥＤ面光源を使用し、遮光手段１７として鋼管を挟む遮光素材に黒色のスポンジを用いた。集光手段１９には、焦点距離３５ｍｍ、φ１７５ｍｍ、ピッチ０．２５ｍｍのフレネルレンズを用いた。拡散光源１４（白色ＬＥＤ面光源）と集光手段１９（フレネルレンズ）との間は焦点距離の３５ｍｍに設定した。 Further, a white LED surface light source was used as the diffusion light source 14, and a black sponge was used as a light shielding material for sandwiching the steel pipe as the light shielding means 17. As the condensing means 19, a Fresnel lens having a focal length of 35 mm, φ175 mm, and a pitch of 0.25 mm was used. The focal length between the diffused light source 14 (white LED surface light source) and the light collecting means 19 (Fresnel lens) was set to 35 mm.
検査台１８は、一方の管端（Ａ端）から検査する第１検査台と、もう一方の管端（Ｂ端）から検査する第２検査台を備える。第１検査台は、Ａ端側にカメラ・レンズ・ユニット１、Ｂ端側に光源ユニット５として白色ＬＥＤとフレネルレンズ、その間に遮光手段１７を備え、管材１０、カメラ１３、白色ＬＥＤ１４がそれぞれ平行になるように設置する。第２検査台は、第１検査台と逆の配置にする。 The inspection table 18 includes a first inspection table inspected from one tube end (A end) and a second inspection table inspected from the other tube end (B end). The first inspection table includes a white lens and a Fresnel lens as a light source unit 5 on the A end side and a light source unit 5 on the B end side, and a light shielding means 17 between them, and the tube material 10, the camera 13, and the white LED 14 are parallel to each other. Install to be. The second inspection table is arranged opposite to the first inspection table.
管材１０の搬送装置は、コンピュータと連携して空気圧によって制御し搬送動作を行う。それに連動して、カメラ１３、ズームレンズ１１、拡散光源１４も、コンピュータから同時に制御している。搬送装置の開始ボタンが押されると、管材投入ユニット２から第１検査台へと管材をカメラと水平になるように搬送する。搬送完了後、搬送装置は、コンピュータへＡ端検査開始の指令を送信する。コンピュータがＡ端検査開始の指令を受信すると、Ａ端側を検査する。Ａ端側の検査が終われば、その指令を搬送装置へと伝える。次に、搬送装置は、第１検査台の管材を第２検査台へ搬送すると同時に、管材投入ユニット２の管材を第１検査台へ搬送する。搬送が完了すれば、搬送装置は、コンピュータへＡ端検査開始とＢ端検査開始の指令を送信し、コンピュータはこれを受けて両端の検査を開始する。 The transport device for the tube material 10 performs a transport operation by controlling with air pressure in cooperation with a computer. In conjunction with this, the camera 13, the zoom lens 11, and the diffusion light source 14 are simultaneously controlled from the computer. When the start button of the transport device is pressed, the tube material is transported from the tube material loading unit 2 to the first inspection table so as to be level with the camera. After the completion of conveyance, the conveyance device transmits a command to start A-end inspection to the computer. When the computer receives the A-end inspection start command, the A-end side is inspected. When the inspection on the A-end side is completed, the command is transmitted to the transfer device. Next, the transport device transports the tube material of the tube material input unit 2 to the first inspection table at the same time as it conveys the tube material of the first inspection table to the second inspection table. When the conveyance is completed, the conveyance apparatus transmits an A-end inspection start command and a B-end inspection start command to the computer, and the computer receives the instructions and starts inspection at both ends.
両端での検査が終われば、コンピュータは、検査終了の指令を搬送装置へと伝え、搬送装置は管材投入ユニット２の管材を第１検査台へ、第１検査台の管材を第２検査台へ、第２の検査台は両端共に良品ならば良品ストッカーＳ１へ、それ以外は不良ストッカーＳ２へそれぞれ同時並行して搬送する。 When the inspection at both ends is completed, the computer transmits an instruction to end the inspection to the transfer device, and the transfer device transfers the tube material of the tube material input unit 2 to the first inspection table and the tube material of the first inspection table to the second inspection table. The second inspection table is conveyed simultaneously in parallel to the good stocker S 1 if both ends are good and to the defective stocker S 2 otherwise.
