Conveying control system and vibratory conveying apparatus

Abstract

The conveying control system and the vibrating conveying device provided by the application can ensure the conveying performance while inhibiting the cost of the conveying control system and easily coping with various external disturbances; the conveying control system comprises a conveying object detection and determination unit and a management control part; the conveying object detection and determination unit independently performs detection and determination processing and action control processing on the conveying object; the action control processing refers to outputting a conveying object action signal according to the determination result and making the conveying object action mechanism act according to the conveying object action signal; the management control part is configured to receive acquisition information composed of detection information or other information obtained through the detection and determination processing or the action control processing, and can process the acquisition information in parallel with the detection and determination processing and the action control processing, thereby deriving analysis information associated with the conveying condition.

Description

Technical Field

[0001] This invention relates to a conveying control system and a vibrating conveyor. Background Technology

[0002] Currently, among vibratory conveying devices such as feeders, there are known devices configured to convey electronic components and other conveyed items while arranging them in a predetermined posture. In such conveying devices, the posture of the conveyed items on the conveying path is determined by visual inspection, and airflow is sprayed onto the conveyed items based on the determination result. This removes conveyed items with improper postures from the conveying path or rotates the conveyed items to change their posture, thereby unifying the posture of the conveyed items.

[0003] Furthermore, a method for controlling the posture of a conveyor is known, which, in order to change the posture of the conveyor, uses airflow to flip the posture of the conveyor that is being transported in an improper posture on the conveyor path, and merges the conveyor with the original conveyor line composed of conveyors that do not need to be flipped, thereby unifying the posture of the conveyor (see Patent Document 1 below). In this case, in order to reliably flip the conveyor, steps are usually formed on the conveyor path, thereby reliably rotating the conveyor subject to the airflow in a state where it is locked by the steps. In addition, as a method for changing the posture of the conveyor, various methods have been proposed, such as methods for changing the posture in a side-slip manner by applying airflow to the bottom of the conveyor (see Patent Document 2 below), and methods for rotating the conveyor by airflow in both left and right directions (see Patent Document 3 below), etc.

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent Application Publication No. 2000-264430

[0007] Patent Document 2: Japanese Patent Application Publication No. 7-228332

[0008] Patent Document 3: Japanese Patent Application Publication No. 10-053320 Summary of the Invention

[0009] However, in recent years, with the miniaturization of conveying devices, especially with the increasing miniaturization of conveyed materials such as electronic components, the conveying performance, including higher speeds and higher densities, has significantly improved. Increasing conveying speed or density in this way presents the following problems: it requires high-speed processing of the conveyed material's detection information and subsequent judgment and processing based on that information, thus increasing the load on the conveying control system and raising costs.

[0010] Furthermore, under the circumstances described above in recent years, the aforementioned conveying devices are subject to external disturbances such as changes in the type or batch of conveyed materials, pressure fluctuations in the air compressor, and long-term conveying processes, which cause changes in the surface of the conveyed materials (stains, etc.), changes in conveying speed, and changes in valve response time. As a result, it is difficult to maintain high conveying performance, and the workload of adjusting various setting parameters or teaching by skilled technicians becomes a problem.

[0011] Therefore, the present invention was made to solve the above-mentioned problems. Its objective is to provide a conveying control system and a vibrating conveying device that can suppress the cost of the conveying control system while ensuring conveying performance, and can easily cope with various external interferences.

[0012] To address the aforementioned problems, the present invention relates to a conveying control system that detects and determines the transported items along a conveying path during transport, and controls the transport mode of the transported items based on the determination result. The conveying control system includes a transported item detection and determination unit and a management control unit. The transported item detection and determination unit independently performs detection and determination processing and action control processing relative to the transported items. The detection and determination processing involves acquiring detection information for each transported item and processing the detection information to derive the determination result. The action control processing involves outputting a transported item action signal based on the determination result and actuating the transported item action mechanism that applies action to the transported item based on the transported item action signal. The management control unit is configured to receive acquired information consisting of the detection information or other information obtained through the detection and determination processing or the action control processing, and is capable of processing the acquired information in parallel with the detection and determination processing and the action control processing performed by the transported item detection and determination unit, thereby deriving analytical information related to the transport status. Here, the acquired information can include, for example, the detection information, the determination result of the detection determination process, and the change in position or posture of the conveyed object caused by the action control process of the conveying mechanism. Additionally, the analyzed information can include, for example, the number of conveyed objects, the conveying speed, the conveying density, the number of detection defects, and the number of control defects of the conveying mechanism. In this case, it is preferable that the management control unit is configured to output the analyzed information to a display device and display it. Furthermore, it is preferable that the management control unit calculates setting information such as various setting values ​​used in the detection determination process or the action control process as the analyzed information, and reflects this setting information in the conveyed object detection determination unit.

[0013] Therefore, for each conveyed item, the conveyed item detection and judgment unit performs detection and judgment processing, and the conveyed item action mechanism applies an action to the conveyed item based on the conveyed item action signal corresponding to the judgment result, thereby realizing the conveying mode of the conveyed item on the conveying route. At this time, the management control unit derives analysis information related to the conveying status based on the acquired information obtained from the conveyed item detection and judgment unit. In this way, by configuring the conveyed item detection and judgment unit to independently perform the detection and judgment processing related to the conveyed item, and the management control unit to perform the derivation of analysis information based on the acquired information in parallel, it is possible to independently perform the detection and judgment processing related to the conveyed item that should be performed in real time, or the action control processing related to the conveyed item action mechanism, and the derivation of analysis information that can be performed in batch processing. In this way, since the detection and judgment processing or action control processing that should be performed in real time and the derivation of analysis information based on the acquired information that is sufficient for batch processing can be performed separately and in parallel by the conveyed item detection and judgment unit and the management control unit, the processing of each processing content can be distributed according to characteristics, thus ensuring conveying performance, especially reducing the burden of real-time processing, and thus reducing control costs. Here, independently performing detection and judgment processing and action control processing in the aforementioned conveyor detection and judgment unit means independently performing real-time processing of multiple conveyed items that are conveyed one after another on the conveyor path. For example, even if there is a situation where an instruction to start or stop the processing and action is received indirectly from the outside, no instruction from the outside is required. Instead, once the processing or action has started, the aforementioned processing and action are continuously performed as multiple conveyed items are conveyed one after another on the conveyor path.

[0014] In this invention, it is preferable that the acquired information is transmitted from the transport object detection and determination unit to the management control unit in parallel with the detection and determination processing and the operation control processing. In this case, it is desirable to transmit the acquired information periodically, in units of information related to multiple transport objects.

[0015] In this invention, the transport object detection and determination unit preferably includes: a unit control unit that performs input / output control with the management control unit and setting control for the detection determination process or the action control process; and a detection determination processing unit that includes a detection determination circuit and a signal output circuit, wherein the detection determination circuit performs the detection determination process, and the signal output circuit outputs the transport object action signal to the transport object action mechanism according to the determination result. By providing the above-mentioned unit control unit, the exchange of the above-mentioned acquisition information or setting information with the management control unit can be easily and smoothly performed.

[0016] In this invention, preferably, the acquired information includes the detection information, which includes image data obtained by photographing the transport section of the transported object.

[0017] In this invention, it is desirable that the analytical information is the number of transported items, and more particularly, it is desirable that the number of transported items be classified according to the type of detection information. Here, the aforementioned number of transported items includes the quantity of transported items per unit time.

[0018] In this invention, it is preferable that the acquired information is image data representing the movement pattern of the conveyor under the action of the conveyor mechanism, and the analyzed information is the amount of movement and the posture of the conveyor. Furthermore, it is preferable that setting information for the action control processing of the conveyor mechanism on the conveyor is derived as the analyzed information, and this setting information is reflected in the conveyor detection and determination unit. In particular, it is desirable that this setting information is a setting value related to the force and the timing of action relative to the conveyor. Here, the force is at least related to the amount of movement (including changes in posture and rotation), and the timing of action is at least related to the posture (posture angle during movement). When the conveyor mechanism applies action to the conveyor via airflow, the force corresponds to the jet pressure of the airflow, and the timing of action corresponds to the jet timing of the airflow.

[0019] In this invention, it is preferable that the management control unit is connected to the conveying mechanism control unit, which controls the conveying mechanism for conveying the transported object on the conveying path. In particular, it is preferable that the management control unit is configured to control the conveying mechanism control unit. Here, it is desirable that the management control unit outputs a conveying mechanism control signal to the conveying mechanism control unit in a manner that changes the conveying mode of the conveying mechanism towards the transported object based on the analysis information. Furthermore, it is desirable that the management control unit, based on the acquired information and the control mode of the conveying mechanism control unit towards the conveying mechanism, determines setting information related to the action mechanism of the transported object, such as a setting value related to the action force or action time. Further, it is desirable that the management control unit is configured to obtain the driving mode of the conveying mechanism from the conveying mechanism control unit.

