Conveyance control system and conveyance device

Abstract

The present invention provides a transport control system capable of avoiding defective transport and overlapping of front and rear transport objects, and a transport device using the same; the transport control system includes: an image acquisition unit that repeatedly acquires images of a measurement area on a transport path of a transport object by a photographing unit; a transport object occupied range discrimination unit that detects a continuous occupied range within the measurement area, and judges the size of the continuous occupied range based on a unit occupied range corresponding to one transport object, the continuous occupied range referring to a range in which occupied areas of the transport object on the transport path are integrated, or a range in which the occupied areas are adjacent at intervals less than a prescribed value; and a transport object control unit that controls the transport state of at least one transport object disposed within the continuous occupied range when the continuous occupied range satisfies a condition for improper judgment based on the unit occupied range.

Description

Technical Field

[0001] This invention relates to a conveying control system and a conveying device, and particularly to a conveying control technology that is especially suitable for use in vibrating conveying devices and is particularly effective in supplying conveyed materials moving along a conveying path to various supply destinations. Background Technology

[0002] Generally, a conveying device for conveying fine materials such as surface-mount electronic components is configured such that a rotary vibrating conveyor with a spiral conveying path, called a bowl feeder, raises the fine material along a track, and finally a linear vibrating conveyor with a straight conveying path, called a linear feeder, uniforms the posture of the material and supplies it to the component inspection device, component installation device, transfer robot, etc., which are the destinations.

[0003] In the aforementioned conveying devices, the conveyed materials have become increasingly miniaturized in recent years, requiring the ability to supply large quantities of electronic components the size of sand grains. Furthermore, some of these miniature electronic components are extremely thin, measuring only tens of micrometers. Conveying such thin materials in large quantities presents a problem of inefficient conveying due to the tendency for the materials to overlap and thus become difficult to arrange neatly. As existing conveying systems for larger, thin conveyed materials, the conveying systems shown in Patent Documents 1 and 2 are known.

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent Application Publication No. 8-113350

[0007] Patent Document 2: Japanese Patent Application Publication No. 2001-158524 Summary of the Invention

[0008] However, in the devices described in the aforementioned existing patent documents 1 and 2, since the conveyed material is relatively large and thicker than that of recent conveyed materials, this is addressed by using mechanical overlap prevention devices or by matching the position and shape of the air nozzle to the thickness of the conveyed material. However, in recent years, with the conveyed materials becoming increasingly miniaturized as described above, mechanical processing becomes difficult to handle, resulting in problems such as conveyed material blockage or difficulty in detecting the overlap of the conveyed material by sensors.

[0009] Furthermore, in the prior art, sometimes a covered structure with a cross-section consistent with the shape of the conveyed material is formed by setting a cover on the conveying path at the end of the conveyed material that outputs towards the supply destination, thereby preventing the conveyed materials from overlapping or supplying conveyed materials in different postures. However, even in such cases, the following problem exists: because the conveyed materials become smaller and thinner, they are prone to clogging in the covered structure, making it difficult to maintain a stable conveying state.

[0010] Regarding the above-mentioned problems, especially in the case of vibrating conveyor devices, since the conveyed material moves up and down in the conveying path while vibrating, it is extremely difficult to prevent blockage or detect overlap of the conveyed material in the conveying path.

[0011] Therefore, the present invention was made to solve the above-mentioned problems. Its objective is to provide a conveying control system that can avoid conveying defects such as blockage of conveyed materials and detection defects of overlapping states of conveyed materials, as well as a conveying device using the conveying control system.

[0012] In view of the above facts, the conveying control system of the present invention comprises: an image acquisition unit that repeatedly acquires images of a measurement area (ME) on a conveying path (121) for conveying a conveyed object (CA) by means of an image capture unit; a conveyed object occupancy range discrimination unit that detects a continuous occupancy range (121CT) within the measurement area (ME) and determines the size of the continuous occupancy range (121CT) based on a unit occupancy range (121U) equivalent to one of the conveyed objects (CA), wherein the continuous occupancy range (121CT) refers to a range in which the occupancy area of ​​the conveyed object (CA) on the conveying path (121) is connected as one unit, or a range in which the occupancy area is continuous at intervals less than a predetermined value; and a conveying object control unit that controls the conveying state of at least one of the conveyed objects (CA) disposed within the continuous occupancy range (121CT) when the continuous occupancy range (121CT) satisfies the condition of improper judgment based on the unit occupancy range (121U).

[0013] According to the present invention, the size of the continuous occupancy range of the conveyed items on the conveying path is determined based on the unit occupancy range. For example, if the size of the continuous occupancy range exceeds the unit occupancy range, there is a high probability that two or more conveyed items on the conveying path will overlap. Furthermore, if the continuous occupancy range includes multiple occupancy areas with intervals less than a predetermined value, and the overall size of these areas exceeds the unit occupancy range, there is a high probability that the preceding and following conveyed items will subsequently overlap. Therefore, when the probability of the conveyed items overlapping is high, or the probability of overlap is high, by controlling at least one conveyed item disposed within the continuous occupancy range, overlapping conveyed items or conveyed items with a high probability of overlap can be removed from the conveying path. In addition, the conveyed item occupancy range identification unit only needs to determine the size of the continuous occupancy range of the conveyed items on the conveying path based on the unit occupancy range. Therefore, it is not necessary to detect the overlap of the conveyed items themselves as in the prior art. Thus, the possibility or probability of conveyed item overlap can be easily and reliably identified, regardless of whether the conveyed items are fine or thin. In particular, if it is a vibrating conveyor, the conveyed material moves up and down on the conveyor path while being conveyed. However, since the area occupied by the conveyed material on the conveyor path is not easily affected by the up and down movement, the detection accuracy can be avoided due to the vibration of the conveyed material.