管材内面の検査は、ズームレンズ１１のズーム値と白色ＬＥＤの強度を、鮮明な画像を取得できる最適状態に合わせながら複数枚の内面撮影を行う。画像の撮影毎に、その時点のズームレンズのズーム値により決まる焦点の合っている部分の画像を切り出し、その画像内の不良判定を行う。複数枚画像を撮影／不良判定し、管材の中央部までズームした時点で検査を終了する。 In the inspection of the inner surface of the tube material, a plurality of inner surfaces are photographed while adjusting the zoom value of the zoom lens 11 and the intensity of the white LED to an optimum state where a clear image can be acquired. Every time an image is captured, an image of a focused portion determined by the zoom value of the zoom lens at that time is cut out, and a defect in the image is determined. A plurality of images are taken / defected, and the inspection is terminated when zooming to the center of the tube.
複数枚の内面撮影を行うに際し、あらかじめ設定したズーム値に到達したときに、一旦ズーム操作を停止した上で、内面撮影を実施し、不良判定を行う。これは、シャッター速度が低速の場合の撮影画像のぶれを防ぐためである。 When performing a plurality of inner surface shooting, when a preset zoom value is reached, the zoom operation is temporarily stopped and then inner surface shooting is performed to determine a defect. This is to prevent blurring of the captured image when the shutter speed is low.
しかしながら、シャッター速度が高速であり、画像のぶれが不良判定に対して許容できる場合は、ズーム操作を停止すること無く、連続で撮影／不良判定する。 However, if the shutter speed is high and image blurring is acceptable for defect determination, continuous shooting / defect determination is performed without stopping the zoom operation.
ズーム操作を停止することなく連続での撮影／不良判定する結果、検査時間のより高速化が可能になる。 As a result of continuous shooting / defect determination without stopping the zoom operation, the inspection time can be further increased.
これら一連の動作を、供給ストッカーの管材が無くなるまで行い、管材の内面自動検査を完了する。 These series of operations are performed until the pipe stock of the supply stocker runs out, and the inner surface automatic inspection of the pipe material is completed.
１ カメラ・レンズ・ユニット
２ 管材投入ユニット
３ 管材検査ステージ搬送・固定ユニット
４ 管材ストッカ・ユニット
５ 光源ユニット
１０ 管材
１１ 焦点可動型ズームレンズ
１２ 接写リング
１３ カメラ
１４ 拡散光源
１５ 画像処理手段
１７ 遮光手段
１８ 検査台
１９ 集光手段
１４０ 拡散光
１４１ 平行光
Ｓ 未検査鋼管用の供給ストッカー
Ｓ１ 良品鋼管用の良品ストッカー
Ｓ２ 不良鋼管用の不良ストッカー
1 Camera lens unit
2 Tubing input unit
3 Tube inspection stage transfer / fixing unit
4 Tube stocker unit
5 Light source unit
10 Pipe material
11 Focus movable zoom lens
12 Close-up ring
13 Camera
14 Diffuse light source
15 Image processing means 17 Shading means
18 Inspection table
19 Condensing means
140 Diffuse light
141 Parallel light
S Supply stocker for uninspected steel pipe S 1 Good stocker for good steel pipe S 2 Bad stocker for bad steel pipe
Claims (5)
前記管材の他方の開口端部側に配置する焦点可動型ズームレンズを有する撮像手段と
を備えた管材の内面自動検査装置において、
前記焦点可動型ズームレンズの焦点を可変しながら前記管材の内面画像を複数枚撮影する際に、一枚の画像を撮影した後、前記焦点可動型ズームレンズの焦点を次の位置に移動開始すると同時に、前記撮影した画像で焦点の合った範囲を並列に画像処理し、合否判定検査することを特徴とする管材の内面自動検査装置。 A light source arranged on one opening end side of the tube,
In an automatic inner surface inspection apparatus for a tube, comprising an imaging means having a focus movable zoom lens disposed on the other opening end side of the tube,
When shooting a plurality of inner surface images of the tube material while changing the focus of the movable focus zoom lens, when the focus of the movable focus zoom lens starts to move to the next position after taking one image At the same time, an automatic inner surface inspection apparatus for a pipe material, wherein a focused range is processed in parallel in the photographed image, and a pass / fail judgment inspection is performed.