[0020] Next, the vibratory conveying device of the present invention comprises: a vibratory conveying mechanism having a vibration function for conveying a conveyed object along a conveying path; a conveyed object detection and determination unit that independently performs detection and determination processing relative to the conveyed object and action control processing relative to the conveyed object, wherein the detection and determination processing refers to acquiring detection information relative to each of the conveyed objects, processing the detection information to derive the determination result, and the action control processing refers to outputting a conveyed object action signal based on the determination result; a conveyed object action mechanism that applies an action to the conveyed object based on the conveyed object action signal; and a management control unit configured to receive acquisition information consisting of the detection information or other information obtained through the detection and determination processing or the action control processing of the conveyed object detection and determination unit, and to process the acquisition information to derive analysis information related to the conveying status. In this case, it is preferable that the management control unit is configured to be able to set the drive frequency and drive output value relative to the conveying mechanism control unit.

[0021] In this invention, the management control unit is preferably configured to process the acquired information in parallel with the detection and determination processing and the operation control processing performed in the transport item detection and determination unit, thereby deriving analysis information associated with the transport status. Here, it is preferably configured to transmit the acquired information from the transport item detection and determination unit to the management control unit in parallel with the detection and determination processing and the operation control processing performed in the transport item detection and determination unit. In this case, it is desirable to transmit the acquired information periodically, in units of information related to multiple transport items.

[0022] In this invention, it is preferable to further include a conveying mechanism control unit for controlling the conveying mechanism. The management control unit is configured to be connected to the conveying mechanism control unit and capable of controlling the conveying mechanism control unit. Furthermore, it is desirable that the management control unit be configured to control the conveying mechanism control unit. Further, it is desirable that the management control unit be configured to obtain the drive mode of the conveying mechanism from the conveying mechanism control unit.

[0023] (Invention Effects)

[0024] According to the present invention, a conveying control system and a vibrating conveying device can be provided that can suppress the cost of the conveying control system while ensuring conveying performance and can easily cope with various external disturbances. Attached Figure Description

[0025] Figure 1 This is a schematic configuration diagram illustrating the overall configuration of the conveying control system and vibrating conveying device according to the present invention.

[0026] Figure 2This is a schematic block diagram of the conveying control system of this embodiment.

[0027] Figure 3 This is a schematic diagram of the conveying mechanism in the conveying material removal section of this embodiment.

[0028] Figure 4 This is a schematic diagram of the conveyor action mechanism in the conveyor tilting part of this embodiment.

[0029] Figure 5 This is an explanatory diagram showing the composition of an image captured by a camera in this embodiment.

[0030] Figure 6 Figures (a)-(d) are explanatory diagrams showing the detection pattern of the conveyed object on the conveying path in this embodiment.

[0031] Figure 7 Figures (a)-(e) are explanatory diagrams showing the detection pattern of the conveyed object on the conveying path in this embodiment.

[0032] Figure 8 Figures (a)-(g) are explanatory diagrams showing the changes in the recorded content of the memory (tracking queue) in the transport detection process of this embodiment.

[0033] Figure 9 This is a simplified flowchart illustrating the steps of the transport inspection process performed in the transport inspection and determination unit of this embodiment.

[0034] Figure 10 This is a simplified flowchart illustrating an example of the steps in the transport object detection and determination unit of this embodiment for determining the transport object.

[0035] Figure 11 This is a simplified flowchart illustrating an example of the control steps performed in the management control unit of this embodiment.

[0036] Figure 12 This is a diagram illustrating an example of the main screen of the display screen configured in the management and control unit of this embodiment.

[0037] Figure 13 This is a diagram illustrating an example of a setting screen for a display screen configured in the management control unit of this embodiment.

[0038] Figure 14 This is a diagram illustrating an example of an analysis information screen displayed in the management control unit of this embodiment.

[0039] Figure 15This is an explanatory diagram illustrating the structure of the analysis area used in an example of the method for exporting analysis information in the management control unit of this embodiment.

[0040] Figure 16 This is an explanatory diagram showing the posture angle of the conveyor used in an example of the method for deriving analysis information in the management control unit of this embodiment.

[0041] Figure 17 This is an explanatory diagram illustrating the configuration of a pattern model used in an example of a method for deriving analysis information in the management control unit of this embodiment.

[0042] Figure 18 This is a simplified flowchart illustrating an example of the steps in the management control unit of this embodiment to export analysis information.

[0043] Figure 19 This is an explanatory diagram showing the image data of the flight pattern of the conveyor used to acquire information in this embodiment.

[0044] Figure 20 It is a graph showing the flight distance and flight posture as analysis information in this embodiment.

[0045] (Symbol Explanation)

[0046] 100… Vibrating conveyor, 101… Conveying control system, 110… Conveying mechanism, 111… Drive unit, 112… Conveying body, 112a… Conveying path, 112b… Jet nozzle, 120… Conveying mechanism control unit, 130… Conveying material action mechanism, 131… Airflow source, 132… Base-side piping, 133… On / off valve, 134… Front-end piping, 135… Valve drive circuit, 140… Imaging unit, 141, 142… Imaging equipment, 150… Conveying material detection and judgment unit, 151, 152… Conveying material detection and judgment unit, 153… Unit control unit, 154… Imaging control unit, 155… Frame buffer memory, 156… Detection and judgment processing unit, 157… Image extraction unit, 158…transmission unit, 160…management and control unit, 161…control execution unit, 162…analysis unit, 163-166…analysis unit, 167…buffer memory, 168…receiving unit, 169…display configuration unit, 170…peripheral equipment, 171…display device, 172…input device, Gf…image (detection data), Gg…image data set (detection data set), Od…detection judgment data, Og…detection judgment data set, Rg…acquisition information, Ag…analysis information, Ov…carrier action signal, Da…detection area, Px…action output judgment position, Py…tracking search end position, Ta…tracking area, L…length, W…width, H…height Detailed Implementation

[0047] Next, embodiments of the present invention will be described in detail with reference to the accompanying drawings. First, referring to... Figure 1 A vibratory conveying device constituting the conveying system of the present invention will be described. This vibratory conveying device 100 includes a vibratory conveying mechanism 110 such as a feeder, linear feeder, parallel feeder, or circulating feeder, and a conveying mechanism control unit 120 for controlling the conveying mechanism 110. Furthermore, the conveying mechanism 110 is provided with a drive unit 111 and a conveying body 112. The drive unit 111 is composed of an electromagnetic drive or a piezoelectric drive and has a vibration function; the conveying body 112 vibrates via the drive unit 111. Figure 3 , Figure 4 as well as Figure 5 As shown, a conveying path 112a is provided on the conveying body 112, and vibration is applied to the conveying body 112 in an obliquely upward direction of the conveying direction F to make it reciprocate, so as to convey the conveyed object P (product) on the conveying path 112a.

[0048] The conveyor path 112a is provided with conveyor action parts S1, S2, S3, and S4 for changing the position or posture of the conveyed item P. These conveyor action parts include removing unwanted conveyed items P from the conveyor path 112a, rotating improperly positioned conveyed items P to an appropriate angle, or distributing conveyed items P in an appropriate direction using the fork in the conveyor path 112a. Regarding the conveyor action parts S1-S4 of this embodiment, as an example, S1-S3 are respectively as follows: Figure 4 The conveyor tilting section S4, which causes the conveyor P to tilt 90 degrees to the side, is as shown. Figure 3 The conveyor removal section shown is for removing conveyor P that is in an improper posture from the conveyor path 112a.

[0049] In the aforementioned conveying action parts S1-S4, a conveying action mechanism 130 is provided to control the position or orientation of the conveyed object P on the conveying path 112a. This conveying action mechanism 130 is not particularly limited; in this embodiment, the position or orientation of the conveyed object P is changed by applying air pressure to it. In this embodiment, the conveying action mechanism 130 is configured to have a base-end side pipe 132 connected to an air pressure source 131 such as a compressor, and to allow air to flow from an air outlet 112b (see reference 112b) opening toward the conveying path 112a of the conveyor body 112 via an on / off valve 133 connected to the base-end side pipe 132 and a front-end side pipe 134. Figure 3 and Figure 4 An airflow is sprayed onto the conveyed material P. As the on / off valve 133, a solenoid valve or piezoelectric valve that is controlled to open and close by a drive signal output from the valve drive circuit 135 is preferably used.