[0014] In this invention, it is preferable that the transport object occupancy range discrimination unit determines the occupancy range when viewed from a specific direction where two or more transport objects (CA) are more likely to overlap on the transport path (121) compared to other directions. This makes it easier and more reliable to detect overlap of transport objects on the transport path. In this case, it is preferable that the image acquisition unit's shooting direction is the specific direction. This simplifies image processing for determining the occupancy range and improves discrimination accuracy. The aforementioned specific direction sometimes refers to, for example, the height direction where the height dimension of the transport object among its longitudinal, transverse, and height dimensions on the transport surface of the transport path has its minimum value.

[0015] In this invention, it is preferable that the transport control unit applies a rejection force to the portion of the unit occupying range (121U) that is located in the forward direction of the transport direction, compared to the portion where the unit occupying range (121U) is assumed to be within the continuous occupying range (121CT). Thus, by continuing to transport the transported portion in front of overlapping or closely spaced transported goods, while applying a rejection force to the transported portion in the rear, the overlapping transported goods can be easily separated by the direction of transport, thereby enabling easy and reliable removal of the overlap.

[0016] In this invention, the measuring area (ME) is preferably located at the end (121e) of the conveying path (121). This allows for the detection and resolution of overlapping or proximity of the conveyed items at the downstream end of the conveying path, ensuring that the conveyed items are neatly arranged towards the supply destination and preventing blockages at the transfer section towards the supply destination. In this case, the image acquisition unit preferably also includes a conveyed item reception capability detection unit. This unit acquires an image captured by the imaging unit, including the measuring area (ME) and the receiving section (21a) at the supply destination from the end (121e) where the conveyed item (CA) is supplied, and processes the image to detect whether the receiving section (21a) can receive the conveyed item (CA). Therefore, it is possible to detect whether the receiving section at the supply destination can receive the conveyed item based on an image including the end, thus enabling control of the supply destination or responses to supply stoppages relative to the supply destination without the need for an additional imaging unit.

[0017] In this invention, preferably, the transport occupancy range identification unit has a detection area (Ls) within the measurement area (ME). The detection area (Ls) is fixed along the transport direction (F), and the continuous occupancy range (121CT) that satisfies the condition for improper judgment must occupy the detection area (Ls). Thus, the transport occupancy range identification unit makes an improper judgment when the continuous occupancy range occupies (fully includes) the detection area fixed along the transport direction within the measurement area. Therefore, the detection position within the measurement area at the time of improper judgment is fixed in the transport direction. Consequently, the moment when the transport reaches a consistently relatively constant position can be used as the judgment moment, thus simplifying the management of the transport control timing, etc.

[0018] In this invention, the image acquisition unit preferably takes continuous pictures at a predetermined shooting interval (Ts) via the shooting unit, and the measurement area (ME) is pre-set to include all the transported items (CA) passing through the transport path (121) based on the relationship between the transport speed (Vs) of the transported items (CA) and the shooting interval (Ts). Therefore, even if the arrival time of the transported items is inconsistent with the shooting time, since all transported items are necessarily positioned within the measurement area of ​​any image, all transported items can be detected simply by processing each image within the measurement area to detect them. This eliminates the need to generate trigger signals for detecting the position of each transported item as in the prior art, thus eliminating the need for sensors for detecting the transported items and allowing for a simple configuration of the detection unit. Therefore, based on the fact that in the case of continuous transported items, there is no need to consider the detection omission of each transported item, and therefore no need to pre-form gaps between transported items, high-speed or high-density transport of transported items becomes easy, and the overall configuration of the detection system can be easily constructed. Furthermore, since only image data within a pre-defined measurement area from multiple consecutively captured images can be processed, image measurement processing for determining the CA of the transported object can be performed at high speed and with high accuracy. Moreover, this configuration can also be achieved through general video recording, provided the above conditions are met.

[0019] In the above case, preferably when the length of one of the conveyed objects in the conveying direction (F) is set to L, the shooting period is set to Ts, and the conveying speed is set to Vs, when n = a natural number from 1 to 10 and β = Ts·Vs, the length LD of the measurement area (ME) in the conveying direction (F) along the conveying path (121) has the following value.

[0020] LD≥L+n·β=L+n·Ts·Vs

[0021] Therefore, since the continuous occupancy range of all transported items is continuously detected based on their status within the area along the transport direction in any image data, and it is determined whether the unit occupancy range is exceeded, reliable judgment can be made regardless of the type of transported item. Here, it is further preferred that n be in the range of 3 to 7.