画像撮影後、前記焦点可動型ズームレンズの焦点を次の位置に移動開始する時点で、前の撮影画像の画像処理による合否判定検査が終了しなかった場合に、次の撮影画像を一時退避画像ファイルとして保存し、
前の撮影画像の画像処理による合否判定検査が終了したのちに、前記保存された一時退避画像ファイルの撮影画像の画像処理による合否判定検査を開始するか、あるいは、前の撮影画像の画像処理による合否判定検査と並列して、次の撮影画像の画像処理を開始することを特徴とする管材の内面自動検査装置。 In the pipe inner surface automatic inspection device according to claim 1,
After the image is captured, if the pass / fail determination inspection by image processing of the previous captured image is not completed when the focus of the movable focus zoom lens starts to move to the next position, the next captured image is temporarily saved. Save it as a file,
After the pass / fail judgment inspection by the image processing of the previous photographed image is completed, the pass / fail judgment inspection by the image processing of the photographed image of the temporarily saved image file is started, or by the image processing of the previous photographed image An automatic inner surface inspection device for a pipe material, which starts image processing of the next photographed image in parallel with the pass / fail judgment inspection.
撮影した画像の画像処理で、不良と判定された場合、その画像以降の画像撮影を中止し、次の管材の検査に移ることを特徴とする管材の内面自動検査装置。 In the pipe inner surface automatic inspection device according to claim 1 or 2,
An automatic inner surface inspection apparatus for a pipe material, in which, when image processing of a photographed image is determined to be defective, image photographing after that image is stopped and the next pipe material inspection is performed.
焦点可動型ズームレンズの焦点を可変しながら管材の内面画像を複数枚撮影する際に、ズームレンズの移動を止めず連続的に動かしながら、同時に撮影条件を連続的に可変して撮影し、得られた連続的な画像から複数枚の画像を選別し、選別した画像毎に、その画像の焦点が合った範囲を並列に画像処理し、合否判定検査することを特徴とする管材の内面自動検査装置。 In the pipe inner surface automatic inspection device according to any one of claims 1 to 3,
When taking multiple images of the inner surface of the tube while changing the focus of the movable focus zoom lens, you can continuously move the zoom lens without stopping the movement while simultaneously changing the shooting conditions. A plurality of images are selected from the continuous images obtained, and the inner surface automatic inspection of the tube material is characterized in that for each selected image, the in-focus range of the image is processed in parallel, and a pass / fail judgment inspection is performed. apparatus.
一枚の画像を撮影した後、焦点を次の位置に移動開始すると同時に、前記撮影した画像で焦点の合った範囲を並列に画像処理し、合否判定検査することを特徴とする管材内面の自動検査方法。 From the opening end side of the tube material, taking a plurality of images of the inner surface of the tube material while changing the focus, a method of automatically inspecting the inner surface of the tube material,
After taking one image, the focus starts to move to the next position, and at the same time, the in-focus range of the taken image is processed in parallel, and pass / fail judgment inspection is performed. Inspection method.
Priority Applications (1)
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| JP2017002558A JP2018112454A (en) | 2017-01-11 | 2017-01-11 | Inner surface automatic inspection device of pipe material and automatic inspection method of pipe inner surface |
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| CN110103374A (en) * | 2019-06-06 | 2019-08-09 | 上海长园电子材料有限公司 | A kind of tubing bad recognition methods, apparatus and system |
| JP2021001734A (en) * | 2019-06-19 | 2021-01-07 | 株式会社オートインスペクト | Inner surface automatic inspection apparatus of pipe material and inner surface automatic inspection method of pipe material |
| JP2021143965A (en) * | 2020-03-12 | 2021-09-24 | 株式会社オートインスペクト | Pipe material automatic inspection device |
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| JP7113533B2 (en) | 2020-03-12 | 2022-08-05 | 株式会社オートインスペクト | Automatic pipe inspection device |
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