[0050] At the transport objects' working areas S1-S4 of the aforementioned transport path 112a, an imaging unit 140, such as a CCD camera, is provided. In the example shown, the imaging unit 140 includes a first imaging device 141 and a second imaging device 142. The first imaging device 141 has an optical system that converges the transport objects' working areas S1 and S2 within the imaging range, and the second imaging device 142 has an optical system that converges the transport objects' working areas S3 and S4 within the imaging range. Figure 5 As shown, these imaging devices 141 and 142 generate an image Gf, which is formed by integrating an image portion Gfa with the imaging range of the transport object's action part S1 (S3) and an image portion Gfb with the imaging range of the transport object's action part S2 (S4). Thus, as a structure for forming an image by integrating two mutually separate image portions, an optical system can be described as follows: light reflected by mirrors arranged in their respective fields of view toward adjacent areas is reflected by two mirrors arranged in those adjacent areas in such a way that it becomes a beam of light traveling in the same direction. Furthermore, the aforementioned image portions Gfa, Gfb, or image Gf corresponds to the image data of the aforementioned detection information of the transport object P as disclosed in this invention.

[0051] In this embodiment, a transport object detection and determination unit 150 is provided. In the example shown, the transport object detection and determination unit 151 is connected to the drive units D1 and D2 of the valve drive circuit 135 corresponding to the transport object action parts S1 and S2 in the transport object action mechanism 130, and to the image output unit C1 of the imaging device 141 corresponding to the transport object action parts S1 and S2 in the imaging unit 140. Furthermore, the transport object detection and determination unit 152 is connected to the drive units D3 and D4 of the valve drive circuit 135 corresponding to the transport object action parts S3 and S4 in the transport object action mechanism 130, and to the image output unit C2 of the imaging device 142 corresponding to the transport object action parts S3 and S4 in the imaging unit 140.

[0052] The conveying object detection and determination unit 150 (conveying object detection and determination units 151, 152) is connected to the imaging unit 140 (imaging device 141, 142). It receives images Gf of the conveying object P at the conveying object action points S1-S4 from the imaging unit 140, and determines the posture of the conveying object P based on the image Gf and the detected posture. In addition, based on the determination result, it outputs the conveying object action signal to the valve drive circuit 135 (D1-D4) to drive the opening and closing of the valves 133 (V1-V4), and changes the position or posture of the conveying object P through the action of the conveying object action mechanism 130 (jetting airflow).

[0053] In this embodiment, a management and control unit 160, which is composed of an MPU (microprocessor unit) such as a computer, is provided. This management and control unit 160 is connected to the aforementioned conveyor control unit 120 and the aforementioned conveyed object detection and determination units 150 (conveyed object detection and determination units 151, 152), and exchanges data or instructions with them. Furthermore, the management and control unit 160 is connected to peripheral devices 170, such as a display device 171 composed of various monitors such as an LCD, or an input device 172 such as a keyboard or mouse. In addition, the conveying control system 101 of this embodiment is composed of the conveyor control unit 120, the conveyed object detection and determination unit 150, the management and control unit 160, and the peripheral devices 170.

[0054] Figure 2 This is a functional block diagram showing the relationship between the management control unit 160 and the transported goods detection and judgment unit 150 (transported goods detection and judgment units 151, 152). The transport object detection and determination unit 150 includes: a unit control unit 153 that controls the entire transport object detection and determination unit; a shooting control unit 154 that outputs a trigger signal Tg to the shooting unit 140 (shooting devices 141, 142); a frame buffer memory 155 that temporarily stores the data of the image Gf output from the shooting unit 140; a detection and determination processing unit 156 that processes the image Gf and performs detection and determination processing of the transport object P; an image extraction unit 157 that generates dynamic image data containing a display image Gf′ as a frame image by performing frame and / or pixel interval removal on the dynamic image data containing the image Gf as a frame image; and a transmission unit 158 ​​that transmits the dynamic image data output from the image extraction unit 157. The shooting control unit 154, the frame buffer memory 155, the detection and determination processing unit 156, the image extraction unit 157, and the transmission unit 158 ​​are each controlled by the unit control unit 153.

[0055] On the other hand, the management control unit 160 includes: a control execution unit 161 functionally configured to execute the action program described later via operation from the input device 172 as needed; an analysis unit 162 including multiple analysis units 163-166 of different forms; a buffer memory 167 holding acquisition information Rg, which is metadata of the analysis object processed in each analysis unit 163-166; a receiving unit 168 receiving dynamic image data including the display image Gf′; and a display configuration unit 169 that processes the analysis information Ag output from the analysis unit 162 together with the display image Gf′ to form a display screen. The analysis unit 162, buffer memory 167, receiving unit 168, and display configuration unit 169 are controlled by the control execution unit 161 as functional implementation components. However, the management control unit 160 is preferably physically composed of a CPU (central processing unit), a bus, a memory, input / output circuits, etc.

[0056] The transport object detection and determination unit 150 (transport object detection and determination units 151, 152) triggers the imaging unit 140 (imaging devices 141, 142) to capture images of one or more transport objects P transported on the transport path 112a at each transport object action point S1-S4 via the trigger signal Tg output from the imaging control unit 154, and outputs images Gf as its imaging data (equivalent to detection information and image data) to the frame buffer memory 155. Images Gf are transmitted to the detection and determination processing unit 156 frame by frame and stored in the buffer. The number of frames of images Gf stored in the buffer are transmitted together as image data group Gg to the buffer memory 167 of the management control unit 160.

[0057] Furthermore, the detection determination data Od obtained by processing the image Gf (detection information) in the detection determination processing unit 156 is also stored in the buffer. The detection determination data Od of a predetermined number of frames stored in the buffer is transmitted to the buffer memory 167 of the management control unit 160 as a detection determination data group Og. Here, the image data group Gg and the detection determination data group Og constitute the acquisition information Rg of the present invention. In addition, the detection determination processing unit 156 outputs the transport action signal Ov to the valve drive circuit 135 (D1-D4) according to the determination result. When the transport posture of the transport P in the determination result is NG, the transport action signal Ov is output at a predetermined time to activate the opening and closing valves 133 (V1-V4). Furthermore, in the case where airflow is always blown from the jet nozzle 112b in the transport action mechanism 130, and the airflow is stopped only when the normal transport P arrives, although it also depends on the configuration of the opening and closing valves 133, the output of the transport action signal Ov can also be stopped when the normal transport P arrives.

[0058] The image data group Gg and the detection determination data group Og, which are held in the buffer 167 of the management control unit 160 as the acquisition information Rg, undergo various analysis processes through the analysis unit 162. In the example shown, the analysis unit 163 performs counting processing to count the number of transported items P, which are the analysis information Ag. Here, the number of transported items can also be counted by referring to the discrimination result of the transported item P contained in the detection determination data group Og. However, as will be described later, in the analysis unit 162, the detection determination can be re-performed based on the image data group Gg, and the number of transported items P in each posture, which are the analysis information, can be counted based on the result. As a result, high-precision counting processing can be performed.

[0059] In addition, the analysis unit 164 performs setting information processing. In this setting information processing, setting information (process recipe) Gs for various processes of the detection and determination processing unit 156 is derived as analysis information Ag. The derived setting information Gs is output to the transport material detection and determination unit 150 through the control execution unit 161, and within the transport material detection and determination unit 150, the various setting information of the detection and determination processing unit 156 is replaced with the derived setting information Gs by the unit control unit 153.

[0060] Furthermore, the analysis unit 165 performs action analysis processing. In this action analysis processing, the changes in the position or posture of the conveyor P caused by the action of the conveyor action mechanism 130 are analyzed based on the aforementioned image data group Gg, and the amount of movement and movement posture of the conveyor P are derived as analysis information Ag. As will be described later, in this embodiment, since the conveyor P is acted upon by the airflow blown by the conveyor action mechanism 130, specifically the flight distance and flight posture of the conveyor P are derived. Moreover, based on the movement pattern of the conveyor P determined by such a conveyor action mechanism 130, the setting information Cp for the action control processing of the conveyor, such as the content of the conveyor action signal Ov corresponding to the drive output value or drive waveform of the valve drive circuit 135, can be derived and reflected in the action control processing in the detection and determination processing unit 156.

[0061] Furthermore, the analysis processing performed by the analysis unit 162 is not limited to the above-described processing. As shown in the analysis unit 166, various other analysis processing can be performed as long as the information Rg is acquired based on the image data group Gg or the detection and determination data group Og. For example, as one of the analysis information Ag, an index representing the stability of the normal conveying posture of the conveyed object P on the conveying path 112a can be derived, and the setting information of the conveying mechanism control unit 120 can be changed according to this index to improve the stability of the conveying posture.