[0022] In this case, it is further preferred that, when the continuous occupying range (121CT) that satisfies the condition of improper judgment is necessarily occupied by a detection area (Ls) fixed along the conveying direction (F) and set within the measurement area (ME), the shooting interval (Ts) is set according to the conveying speed (Vs) so that all the continuous occupying ranges (121CT) that satisfy the condition of improper judgment will be photographed when occupying the detection area (Ls). Specifically, when improper judgment is made on the continuous occupying range (121CT) of the length (Lct) of the conveying direction (F) based on the unit occupying range of the same length (L) in the detection area, if the same length (Ls) of the detection area is used, and the length of the continuous occupying range (121CT) in the conveying direction (F) is Lct=Ls+ΔLt (ΔLt>0), then as long as ΔLt≥β=Ts·Vs holds, an image of the continuous occupying range configured in the area can definitely be obtained. Therefore, it is possible to detect the continuous occupying range of all transported items using any captured image.

[0023] In this invention, it is preferable to further include: a light-transmitting area (121c) formed on the transport surface (121a, 121b) of the transport path (121) within the measurement area (ME), and a back-side illumination unit that irradiates light from the back side of the transport surface (121a, 121b) to the imaging unit side through the light-transmitting area (121c); the transport object occupancy range discrimination unit detects the size of the continuous occupancy range (121CT) within the measurement area (ME) relative to image data within the measurement area (ME) using information representing the range of the light-blocking portion or the non-light-blocking portion of the light-transmitting area (121c) covered by the transport object (CA). Therefore, in the image data of the measurement area obtained by the image acquisition unit, by using the back-side illumination unit to illuminate the light-transmitting area towards the imaging unit, information representing the range of the light-blocking or unblocked portion of the light-transmitting area that is covered by the transported object is extracted. This information is then used to detect the size of the continuous occupancy range within the measurement area, thereby making the image processing easier and more reliable. Thus, the identification and processing of the occupancy range of the transported object can be achieved quickly and with high precision. Specifically, a continuous occupancy range smaller than a unit occupancy range does not occupy the entire detection area, while a continuous occupancy range that meets the conditions for improper judgment occupies the entire detection area. Therefore, a judgment is made based on whether the continuous occupancy range occupies the entire detection area.

[0024] In this case, it is preferable that the light-transmitting area (121c) is narrower than the width of the transported object (CA) on the transport path (121). According to this invention, in the image data of the measurement area obtained by the image acquisition unit, the light-transmitting area through which light is transmitted to the imaging unit side using the back-side illumination unit is limited to a width narrower than the width of the transported object, thereby suppressing the amount of light from the back-side illumination. Therefore, it is possible to better extract the surface morphology of the transported object from the image information captured by the imaging unit. Furthermore, when the width of the transported object changes due to the posture of the transported object on the transport path, the light-transmitting area only needs to be formed to be narrower than the maximum width. However, it is more preferable that the light-transmitting area is narrower than all widths corresponding to the postures that the transported object can take on the transport path.

[0025] In this invention, the light-transmitting area (121c) is sometimes configured as a slit-shaped form that is longer than the length of the conveyed object (CA) in the conveying direction. In this case, by having the conveyed object block a portion of the slit-shaped light-transmitting area extending along the conveying direction, the position range of the conveyed object can be determined more easily and reliably based on the extent of the light-blocking or unblocked portion of the light-transmitting area blocked by the conveyed object. In this case, it is preferable that the light-transmitting area (121c) is formed over the entire range of the measuring area (ME) in the conveying direction. Thus, since the light-blocking or unblocked portion can be determined at any point in the measuring area along the conveying direction, the presence or absence and position range of the conveyed object are more easily determined.

[0026] Furthermore, the light-transmitting area (121c) is sometimes composed of a group of multiple light-transmitting areas (121g to 121i) arranged within the measurement area (ME). In this case, by observing whether any one of the multiple light-transmitting areas is blocked by the transported object, the position range of the transported object (CA) can be easily and reliably determined. In particular, the light-transmitting areas are preferably arranged along the transport direction, and can also be arranged along the width direction, or both directions. In this case, it is preferable that the light-transmitting areas are arranged throughout the entire range of the measurement area (ME) in the transport direction. Thus, since the blocked or unblocked portion can be determined at any point in the transport direction of the measurement area, it is easier to determine the presence or absence and position range of the transported object. In these cases, it is preferable that the light-transmitting areas (121g to 121i) are shorter than the length of the transported object (CA) in the transport direction. By arranging multiple light-transmitting areas smaller than the transported object in the transport direction, the light-transmitting area is further defined, thus enabling easier extraction of image information of the surface captured by the imaging unit.

[0027] In this case, the plurality of light-transmitting areas (121g to 121i) of the preferred light-transmitting area (121c) include: a first light-transmitting area (121h) and a second light-transmitting area (121i) formed to be included within a length range in the transport direction of the unit occupied area, and a third light-transmitting area (121g) having a portion that is not covered when the first light-transmitting area (121h) and the second light-transmitting area (121i) are covered in the unit occupied area (121U). Thus, it is possible to determine whether the continuous occupied area exceeds the unit occupied area based on whether the uncovered portion (or at least a portion thereof) of the third light-transmitting area is covered when both the first and second light-transmitting areas are covered. At this time, the discrimination accuracy of whether the continuous occupied area exceeds the unit occupied area can be determined based on the size of the uncovered portion (or at least a portion thereof) of the third light-transmitting area or the detection accuracy of the uncovered portion.