[0062] Next, refer to Figures 6 to 10The detection and determination processing performed by the detection and determination processing unit 156 in the transport object detection and determination unit 150 (transport object detection and determination unit 151, 152) and the operation control processing relative to the transport object action mechanism 130 will be explained.

[0063] Figure 6 and Figure 7 This diagram illustrates the conveying pattern of the conveyed item P on conveyor path 122a in contrast to the detection and judgment processing of the conveyed item P. Here, as... Figure 6 As shown in (a), the detection area Da is set such that it always maintains the same positional relationship with the mark 112c fixed to the conveyor path 112a in the images Gf of the above-mentioned transport action parts S1-S4 of the transport path 112a, thus becoming a fixed area on the transport path 112a. In particular, in this embodiment, the transport mechanism 110 is a vibrating transport mechanism, so the appearance of the transport body 112 constantly reciprocating along the transport direction F is captured as a dynamic image with each image Gf as a frame image. Therefore, the position (frame line) of the detection area Da in the image Gf is corrected and displayed synchronously at the time of the reciprocating movement towards the mark 112c in the left and right direction, so that the detection area Da is set in a fixed area on the transport path 112a.

[0064] Furthermore, on the image Gf, the action output determination position Px and the tracking search end position Py are represented by lines orthogonal to the conveying direction F. The display of these positions, like the aforementioned detection area Da, is corrected for timing and movement in sync with marker 112c, thus setting them to positions that are always fixed relative to the conveying path 112a. Here, the action output determination position Px refers to the reference position (valve output determination position) at which the conveyed object detection determination unit 150 (conveyed object detection determination units 151, 152) outputs the conveyed object action signal Ov relative to the valve drive circuit 135 (D1-D4) when the corresponding part, such as the center (center of gravity) of the detected conveyed object P, passes through position Px. Similarly, the tracking search end position Py refers to the reference position relative to the end of the aforementioned tracking search process when the conveyed object P reaches position Py at the corresponding part, such as the front end.

[0065] Furthermore, the position (front end or center of gravity, etc.) of the corresponding part of the transport object P, which is considered to be the action output determination position Px or the tracking search end position Py, can be appropriately set, and therefore is not particularly limited. Additionally, for example, when a transport object P is marked as NG, when the corresponding part of the transport object P reaches the action output determination position Px, the detection determination processing unit 156 outputs a transport object action signal Ov. At this time, in any frame image, the transport object P is not necessarily positioned exactly at the action output determination position Px. Therefore, for example, when the corresponding part of the transport object P approaches or moves closer to the action output determination position Px in the transport direction F within the range of the movement amount β described later, the transport object action signal Ov is output. At this time, by adjusting the output time of the transport object action signal Ov relative to the reference time based on the offset of the corresponding part from the action output determination position Px in the transport direction F, a force can be applied to the transport object P at a more accurate action time.

[0066] Here, the detection zone Da is set at a position upstream of the action output determination position Px along the conveying direction F of the conveying path 112a, preferably at the position where the aforementioned movement amount β is separated. Furthermore, the action output determination position Px is positioned adjacent to the jet nozzle 112b, further upstream. Moreover, the interval between the jet nozzle 112b and the action output determination position Px can be adjusted by the delay time between the output time of the aforementioned conveyed action signal Ov and the operating time of the opening and closing valves 133 (V1-V4) via the valve drive circuits 135 (D1-D4).

[0067] The detection area Da is related to the length L of the transport direction F of the transported object P on the transport path 112a and the time when the shooting unit 140 (shooting device 141, 142) shoots the image via the trigger signal Tg. Here, when the shooting period is set to Ts [sec], the length of the transport direction F of the transported object P is set to L [mm], and the transport speed of the transported object P is set to Vs [mm / sec], the length (range) DL of the transport direction F of the detection area Da is set as follows (1) so that the images of all transported objects P are necessarily contained within the detection area Da of the image Gf of a certain frame.

[0068] DL≥L+β=L+Ts·Vs…(1)

[0069] For example, if the length L of the conveyed object P in the conveying direction F is 0.6 mm, the conveying speed Vs is 50 mm / sec, and the shooting period Ts is 1 msec, then L = 0.6 mm, the movement between one frame of images β = 0.05 mm, and thus DL ≥ 0.65 mm. Alternatively, if the shooting period Ts is set to 0.5 msec, then by setting L = 0.6 mm and β = 0.025 mm, DL ≥ 0.625 mm.

[0070] In reality, for each individual, the conveying speed of the transported item P will vary depending on the location or the passage of time. Therefore, it is preferable to set the entirety or part of the transported item P to be captured in the image data two or more times, preferably three or more times. Typically, in order to be captured in the image data n (n is a natural number) or more times, the length DL of the detection area Da in the conveying direction F is set in such a way that the following equation (2) holds.

[0071] DL≥L+n·β=L+n·Ts·Vs…(2)

[0072] In this embodiment, n is set to a range of 3-7. This is because if n is small, the possibility of the transported object CA being missed due to deviations in transport speed increases; conversely, if n is large, the image processing load increases. Generally, a natural number n in the range of 1-10 is preferred. Furthermore, in this embodiment, the image processing time is generally around 150μsec-300μsec. Additionally, the shooting interval Ts is around 500μsec-840μsec.

[0073] However, if the length DL of the detection area Da exceeds twice the length L of the transported object P, more than two transported objects P may be detected simultaneously during the detection and search process within the detection area Da. Therefore, image processing becomes complex and difficult to achieve high speed. Thus, it is preferable that DL ≤ L × 2, and more preferably DL < L × 2.

[0074] exist Figure 6In (a) and (b), the transport object P1 is detected within the detection area Da. The detection search process within the detection area Da is performed in this embodiment using pattern matching processing. This pattern matching processing is generally performed by determining the regions of the pattern with high similarity to the shaded image using processing such as a grayscale search module. The reference pattern used in the detection search process is included in the aforementioned setting information Gs. The reference pattern is, for example, an image of the transport object P in a standard transport posture. In this detection search process, when the integration of the image within the detection area Da with the reference pattern is higher than a threshold, the transport object P is considered to have been detected. Specifically, for example, in the case of normalized correlation search, the similarity or dissimilarity, such as the correlation coefficient with the reference pattern, is calculated. When it exceeds a threshold, a transport object P similar to the reference pattern is detected. Here, as indicators representing similarity or dissimilarity, various indicators such as NCC (normalized cross-correlation), SSD (sum of squared differences in pixel values), SAD (sum of absolute differences in pixel values), and Z-NCC (NCC minus the average pixel value) can be used. Alternatively, geometric shape pattern matching techniques can be used instead of pixel-image-based correlation searches as described above.

[0075] For the conveyed item P1 being inspected as described above, a mark Pm is positioned within the upper portion P1u of its inspection pattern. Whether the item is functioning correctly is determined by whether the mark Pm is positioned at a specified location (in the example, behind the conveying direction F). For instance, if the edge module determines that the boundary of the mark Pm exists within the upper portion P1u, and the two region modules confirm that the mark Pm exists behind the upper portion P1u in the conveying direction F, but not in front of it, then the item is determined to be in a standard posture (good product).

[0076] In the example shown, since the length DL = L + nβ in the conveying direction F of the detection zone Da is set to n = 3, the same conveyed item P with length L is detected at least twice within the detection zone Da. Thus, when the length DL is set to n = 2 or more, the same conveyed item P will be detected multiple times within the detection zone Da. However, by detecting the same conveyed item P multiple times and performing a judgment process each time, the accuracy of the judgment result can be improved.

[0077] As described above, by performing multiple detections and judgments on the same transport object P, the accuracy of the judgment results and the posture accuracy of the transport object P can be improved. This embodiment is configured such that a threshold can be set for the number of judgments when a specific transport object P is determined to have a standard posture (marked as OK judgment). Additionally, a threshold can be set for the number of judgments when a specific transport object P is determined to have a non-standard posture (marked as NG judgment). For example, the threshold for the number of OK judgments when OK is determined can be set to three, and the threshold for the number of NG judgments when NG is determined can be set to two, and so on. In this case, by limiting the upper limit of the number of judgments relative to a single transport object P, the characteristics of the system can be set according to whether the same processing is performed as OK judgment or NG judgment when the upper limit of the number of judgments cannot be marked. Furthermore, the upper limit of the number of judgments needs to be set to be greater than or equal to the threshold of either OK judgment or NG judgment (e.g., more than three times). At this time, as described above, the number of times the same transport object P is detected within the detection area Da can be increased by adding an amount of n to the length DL of the detection area Da, thereby ensuring that the number of judgments exceeds the threshold. However, by performing the following tracking search process, the number of decisions can be greater than the number of detections within the detection zone Da. Furthermore, even if the n of the length DL of the detection zone Da is 2 or less (even if the detection count of the same transported item P can only be guaranteed once), multiple decision counts can be ensured through the tracking search process.

[0078] In this embodiment, according to Figure 6 In frame image (b), the predicted range after the detection position of the transported object P1 within the detection area Da is moved by the next movement amount β in the transport direction F is... Figure 6 In the next frame image of (c), the tracking area Ta is set, and a search is performed within the tracking area Ta, thereby performing the same tracking search process for detecting the transport object P1 as described above. At this time, by using... Figure 6 In frame image (b), the predicted range after the detection position (centroid of the detection range) of the transported object P1 in the frame image is moved by a movement amount β in the transport direction F is set as the tracking area Ta (the above detection position becomes the center position of the tracking area Ta). This can increase the probability of detecting the same transported object P1 within the tracking area Ta. Then, in Figure 6 In the frame image shown in (d), a tracking area Ta is also set with a movement amount β, and the same transported object P1 is detected within this tracking area Ta. At this time, the search process within the tracking area Ta can be performed in the same way as the detection search process described above.

[0079] In addition, such as Figure 7As shown in (a), if the corresponding part (front end) of the conveyed object P1 exceeds the action output judgment position Px and the conveyed object P1 is not in a standard posture (for example, if two consecutive NG judgments are made), the tracking and search for the conveyed object P1 will no longer continue. Furthermore, in this embodiment, conveyed objects P not marked as OK judgments (conveyed objects marked as NG judgments and unmarked conveyed objects) are treated as conveyed objects not in a standard posture, and the action is applied through the conveyed object action mechanism 130. At this time, as... Figure 7 As shown in (b), when the corresponding part of the conveyed object P1, such as its center (center of gravity), exceeds the action output determination position Px, the detection determination processing unit 156 outputs a conveyed object action signal Ov, and airflow is sprayed onto the conveyed object P1 from the jet nozzle 112b. Furthermore, the conveyed object at this time is subsequently excluded from the tracking search process. However, in the example shown, since three OK determinations are made, the conveyed object P1 is determined to be in a standard posture and marked as OK, therefore the above-mentioned action control processing is not performed. Furthermore, the detection of the conveyed object P1 marked as OK during the tracking search process continues even after it has passed the action output determination position Px, as... Figure 7 As shown in (c) and (d), the transported material P1 passes beside the jet nozzle 112b, as... Figure 7 As shown in (e), a transport inspection process is performed relative to the transport P1 until it passes through the jet nozzle 112b. Then, when the corresponding part (front end) of the transport P1 reaches the tracking search end position Py, the tracking search process relative to the transport P1 is no longer performed. The reason for performing inspection relative to the good transport P1 until it has completely passed through the jet nozzle 112b is that if the next transport P2 is not good, it is necessary to delay the start of airflow from the jet nozzle 112b until the airflow no longer affects the transport P1. That is, in this embodiment, it is preferable to start airflow from the jet nozzle 112b to the transport P marked as NG after the point at which the transport P marked as OK has passed through the jet nozzle 112b and is no longer affected by the airflow from the jet nozzle 112b.

[0080] Figure 8 This is an explanatory diagram illustrating the management steps of the memory (tracking queue) for the execution method of the transport detection process, which includes the above-described detection and tracking processes. Figure 9 This is a simplified flowchart illustrating the steps of the conveyed goods inspection process. In this conveyed goods inspection process, such as... Figure 8As shown in (a), the detection data of the transport object P1 detected in the detection area Da within each frame image Gf, where the detection object D1 meets the specified conditions, is registered in the memory, i.e., the tracking queue, provided in the detection determination processing unit 156. Here, the detection data for the detection object D1 can include, for example, the position or range of the detection object D1 (coordinate values, etc.), the presence or absence of a determination mark, the number of OK determinations, the number of NG determinations, the number of determinations, and whether determination processing is required (the presence or absence of a determination flag). Here, as... Figure 8 As shown in (b), when a value representing the similarity or dissimilarity with a reference pattern, such as the correlation coefficient or the NCC (Normalized Cross-Correlation) value, indicates a certain degree of similarity, the detected object D1 is registered in the tracking queue and becomes registered object T1 (first detection information). This is because, in the case of detected objects with relatively low similarity, the possibility of some false detections is high, and therefore they must be excluded from the tracking search process. Furthermore, in this embodiment, as a registration condition for detected objects, a percentage (e.g., 10% in the transport direction F) that allows partial overlap between the position or range of the detected object and the position or range of the last detected registered object can be set. This is to prevent falsely detected objects from being registered and to prevent objects that should be detected from being excluded due to false detection.

[0081] The aforementioned registered object T1 is also searched in the next frame's image Gf. Here, as described above, when it is also searched in the next image Gf... Figure 8 As shown in (b), when a registered object T1 is detected within the detection area Da, the detection search process is performed again. If its position or range relative to the position or range of the previous frame image is close to the value of the movement amount β corresponding to the shooting interval, it is the same registered object T1. However, in the case of an object that has already been detected and registered, even if it is predicted to exist within the detection area Da, the usual tracking search process, which sets the tracking area Ta as the prediction range and performs a search each time, can be performed instead of the above detection search process. In any case, when a registered object T1 relative to the same transport P1 as in the previous frame image is detected again in the current frame image, as... Figure 8 As shown in (C), the position or range information within the tracking queue is updated and registered as object T1 (second detection information). Furthermore, in Figure 8 In the diagram, the circled number, which is added each time the information of each registered object is updated, indicates which number of the updated information is being updated.

[0082] During the tracking and search process, such as Figure 9As shown, if a registered object has already been recorded in the tracking queue, a tracking search is first performed on all registered objects to update their position or range information. This tracking search, as described above, sets the tracking area Ta in the current frame image based on the position or range of the object detected in the previous frame image, and detects objects corresponding to the same transport P again through pattern matching or similar processes. Then, for the same frame image, a detection search is performed within the detection area Da. If a new object is detected within the detection area Da and meets the registration conditions, it is registered as a new registered object in the tracking queue. Then, for registered objects already registered in the tracking queue that require judgment processing (e.g., objects with judgment flags), judgment processing is performed. Then, when any registered object is marked as NG and the corresponding part of that registered object reaches the position corresponding to the aforementioned action output judgment position Px, a transport action signal Ov is output. The registered object that becomes the transport action signal Ov is removed from the tracking queue and removed from subsequent tracking searches. Furthermore, in this specification, for a specific transported item P, the terms "OK determination" or "NG determination" are used to indicate that the status has been determined.

[0083] Back to Figure 8 Let's continue with the explanation. For example... Figure 8 As shown in (c), the registered object T1 of the transport P1 is detected for the third time through tracking and searching for the next frame image, thus... Figure 8 As shown in (d), it is updated to registered object T1 (third registration information). Additionally, in the detection area Da, as... Figure 8 As shown in (c), an object (detection object D2) is detected for the new transport P2. For this detection object D2, it is also confirmed whether the above registration conditions are met. If the registration conditions are met, then... Figure 8 As shown in (d), registration object T2 (first registration information) is recorded in the tracking queue. Then, when... Figure 8 As shown in (d), when registered object T1 is found again in the next frame image, and registered object T2 is also found again, as follows... Figure 8 As shown in (e), in the tracking queue, registration object T1 (fourth registration information) and registration object T2 (second registration information) are updated. Thereafter, similarly to the above, as... Figure 8 As shown in (e), registered objects T1 and T2 were detected during the tracking search. Additionally, a new transport object P3 (detected object D3) was detected during the detection search within the detection area Da. Therefore, as... Figure 8As shown in (f), in the tracking queue, the registration object T1 (fifth registration information) and the registration object T2 (third registration information) are updated, and when the detection object D3 meets the above registration conditions, a new registration object T3 (first registration information) is registered.

[0084] Furthermore, in the next frame image, such as Figure 8 As shown in (f), although registered objects T2 and T3 are detected again through tracking search, for example, registered object T1 is removed from the tracking queue because its position or range in the fifth registration information has reached the end position Py of the tracking search, or it has already reached it during the next shot. Figure 8 The tracking search will no longer continue as shown in (g). Figure 8 In the form shown in (g), it indicates that because Figure 8 In (f), registered objects T2 and T3 are searched again and the updated registered objects T2 (fourth registration information) and registered objects T3 (second registration information) in the tracking queue are recorded, and the appearance of registered object T3 being searched again and new objects (detected object D4) being detected in the detection area Da is recorded relative to the next frame image.