[0028] In this invention, it is preferable that the conveyor path (121) is vibrated in a reciprocating manner along the conveying direction (F) of the conveyed object (CA) to transport the object, while the imaging unit is stationary. The position of the measurement area (ME) within the captured image (GPX) is corrected to eliminate positional variations relative to the conveyor path (121) within the captured image (GPX) caused by the vibration of the conveyor path (121) during imaging. Thus, since positional shifts relative to the conveyor path in the image processing area of ​​the captured image caused by the vibration of the conveyor can be eliminated, image processing position shifts caused by such positional shifts can be prevented, thereby enabling the object occupancy range identification processing to be performed at a certain position on the conveyor path. Therefore, improper control of the object caused by the aforementioned positional shifts can be avoided, allowing for reliable and accurate control of the object.

[0029] In this case, it is preferable that the transport object occupancy range identification unit detects the position of a specific part (121y) on the transport path (121) captured in the captured image through image measurement processing, and corrects the position of the measurement area (ME) based on this position. Alternatively, the positional offset relative to the transport path caused by the vibration of the transport path can be calculated in each captured image using preset values ​​of the vibration amplitude and vibration period of the transport path, and the position of the measurement area in the captured image can be corrected based on this positional offset. However, by detecting the position of a specific part on the transport path in the captured image through image processing, corrections can be made that correspond to the vibration mode of the actual transport object appearing in the captured image. Therefore, the position of each area can be set reliably and with high accuracy. As a specific part on the transport path, various parts captured in the image (position display marks shown on the transport path) can be used.

[0030] Next, the conveying device of the present invention is characterized in that it has the above-described conveying control system and a conveying mechanism having the conveying path (121).

[0031] In this invention, the conveying mechanism preferably includes an excitation unit that vibrates the conveying path (121) and an excitation control unit that controls the driving mode of the excitation unit. Examples of driving modes controlled by the excitation control unit include stopping the excitation unit's drive, changing the excitation unit's drive frequency, and changing the drive voltage. This allows for adjustment of the conveying mode of the conveyed material (conveying speed, stability of the conveying posture, etc.).

[0032] (Invention effect)

[0033] According to the present invention, the following excellent effect can be achieved: by processing the captured image of the conveyed object and identifying the size of the continuous occupancy range of the conveyed object based on the unit occupancy range, it is possible to avoid poor conveying conditions such as blockage of the conveyed object and poor detection of the overlap state of the conveyed objects. Attached Figure Description

[0034] Figure 1 This is a top view of an embodiment of a conveying device (vibrating conveying device) equipped with the conveying control system of the present invention.

[0035] Figure 2 This is the front view of this embodiment.

[0036] Figure 3 This is a perspective view of this embodiment.

[0037] Figure 4 (a) is an enlarged perspective view showing the end portion of the conveying path and its surrounding area in this embodiment, and (b) is an enlarged perspective view showing the end portion of the conveying path further enlarged.

[0038] Figure 5 (a) is a side view of the end portion of the conveying path in this embodiment, and (b) is an enlarged side view illustrating region B within side view (a).

[0039] Figure 6(a) is a top view showing the structure of the end of the conveying path and the receiving part of the indexing table of the inspection device for supplying the destination in this embodiment. Figure 6(b) is a longitudinal sectional view showing the structure of the end of the conveying path and the receiving part of the indexing table of the inspection device for supplying the destination.

[0040] Figure 7(a) is an explanatory diagram showing the state of the first embodiment when the end of the conveying path and the receiving part of the indexing worktable of the inspection device for supplying the destination correspond to a single conveyed item, and (b) is an explanatory diagram showing the state of the first embodiment when the conveyed items correspond to an overlapping state.

[0041] Figure 8 (a) is an explanatory diagram showing the state of the second embodiment when the end of the conveying path and the receiving part of the indexing worktable of the inspection device for supplying the destination correspond to a single conveyed item, and (b) is an explanatory diagram showing the state of the second embodiment when the conveyed items correspond to an overlapping state.

[0042] Figure 9 Figures (a) to (e) are explanatory diagrams showing the conveying state and processing method of overlapping conveyed items in the receiving section of the indexing worktable of the inspection device for supplying the destination at the end of the conveying path in this embodiment.

[0043] Figure 10 This is a schematic block diagram showing the overall configuration of this embodiment.

[0044] Figure 11 This is a simplified flowchart representing the overall control steps of the operation procedure in this embodiment.