[0085] Figure 10 It means targeting Figure 9 The flowchart shown is a simplified representation of the module portion of the transport inspection process, which involves the objects (objects with information indicating the need for inspection, such as objects with an inspection flag) registered in the aforementioned tracking queue that require an inspection result. In this portion, firstly, the information of the registered objects is read, and registered objects that do not require inspection (no inspection flag is set) are extracted. Whether inspection is required is determined based on the object's location or range, or whether it is marked. For registered objects that meet the conditions, the information requiring inspection is added (indicating an inspection flag is set). Here, since registered objects that have already been determined to be OK and whose corresponding parts have passed the output inspection position Px do not require inspection, no inspection flag is set. Furthermore, in the following explanation, registered objects with added information requiring inspection (indicating an inspection flag is set) are referred to as "inspection registered objects".

[0086] Next, the aforementioned judgment process is performed on the registered objects among the registered objects. If an OK judgment result is obtained through this process, the number of OK results and the total number of judgments are incremented by 1 each time. When the number of OK results exceeds a threshold (e.g., three times), the registered object is marked as OK. On the other hand, if the number of OK results does not exceed the threshold, but exceeds the upper limit of the number of judgments, the judgment process is stopped, and the judgment flag is removed. If the upper limit of the number of judgments is not exceeded, the process proceeds directly to the next step (judgment process for other registered objects).

[0087] In contrast, if an NG (Not Good) result is obtained through the above-described judgment process, the NG count is incremented by 1, and the OK count is set to 0. Then, in this judgment registration object, when an NG result is obtained consecutively (twice), the judgment flag is removed, and the process proceeds to the next step (judgment processing of other judgment registration objects). Furthermore, the above explanation addresses the following scenario: when only OK judgments are marked, judgment is stopped when consecutive NG judgments are obtained; when no OK judgment is marked, it is considered an NG judgment. However, for handling multiple judgments in the judgment process, various thresholds can be set, and appropriate settings can be made, such as marking both OK and NG judgments, etc. For example, it can be different from... Figure 10 Instead of checking for two consecutive NG (Not Good) judgments, the following processing steps are selected: If an NG judgment is obtained, instead of checking for two consecutive NG judgments, similar to the OK judgment, if the number of NG judgments exceeds the threshold, it is marked as NG and the judgment flag is removed. If the number of NG judgments does not exceed the threshold, but the number of judgments exceeds the upper limit, the judgment flag is removed; otherwise, other processing is performed directly. Furthermore, for transport items (registered objects) determined to be NG, by deleting the registered object when the corresponding part exceeds the effective output judgment position Px, unnecessary transport item inspection procedures can be avoided.

[0088] In addition, Figure 8 In the illustration, for ease of understanding, registered object T1 is deleted from memory after being updated to the fifth registration information, thus ceasing the transport item detection process (tracking and searching process). However, it should be noted that the actual processing differs from the illustration based on the determined judgment result. That is, in Figure 6 and Figure 7In the transport item P1 shown, if it is determined to be OK, the determination flag is released after the corresponding part reaches the action output determination position Px, thus continuing the transport item detection process, but not the transport item determination process. Furthermore, after the corresponding part of transport item P1 reaches the tracking search end position Py, the registered object is deleted from memory and deregistered, thus also ceasing the transport item detection process. Additionally, for transport items P determined to be NG (including transport items not determined to be OK), after the corresponding part reaches the action output determination position Px, the registered object is deleted from memory and deregistered, thus ceasing the transport item detection process.

[0089] Next, refer to Figures 11 to 20 The operation of the management control unit 160 described above will be explained. In the management control unit 160 of this embodiment, processing is performed according to a specific operation procedure executed by the MPU, as described later. The management control unit 160 is connected as an external device to be managed: a transport control mechanism 120 that controls the transport mechanism 110, a transport action mechanism 130 that applies an action to the transported object P on the transport path 112a to change the position or posture of the transported object P, and a transport detection and determination unit 150 (transported object detection and determination units 151, 152) including imaging units 140 (imaging devices 141, 142). Furthermore, the management control unit 160 can control the start-up or stop of the transport mechanism 110 itself, and its operating mode during operation, via the transport control mechanism 120.

[0090] like Figure 11 As shown, after startup, the management control unit 160 checks the connection status of its internal components (CPU, memory, bus, input / output circuits), display device 171, input device 172, etc., with external devices such as the conveying mechanism 110, conveying control mechanism 120, conveying action mechanism 130, and conveying detection and determination unit 150. It also checks the operational status of external devices as needed. Next, it checks operation inputs such as setting operations from input device 172, etc., and performs readings of various information corresponding to the operation input, setting of reference values ​​or thresholds, and other processing when such operation inputs are present. Furthermore, it checks whether a conveying start operation has been input. When a conveying start operation is input, it activates the conveying mechanism control unit 120 and the conveying detection and determination unit 150 (conveying detection and determination units 151, 152), and starts the conveying mechanism 110 via the conveying mechanism control unit 120.

[0091] When each part is started, in the conveying mechanism 110, under the control of the conveying mechanism control unit 120, the conveyed object P begins to be conveyed. The conveyed object detection and determination unit 150 performs an imaging action using the imaging unit 140, and performs detection and determination processing in the detection and determination processing unit 156 based on the acquired image Gf (detection information). In addition, based on the determination result of the detection and determination processing, the conveyed object action signal Ov is output to the valve drive circuit 135 (D1-D4) of the conveyed object action mechanism 130 through the action control processing. The opening and closing action of the opening and closing valves 133 (V1-V4) generated therefrom causes airflow to be blown from the jet port 112b of the conveying path 112a to the conveyed object P.

[0092] In this startup state, according to the settings described later, the transport detection and determination units 151 and 152 are requested to transmit acquisition information Rg, which consists of image data group Gg and detection determination data group Og, at predetermined intervals (e.g., 30 seconds). The image data group Gg includes multiple frames (e.g., 2000 frames) of images captured within the predetermined time period, and the detection determination data group Og includes detection determination data Od obtained by the detection determination processing unit 156 based on these images Gf. The management control unit 160 then receives the acquisition information Rg sent from the transport detection and determination units 151 and 152. Furthermore, it performs data analysis as described later based on the acquisition information Rg and displays analysis information Ag derived as a result, or derives various setting information Gs as needed from the analysis information Ag. This setting information Gs reflects various setting values ​​or thresholds in the detection determination processing unit 156 of the transport detection and determination units 151 and 152, and also reflects the setting value or signal waveform of the transport action signal Ov. In addition, the aforementioned setting information Gs is also reflected in the setting values ​​used by the conveying mechanism control unit 120 to control the conveying mechanism 110, and is indirectly reflected in the operating state of the conveying mechanism 110.

[0093] The above process is repeated before a stop operation is input. When a stop operation is input, the opposite occurs: the conveyor 110 stops, and the conveyor control unit 120 and the conveyed item detection and determination unit 150 (conveyed item detection and determination units 151 and 152) also stop. Furthermore, the above steps are repeated before a system-wide end operation is input.

[0094] Figure 12The diagram shows a general outline of the main screen 200, one of the display screens displayed on the display device 171 when the management control unit 160 is in operation. This main screen 200 includes a screen switching operation unit 201, a status display operation unit 210, and a function display operation unit 220. The status display operation unit 210 displays the settings of each part of the transport control system 100 and configures it for operation. The function display operation unit 220 displays in real time a display image Gf′ derived from the image Gf obtained from the transport detection and determination units 151 and 152, and shows the results or processing content detected and determined by the detection and determination processing unit 156. Within the main screen 200, which is constructed by the display configuration unit 169 of the management control unit 160, the function display operation unit 220 is configured as a superimposed (image insertion) area primarily displaying the display image Gf′ showing the processing status of the transport detection and determination units 151 and 152.

[0095] In the example shown, the status display operation unit 210 is provided with a display unit 211, a display operation unit 212, a display operation unit 213, and a display unit 214. The display unit 211 displays the type, size, predetermined supply quantity, and supplied quantity of the current conveyed item. The display operation unit 212, as image devices 1 and 2, displays the working status of the imaging devices 141 and 142 of the imaging unit 140 and performs start or stop operations. The display operation unit 213, as a PF controller, displays the working status of the conveying mechanism control unit 120 that controls the conveying mechanism 110 and performs start or stop operations. The display unit 214, as valve devices 1 and 2, displays the working status of the opening and closing valves 133 of the conveying action mechanism 130 (V1, V2, V3, V4) and the valve drive circuits 135 (D1, D2, D3, D4).