[0045] (Symbol Explanation)

[0046] 10… conveying device; 11… feeder; 110… conveying body; 111… conveying path; 12… linear feeder; 120… conveying body; 121… conveying path; 121a, 121b… conveying surface; 121c… light-transmitting area; 121d… through hole; 121e… (the end of the conveying path); 121g~121j… light-transmitting area; 121gy, 121gz, 121gv, 121hy, 121iy… image portion; 12 2…Recovery path; 122a…Receiving face; 122b…Peripheral part; 122c…Merging part; 121CT…Continuous occupancy range; 121U…Unit occupancy range; 121y…Identification part; 121X…Bottom block; 121Y…Side block; 122X…Recovery block; 131, 141…Support platform; 132, 142…Support arm; 133…Camera mounting part; 143…Lighting mounting part; L…Length of conveyed material (unit occupancy range); LD…range; Ls…length of the detection area in the conveying direction; Lct…length of the continuously occupied area in the conveying direction; Ts…shooting interval; Vs…conveyor speed; W…width of the conveyed object; 130CM (CM1, CM2)…camera device; 140BL…backside lighting device; BLa…illumination light; OP…air nozzle (for overlap removal); SP…air nozzle (for supply stop); OPa, SPa…deformed corner; CA, CA0, CA1~CA3…conveyed object; CL11, CL12…controller; DTU…inspection and processing unit; DP1, DP2…display device; F… Conveying direction; G…gap; GP1, GP2…image processing device; GM1, GM2…image processing memory; GPX…captured image; GPY…image area; MPU…processing unit; MM…main storage device; ME…measuring area; SP1, SP2…operation input device; RAM…processing memory; 20…(supply to destination)inspection device; 20a…support section; 20a1…upper plate; 20a2…window section; 20a3…lower plate; 21…indexing table; 21a…receiving section; 21d…storage section; 21f…light-transmitting area section; 21fy…image section; α…angle. Detailed Implementation

[0047] Next, embodiments of the conveying control system and conveying device according to the present invention will be described in detail with reference to the accompanying drawings. First, referring to... Figure 10 The basic structure of the conveying device according to the present invention will be described. Figure 10 This is a schematic diagram showing the configuration of the drive control system and the conveying control system of the conveying device 10.

[0048] The conveying device 10 is a vibrating conveying device that includes a feeder 11 and a linear feeder 12 as a conveying mechanism. The feeder 11 has a bowl-shaped conveying body 110 with a spiral conveying path 111, and the linear feeder 12 has a conveying body 120 with a straight conveying path 121. This straight conveying path 121 has an inlet configured to receive the conveyed material from the outlet of the conveying path 111 of the feeder 11. In the conveying control system of this embodiment, the conveyed material CA on the conveying path 121 of the linear feeder 12's conveying body 120 is detected based on a captured image (GPX), and the detected image portion is used as the object for inspection and judgment. Here, the conveying control system of this embodiment includes not only the corresponding part of the conveying control system with the configuration of the present invention, but also various inspection units, identification units, screening units, and flipping units for identifying the posture of the conveyed material and arranging it neatly. Furthermore, in the present invention, the configuration, not limited to a vibrating conveying device, can be used in various conveying devices that convey the conveyed material CA along a conveying path. Furthermore, even with vibrating conveyors, the combination of feeder 11 and linear feeder 12 described above is not limited; other types of conveyors, such as circulating feeders, can also be used. Moreover, even in the above combination, the conveyed material CA on the conveying path 121 of the linear feeder 12 can be inspected, identified, screened, or flipped; the conveyed material CA on the conveying path 111 of the feeder 11 can also be inspected.

[0049] The feeder 11 is driven and controlled by the controller CL11. Similarly, the linear feeder 12 is driven and controlled by the controller CL12. The controllers CL11 and CL12 provide AC drive to the excitation unit (including an electromagnetic drive or a piezoelectric drive, etc.) of the feeder 11 or the linear feeder 12, causing the conveyor bodies 110 and 120 to vibrate in a manner that moves the conveyed material CA in the conveying paths 111 and 121 toward a predetermined conveying direction F. Furthermore, the controllers CL11 and CL12 are connected via input / output circuits (I / O) to an inspection and processing unit (DTU) with image processing capabilities, which forms the core of the conveying control system.

[0050] Furthermore, when controllers CL11 and CL12 perform a prescribed operation input (debugging operation) to the processing unit MPU (described later) via operation input devices such as mice (SP1, SP2, etc.), which execute the following action procedure, they stop the drive of the transport device 10 according to the aforementioned action procedure. At this time, according to the aforementioned action procedure, for example, the image measurement processing in the inspection processing unit DTU is also stopped. The debugging operation and the operation of each part corresponding to this operation will be described in detail later.

[0051] The inspection processing unit (DTU) is based on a processing unit (MPU) (microprocessor) such as a personal computer. In the example shown, the MPU consists of a central processing unit (CPU1), a CPU2, a cache memory (CCM), a memory controller (MCL), and a chipset (CHS). The DTU also includes image processing circuits GP1 and GP2, which are connected to cameras CM1 and CM2, which serve as imaging units. These circuits are also connected to image processing memories GM1 and GM2. The outputs of GP1 and GP2 are connected to the MPU, processing image data (GPX) captured from cameras CM1 and CM2 and transmitting the appropriately processed image (e.g., image data within image area GPY, described later) to the MPU. The main memory (MM) stores the operation program for the transport control system. When the DTU is activated, the MPU reads and executes this operation program. In addition, the main storage device MM stores image data of the captured image GPX or image area GPY, which are objects of the image measurement processing described later performed by the arithmetic processing unit MPU.