[0096] In the example shown, the operation display unit 220 includes an image display unit 221. The image display unit 221 displays a display image Gf′ obtained by performing appropriate interval rejection processing on the image Gf captured by the imaging unit 140 (imaging devices 141, 142) under the control of the transport detection and determination units 151, 152. This image display unit 221 can display the display image Gf′ with additional information set according to the processing performed by the detection and determination processing unit 156. This additional information includes a frame indicating the detection area Da or tracking area Ta, a vertical line indicating the operation output determination position Px or the tracking search end position Py, and a frame indicating the position or range of the jet nozzle 112b. Additionally, a determination display unit 222 displays the determination result obtained by the detection and determination processing unit 156, an information display unit 223 displays the processing time required for determination, and buttons 224 for image zooming in and out.

[0097] The operation display unit 220 includes a detection search display unit 225 and a tracking search display unit 226. The detection search display unit 225 displays the status or setting of the detection search process for the aforementioned conveyor detection procedure, while the tracking search display unit 226 displays the status or setting of the tracking search process. Alternatively, other display operation units, such as those for displaying and operating threshold settings for the conveyor judgment procedure, may also be provided. Furthermore, while the main screen 200 displays the operation display units 220 for both conveyor detection judgment units 151 and 152, only one operation display unit 220 may be displayed.

[0098] Figure 13 The diagram shows a general outline of the setting screen 300 that can be switched by operating the screen switching operation unit 201 from the main screen 200. The setting screen 300 includes a setting selection unit 310 (shown on the left) and a setting display operation unit 320. The setting selection unit 310 is used to select the item to be set, and the setting display operation unit 320 corresponds to the item selected in the setting selection unit 310. The options available for selection via the setting selection unit 310 include: "System" for setting settings related to the overall conveying control system 100; "Image Transmission" for setting the content of information Rg acquired between the conveyed object detection and determination units 151 and 152 and the management control unit 160; "Image Device 1" for setting the content performed by image device 1 and "Image Device 2" for setting the content performed by image device 2 in the "Counting" setting of the conveyed object counting process; and "Valve Device 1" for setting the conveyed object operating parts S1 and S2 and "Valve Device 2" for setting the conveyed object operating parts S3 and S4 in the "Valve Control" setting of the airflow pressure or timing in the conveyed object operating mechanism 130.

[0099] In the example diagram, a setting display operation unit 320 is shown when "Counting" for "Image Device 1" is selected in the setting selection unit 310. "Counting" is the setting content for counting the transported items during various analysis processes performed in the management control unit 160. In this setting display operation unit 320, a model display unit 321 with an image display bar 321a and a category display bar 321b is provided on the left side of the diagram. The image display bar 321a displays the registered images of multiple models corresponding to the posture of the transported items. The category display bar 321b indicates the category of each model's image (e.g., whether it is a standard posture). An image display unit 322 displaying the image Gf included in the acquisition information Rg is provided on the right side of the model display unit 321. Below the image display unit 322, a playback operation unit 323 for the image display unit 322 is provided. Furthermore, below the playback operation unit 323, a setting operation unit 324 for setting the measurement range of the image and a model setting unit 325 for registering the images of each model are provided.

[0100] Figure 14 The analysis result screen 400 shows the results of the aforementioned counting process performed by the management control unit 160. In this analysis result screen 400, the results are displayed through... Figure 13 The count processing in the "Image Device 1" of the setting screen 300 is set to "Count". The number of transports corresponding to the "Good" (standard posture) model and the number of transports corresponding to the four "Poor" models are classified and counted according to the transmission units of multiple acquisition information Rgs that are periodically transmitted through image transmission. The subtotal and total of the number of transports of "Good" and "Poor" are displayed in a table.

[0101] Furthermore, the counting process described above, which is one of the analysis processes performed by the management control unit 160, can also be performed directly using the detection and determination data group Og from the acquired information. However, in this embodiment, the management control unit 160 uses only the image data group Gg to separately detect and determine the transported object, and performs counting processing using the determination result derived as a result. In this way, unlike the real-time processing performed in the transported object detection and determination units 151 and 152, processing can be performed with ample time flexibility. Therefore, counting can be performed using a method or state that reduces false detections or false determinations generated in the real-time processing described above, thereby enabling more accurate analysis.

[0102] Figures 15 to 17 This is an explanatory diagram illustrating the counting process described above. For example... Figure 15As shown, an analysis area Aa is set within a portion of the image Gf containing the acquired information Rg. Pattern matching and similarity / difference calculations are performed within this analysis area Aa to detect the transported object P. Furthermore, the analysis area Aa is set within the image Gf in the same manner as the detection area Da or tracking area Ta described above. Here, when the length of the transported object P is L and the width is W, and the length of the analysis area Aa in the transport direction F is set to AL = a·L and the width to AW = b·W, a = approximately 1.7 and b = 1.3. This is because the range of the analysis area Aa needs to be large enough to encompass the transported object P, but cannot contain more than two transported objects P to prevent false detection, and all transported objects P must be detected within the same analysis area Aa. Therefore, the above description regarding the detection area Da also applies to the analysis area Aa. The value of a mentioned above is only one example; the length AL of the analysis area Aa can be set in the same way as the length DL of the aforementioned detection area Da. In addition, the width W of the analysis area Aa is set to take into account the amount of change in the position or posture of the conveyed object P during vibration conveying.

[0103] Within the analysis zone Aa, regions Ra and Rb are defined. In the example shown, region Ra is defined as the portion 0.4AL upstream of the upstream side of the conveying direction F and 0.25AL upstream of the downstream side. Region Rb is defined as the portion 0.25AL downstream of region Ra and extending to the downstream end. Region Ra is defined as the area where point Q (the corresponding location) is located when the conveyed item P located within analysis zone Aa is first detected. Region Rb is defined as the range within which the conveyed item P is detected a second or more times within analysis zone Aa. That is, the conveyed item P located within analysis zone Aa must first be detected at point Q located within region Ra, and then also at point Q located within region Rb.

[0104] Figure 16 This illustrates a case where a model pattern related to the posture angle θ of the conveying posture of the conveyor P is prepared to perform the detection of the conveyor P within the analysis area Aa with higher accuracy than the detection and determination process described above. In this embodiment, since the conveyor P is conveyed by the vibration of the conveyor body 112, the conveyor P is also conveyed while gradually changing its posture angle θ on the conveying path 112a. Therefore, the conveyor P within the analysis area Aa should also have conveying postures with various posture angles θ. Therefore, in this counting process, the different posture angles of the conveyor P are classified into n types in advance. In this way, since pattern matching processing can be performed based on multiple model patterns with different posture angles θ, conveyor detection with high similarity can be performed compared to when the posture angle θ is not considered.

[0105] In addition, such as Figure 17 As shown, there are four different models for the conveying posture of the conveyed object P on conveying path 112a, depending on which side faces upwards. Since each of these four models has two different models depending on which end faces forward, there are a total of eight models. Generally, since the number of conveying postures varies depending on the shape of the conveyed object P, it is set here that there are a total of m conveying posture models. Thus, in the model of the conveyed object P, m×n patterns are set according to these m conveying postures and the aforementioned n posture angles.

[0106] Prepare the model pattern as described above, and follow... Figure 18 The analysis steps shown perform counting of transported items P. First, image Gf of image data group Gg of the aforementioned acquired information Rg is acquired. Analysis region Aa is extracted from image Gf, and the aforementioned m×n model patterns are applied to the detected transported items P to calculate similarity or dissimilarity, thereby determining whether a suitable model with a similarity higher than a preset threshold exists. If a suitable model exists, the suitable model with the highest similarity is determined, and the result is calculated. Figure 15 Point Q is located at the front end of the conveying direction F. If point Q exists within region Ra of analysis area Aa, the conveyed object P is considered to have been detected first within analysis area Aa, a preparation flag is set, the next frame image is acquired, and the aforementioned steps are repeated. Then, when point Q no longer exists within region Ra and the preparation flag is set, if point Q exists within region Rb, the count of the determined suitable model is incremented by 1, and the preparation flag is deactivated. By repeating the above steps, all conveyed objects P detected within analysis area Aa can be counted, and by determining the suitable model, the number of conveyed objects or the conveying ratio can be calculated based on the conveying posture. Furthermore, the distribution of posture angles can also be derived.