[0052] Furthermore, the inspection processing unit (DTU) is connected to display devices DP1, DP2 or operation input devices SP1, SP2, such as LCD monitors, via input / output circuits (I / O). Display devices DP1, DP2 display image data (GPX or GPY of the captured image area) and image measurement processing results processed by the aforementioned processing unit (MPU) in a prescribed display mode. That is, in addition to the transport object occupancy area identification processing described later, the results of transport object detection processing and transport object identification processing in each part are also displayed in a prescribed display mode. Moreover, this display function is not limited to actual transport of transported objects; as described later, it also functions when reading and reproducing past data. Furthermore, by observing the screens on display devices DP1, DP2 while operating the operation input devices SP1, SP2, various operation commands, setting values, and other processing conditions can be input into the aforementioned processing unit (MPU).

[0053] Furthermore, in this embodiment, such as Figure 10The diagram schematically illustrates the following: two cameras CM1 and CM2, two image processing circuits GP1 and GP2, two image processing memories GM1 and GM2, two display devices DP1 and DP2, and two operation input devices SP1 and SP2. However, this is only one example; each component may be provided individually, or even in more than three configurations. In this embodiment, a specific camera device 130CM is provided as an additional device besides the aforementioned cameras CM1 and CM2. Hereinafter, only the image processing of the transport object occupancy range discrimination based on images captured by this camera device 130CM will be described.

[0054] Figures 1 to 5 It is a detailed representation Figure 10 The diagram shows an example of the conveying mechanism of this embodiment. In this embodiment, the conveying material CA is supplied to a receiving section 21a, which is a portion of an indexing table 21 configured to rotate in steps, with the end portion 121e of the conveying path 121 of the linear feeder 12 supported on a support 20a of an inspection device 20, which is the destination of the conveyed material CA. Figure 4 As shown, the indexing table 21 has multiple receiving sections 21d arranged along its outer periphery. Each receiving section 21d is concave, capable of receiving a single transport item CA. When positioned corresponding to the end of the end portion 121e of the transport path 121, each receiving section 21d constitutes a receiving section 21a for the transport item CA in the inspection device 20. Furthermore, although not shown in the figure, each receiving section 21d is provided with a vacuum suction path for attracting, receiving, and holding the transport item CA. Additionally, the inspection device 20 repeatedly performs a stepping action whereby, when a transport item CA is supplied from the end portion 121e to the receiving section 21a, the indexing table 21 rotates, causing the next receiving section 21d to move to the position of receiving section 21a, awaiting the movement of the next transport item CA. Furthermore, the inspection device 20, as an example of a supply destination, is omitted from the figure except for the parts related to the receiving section 21a. In addition to the inspection device 20, various devices such as substrate mounting devices and pick-and-place units for transferring loads to other parts can be considered as the destination for supply.

[0055] In the conveying mechanism of this embodiment, there is a support platform 131 fixed to a base composed of a vibration damping platform, a support arm 132 fixed to the support platform 131, and a camera mounting part 133 supported by the support arm 132. A camera device 130CM is mounted on the camera mounting part 133 with its shooting direction facing downwards. The camera device 130CM has a shooting range capable of simultaneously capturing images of the end portion 121e of the conveying path 121 located below it and the receiving part 21a of the inspection device 20. The camera device 130CM is fixed by a vibration damping platform to prevent direct impact from vibrations of the conveying mechanism. On the other hand, at a position below the end portion 121e and the receiving part 21a, such as... Figure 2 As shown, the device includes a support platform 141 fixed to a base consisting of a vibration damping platform, a support arm 142 fixed to the support platform 141, and an illumination mounting section 143 supported by the support arm 142. A rear-side illumination device 140BL is mounted on the illumination mounting section 143. The rear-side illumination device 140BL has an illumination range capable of simultaneously illuminating the end portion 121e of the conveyor path 121 and the receiving portion 21a of the inspection device 20. The rear-side illumination device 140BL is also fixed via a vibration damping platform to prevent it from being directly affected by vibrations from the conveyor mechanism. Furthermore, the configuration of the camera device 130CM and the rear-side illumination device 140BL is not particularly limited; for example, they can be installed upside down.

[0056] Figure 4 (a) is an enlarged perspective view showing the junction area of ​​the conveyed item CA formed by the end portion 121e of the conveying path 121 and the receiving portion 21a of the inspection device 20, and (b) is a perspective view showing a further enlarged portion thereof. Additionally, Figure 5 (a) is a side view showing the state of the end portion 121e of the linear feeder 12 as viewed from the destination side, and (b) is an enlarged side view showing its central region B. The end portion 121e of the conveying path 121 is composed of a bottom block 121X constituting the conveying surface 121b and a side block 121Y constituting the conveying surface 121a. In this case, the cover block that is usually installed on the end portion 121e of the conveying path 121 is not present, and therefore, a culvert structure is not formed in the end portion 121e. This is because if the conveying path 121 is formed as a culvert structure, the conveyed material CA in the end portion is prone to blockage in the case of small or thin conveyed materials, especially in the case of a vibrating conveyor mechanism like this embodiment, where blockage often occurs. The absence of this cover block and culvert structure is also suitable for photographing the end portion 121e or for back lighting.

[0057] The conveyor path 121 includes a conveyor surface 121a and a conveyor surface 121b. The conveyor surface 121a has a steep inclination angle, and the conveyor surface 121b is approximately orthogonal to the conveyor surface 121a and has a gentle inclination angle. Figure 4 (b) and Figure 5 As shown in (b), the conveyor CA has a fine and thin structure. Examples of such conveyor CAs (CA0, CA1, CA2) include surface-mount electronic components. In terms of dimensions, examples include a thickness t of approximately 60 μm, a length L of approximately 1.0 mm, and a width W of approximately 0.5 mm. This thin conveyor CA is conveyed with its thickness along the vertical direction shown in the figure, and its bottom surface facing the conveyor surface 121b. In the example shown, the width of the conveyor surface 121b is slightly smaller than the width W of the conveyor CA. Furthermore, the edge of the conveyor surface 121b opposite to the conveyor surface 121a is configured with an adjacent gap G. The edge of the conveyor surface 121b is positioned opposite to the edge (receiving surface 122a) of the recovery block 122X, which conveys the conveyor CA in a direction opposite to the conveying direction, returning the conveyor CA to the upstream portion of the conveyor paths 111 and 121 via the gap G. Since the bottom block 121X and side block 121Y constituting the conveying path 121 vibrate in different directions and phases than the recovery block 122X constituting the recovery path 122, they must be separated from each other, hence the aforementioned gap G is provided. However, in this embodiment, this gap G constitutes one of a plurality of light-transmitting areas 121g, wherein the plurality of light-transmitting areas constitute a light-transmitting area 121c through which the illumination light BLa of the rear-side illumination device 140BL is transmitted to the camera device 130CM. Furthermore, as... Figure 5 As shown in (b), the conveying surface 121b of the conveying path 121 is inclined at a small angle α toward the conveying surface 121a relative to the horizontal plane, thereby holding the conveyed item CA within the conveying path 121. Furthermore, as... Figure 4 As shown, the recovery path 122 includes: a receiving surface 122a adjacent to the gap G and having a height approximately the same as the conveying surface 121b; a peripheral portion 122b adjacent to the receiving surface 122a across a stepped portion and inclined toward the recovery direction of the recovery path 122; and a confluence portion 122c adjacent to the peripheral portion 122b in a further recovery direction and extending to a portion parallel to the upstream side of the conveying path 121. The conveyed material CA collected in the confluence portion 122c returns through the recovery path 122 to the upstream portion of the conveying path 121 of the linear feeder 12 or to the feeder 11.

[0058] On the conveying surface 121a, an overlap release nozzle OP is formed at the end portion 121e. This nozzle OP is used to discharge the conveyed material CA towards the receiving surface 122a of the recovery path 122 via the aforementioned gap G. The nozzle OP is connected to an airflow source such as a compressor or compression pump via an airflow channel penetrating the side block 121Y and an on / off valve such as a solenoid valve (not shown). Furthermore, on the end side closer to the supply destination than the nozzle OP, a supply stop nozzle SP is formed to prevent the conveyed material CA from being supplied to the supply destination. This nozzle SP is also connected to the airflow source separately from the nozzle OP via an airflow channel and an on / off valve. Deformed corner portions OPa and SP are provided on the opening edges of the end sides of the nozzles OP and SP. These deformed corner portions OPa and SP are chamfered and rounded to prevent the conveyed material CA from getting stuck. Additionally, a notch-shaped marking portion 121y is formed on the side edge of the end side of the side block 121Y. The marking section 121y, as described below, is a marker used to detect the position in the conveying direction F based on the vibration of the conveying path 121 in an image captured by the camera device 130CM.

[0059] Figures 6(a) and 6(b) are enlarged top views and longitudinal sectional views illustrating the end portion 121e and the receiving portion 21a, respectively. The support portion 20a includes an upper plate 20a1 and a lower plate 20a3. The upper plate 20a1 covers the indexing table 21, which is rotatably configured inside the support portion 20a, and the lower plate 20a3 is positioned below the indexing table 21. A window 20a2 is formed in the upper plate 20a1 at a portion corresponding to the receiving portion 21a, allowing the receiving portion 21a to capture images from the camera device 130CM side. Furthermore, a light-transmitting area 21f is formed on the lower plate 20a3, and it is configured to allow the camera device 130CM to capture the illumination light BLa of the rear-side illumination device 140BL through the light-transmitting area 21f. Here, the captured image GPX or image area GPY is the image shown in the top view of Figure 6(a).

[0060] At the end portion 121e of the conveying path 121 of the linear feeder 12, the conveying path 121 is formed by conveying surfaces 121a and 121b. The conveying surface 121b is adjacent to the receiving surface 122a of the recovery path 122 across the aforementioned gap G. The gap G forms a light-transmitting area 121g, and is configured similarly to the aforementioned light-transmitting area 21f, such that the illumination light BLa of the back-side illumination device 140BL can pass through, allowing the illumination light BLa to be captured by the aforementioned camera device 130CM. On the conveying surface 121b, a plurality of light-transmitting areas 121h and 121i are formed from the end towards the upstream side. These light-transmitting areas 121h and 121i are also configured similarly to the aforementioned, such that the illumination light BLa of the back-side illumination device 140BL can pass through, allowing the illumination light BLa to be captured by the aforementioned camera device 130CM.