[0107] Figure 19 and Figure 20 This is an explanatory diagram illustrating the action analysis process of the transporter (analysis unit 163), which is an example of another analysis process performed by the management control unit 160. (See diagram below.) Figure 19 As shown, based on the determination result obtained through the aforementioned detection and determination process (for example, when the determination result is determined to be NG), the position or orientation of the conveyed object P is changed by airflow blown from the jet nozzle 112b that opens on the conveying surface of the conveying path 112a provided on the conveyor body 112.

[0108] exist Figure 19 In the example shown, with Figure 4Similarly, the case where the orientation of the conveyor P is changed by rotating it through an airflow is also shown. While not particularly limited, rotating the conveyor P on conveyor path 112a through airflow and positioning it on an adjacent conveyor path 112d causes it to rotate 90 degrees about the conveying direction F, so that different sides face upwards. At this time, as shown by the dotted lines in the figure, image Gf records the movement of the conveyor by the airflow ejected from the nozzle 112b. Furthermore, in this example of analysis, not only the illustrated case, but also cases where the conveyor P is removed from conveyor path 112a by airflow or distributed in different directions at the branching points of conveyor path 112a can be described in the following description, without specifying the exact position and orientation changes of the conveyor P.

[0109] Figure 20 It means according to Figure 19 The graph shows the analysis results of the movement of the center of gravity of the transport object P (object) derived from a certain frame of image Gf, including the flight distance ΔY and the attitude angle θ of the transport object P (object) during flight. Here, as shown... Figure 19 As shown, the conveying direction F is taken as the X-axis, and the blowing direction of the airflow is taken as the Y-axis. Figure 20 The flight distance ΔY shown represents the amount of movement by which the conveyed object P is moved in the direction of the airflow (in the example, this is the amount of movement until the conveyed object P returns to its normal conveying state). Additionally, the angle φ of the flight direction of the conveyed object P can also be calculated from this graph. The flight distance ΔY represents the trajectory of the conveyed object P moved by the airflow, and is quantified, for example, by the index shown in Equation 1 below. Here, the difference in the Y-axis coordinates between frames is set as dy. Furthermore, x = s (Start) is the X-axis coordinate of the starting point of flight, and x = e (End) is the X-axis coordinate of the ending point of flight.

[0110]

Formula 1

[0111]

[0112] Furthermore, the angle φ of the flight direction can be represented by representative values ​​such as the mean of dy. Further, the stability of the position of the transported object P after flight can be represented, for example, by the following equation 2.

[0113]

Formula 2

[0114]

[0115] Furthermore, the angle θ representing the flight posture can be expressed, for example, by an index such as the following formula 3. However, the following index is merely an example and is not a limitation.

[0116]

Formula 3

[0117]

[0118] Based on the above indicators, the flight distance, direction, and attitude (attitude angle) of the conveyed object P generated by the jetting airflow can be considered, along with the setting information Cp related to the airflow pressure, jetting time, and jetting timing, and can be manually set. Alternatively, this setting information Cp can be automatically calculated corresponding to the various indicators related to the flight distance, direction, and attitude, and sent to the conveyed object detection and determination unit 150 (conveyed object detection and determination units 151, 152), thereby changing the process formula of the conveyed object action signal Ov output from the detection and determination processing unit 156. Furthermore, it is also possible to... Figure 13 Operate the valve control items shown in the settings screen to change the process formula of the aforementioned conveyor action signal Ov.

[0119] According to the embodiment described above, for each transported item P, detection and determination processing is performed by the transported item detection and determination units 151 and 152. Based on the transported item action signal Ov corresponding to the determination result, the transported item action mechanism 130 applies an action to the transported item P, thereby realizing the transport mode of the transported item P on the transport path 112a. At this time, the management control unit 160 derives analysis information Ag related to the transport status based on the acquisition information Rg (Gg, Og) obtained from the transported item detection and determination units 151 and 152. In this way, the detection and determination processing of the transported item is performed independently by the transported item detection and determination units, while the management control unit 160 performs the derivation of analysis information Ag based on the acquisition information Rg. This allows for the independent performance of detection and determination processing related to the transported item P that should be performed in real time, action control processing such as the output of the transported item action signal Ov relative to the transported item action mechanism, and the derivation of analysis information Ag that can be performed as a batch process. In this way, since the detection and judgment processing or action control processing and batch processing that should be processed in real time can be performed in parallel by the conveyed object detection and judgment units 151, 152 and the management control unit 160 respectively, it is sufficient to derive the analysis information Ag based on the acquired information Rg related to multiple conveyed objects. Therefore, the processing content can be distributed according to the characteristics, thus ensuring the conveying performance. In particular, the burden of real-time processing can be reduced, thus reducing the control cost.

[0120] Furthermore, the conveying control system and vibrating conveying device of the present invention are not limited to the examples shown in the figures above, and various modifications can be made without departing from the spirit of the present invention. For example, in the above embodiment, a unit control unit 153 is provided in the conveyed object detection and determination unit to ensure the degree of freedom of the processing mode within the unit, but the unit control unit 153 may not be provided, and only a processing circuit configured to automatically acquire detection information Gf and automatically execute detection determination processing or action control processing may be provided.

[0121] In addition, in the above embodiment, an OK determination is made for the conveyor P in the standard posture, while an airflow is applied to the conveyor P that is determined to be in the wrong posture (NG). However, the conveyor action mechanism 130 can also be configured so that the configuration is arbitrary, for example, the airflow is continuously sprayed, and the airflow is stopped when the conveyor P that is determined to be in the standard posture (OK determination) passes by.

[0122] Furthermore, in the above embodiment, an example applied to the vibrating conveyor 100 is shown, but as a conveying control system 101, it can be applied not only to the vibrating conveyor 110, but also to various other conveying mechanisms.

Claims

1. A conveying control system, wherein during the conveying of a conveyed object along a conveying path, the conveyed object on the conveying path is detected and determined, and the conveying mode of the conveyed object is controlled according to the determination result, the conveying control system being characterized by comprising: The conveyor detection and determination unit independently performs detection and determination processing and action control processing relative to the conveyor. The detection and determination processing involves acquiring detection information for each conveyor and processing the detection information to derive a determination result. The action control processing involves outputting a conveyor action signal based on the determination result and causing the conveyor action mechanism that applies action to the conveyor to operate according to the conveyor action signal. The management and control unit is configured to receive acquisition information consisting of the detection information or other information obtained through the detection determination process or the action control process, and to process the acquisition information in parallel with the detection determination process and the action control process performed in the transport object detection determination unit, thereby deriving analysis information associated with the transport status. The acquired information consists of an image data set (Gg) and a detection and determination data set (Og). The image data set (Gg) includes multiple frames of images (Gf) captured within a specified time period. The image data set (Gg) represents the transport form of the transported object and the movement form of the transported object under the action of the transported object mechanism. The detection and determination data set (Og) includes detection and determination data (Od) obtained from the images (Gf) through the detection and determination process. The management control unit is configured to display the image (Gf) on the image display unit, and is configured to perform action analysis processing based on image data contained in the image (Gf) representing the movement pattern of the conveyor under the action of the conveyor action mechanism, thereby deriving the amount of movement and movement posture of the conveyor as analysis information, and further, to manually or automatically implement the setting of the action control processing relative to the conveyor action mechanism.

2. The conveying control system as described in claim 1, characterized in that, The management control unit derives the setting information for the action control process, and this setting information is reflected in the action control process of the conveyed object detection and determination unit.

3. The conveying control system as described in claim 1 or 2, characterized in that, The management and control unit is connected to the conveying mechanism control unit and is configured to control the conveying mechanism control unit, which controls the conveying mechanism used to convey the conveyed object on the conveying path.

4. The conveying control system as described in claim 1 or 2, characterized in that, The conveying control system is configured to transmit the acquired information from the conveyed material detection and determination unit to the management control unit in parallel with the detection and determination processing and the operation control processing. The acquired information is transmitted periodically in units of information related to multiple transported items.

5. The conveying control system as described in claim 1 or 2, characterized in that, The transported item detection and determination unit has the following features: The unit control unit implements input / output control with the management control unit and setting control for the detection and determination process or the action control process; as well as The detection and judgment processing unit includes a detection and judgment circuit and a signal output circuit. The detection and judgment circuit performs the detection and judgment processing, and the signal output circuit outputs the conveying action signal to the conveying action mechanism according to the judgment result.

6. A vibrating conveyor device, characterized in that, Equipped with the conveying control system and the conveying mechanism as described in claim 3, The conveying mechanism is a vibratory conveying mechanism with a vibration function for conveying the conveyed object along the conveying path.

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