[0061] Next, an embodiment of the basic conveyed item occupancy range identification processing of the conveying device 10 using the conveying control system described in this embodiment will be described. In the top view shown in FIG6(a), a measurement area ME including the conveying path 121 (end portion 121e) is provided, and a light-transmitting area 121c including the light-transmitting areas 21f, 121g, 121h, and 121i is provided in the measurement area ME. In this measurement area ME, by performing image processing on the image portions 21fy, 121gy, 121gz, 121gv, 121hy, and 121i corresponding to the light-transmitting areas 21f, 121g, 121h, and 121i, it is possible to detect whether there is a conveyed item CA (or its occupancy range) in the end portion 121e and the receiving portion 21f.

[0062] As a prerequisite for constructing the embodiment, the processing content of the inspection processing unit DTU and the setting of the measurement area ME shown in FIG. 6(a) will be explained. In this embodiment, since it is necessary to perform transport object occupancy range identification processing on the captured image GPX or image area GPY obtained as described above through image processing within the measurement area ME, it is necessary to detect the occupancy status of the transport object CA on the transport path based on the image data within the measurement area ME. Therefore, all transport objects CA passing through the transport path 121 must be captured within the aforementioned measurement area ME of either the captured image GPX or the image area GPY. Thus, as a constraint related to the transport speed Vs of the transport object CA and the shooting interval Ts, the measurement area ME must at least satisfy the following conditions.

[0063] In this embodiment, the camera device 130CM continuously captures images at a preset shooting cycle. Similar to the images from cameras CM1 and CM2, in each shooting cycle, the captured image GPX or the image data within the aforementioned image area GPY is transmitted to the aforementioned computing processing unit MPU via image processing devices GP1 and GP2. In the computing processing unit MPU, the image data within the measurement area ME in the transmitted image data is processed as described above using a processing memory RAM to perform object occupancy range identification processing. However, in this embodiment, instead of separately setting a trigger sensor or searching for a predetermined shape pattern of the object CA from the image data of the object CA within a specified area and generating an internal trigger when the shape pattern is detected, shooting is continuously performed at a predetermined shooting cycle by introducing an external trigger indicating a predetermined shooting cycle or by outputting a trigger signal of a certain cycle from the computing processing unit MPU to the camera device 130CM. Therefore, in order to identify all transported items CA on transport path 121 without omission, all transported items CA need to be included in the measurement area ME in any captured image GPX or image area GPY.

[0064] Therefore, when the shooting period is set to Ts[sec], the length of the conveying direction F of the conveyed object CA is set to L[mm], and the conveying speed of the conveyed object CA is set to Vs[mm / sec], the range LD on the conveying direction F of the measurement area ME is set as follows (1) so that the images of all conveyed objects CA are necessarily contained within the above measurement area ME of any image data.

[0065] LD≥L+β=L+Ts·Vs…(1)

[0066] For example, if the length L of the conveyed object CA 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 and β = 0.05 mm, thus LD ≥ 0.65 mm. Alternatively, if the shooting period Ts is set to 0.5 msec, then L = 0.6 mm and β = 0.025, thus LD ≥ 0.625 mm.

[0067] In reality, for each individual, the conveying speed of the conveyed item CA will vary depending on the location or the passage of time. Therefore, it is preferable to set the conveyed item CA, in whole or in part, 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 LD is set in such a way that the following formula (2) holds.

[0068] LD≥L+n·β=L+n·Ts·Vs…(2)

[0069] In this embodiment, n is set to a range of 3 to 7. This is because if n is small, the possibility of the transported material CA being missed due to deviations in transport speed increases; conversely, if n is large, the image processing load increases. Generally, it is preferable that the natural number n is in the range of 1 to 10. Furthermore, in this embodiment, the image processing time is generally around 150 μsec to 300 μsec. In addition, the shooting interval Ts is around 500 μsec to 840 μsec.

[0070] Furthermore, in this embodiment, as described above, a trigger signal for detecting the arrival of the transported object CA in the measurement area ME is not used. Therefore, it is possible that the transported object CA may not be positioned within the measurement area ME of a captured image GPX or image area GPY at all. Therefore, when performing image measurement processing within the measurement area ME, it is necessary to detect whether the image of the transported object CA is contained within the measurement area ME. Then, when the transported object is detected under predetermined conditions during the transported object detection process, that is, when the transported object CA is entirely contained within the measurement area ME, the aforementioned transported object occupancy range identification process may be performed; otherwise, the transported object occupancy range identification process may not be performed. However, in this embodiment, since the image measurement processing is performed at the end portion 121e of the transport path 121, since the transported object CA is transported at high density in most cases, it may not be performed as described above. In addition, when the same transported object CA is detected multiple times within the measurement area ME, the transported object occupancy range identification process may be performed only once (e.g., the first time), and the transported object occupancy range identification process may be omitted for the other times. However, in the embodiments described later, the detection of the continuous occupancy range 121CT is performed only in the area further defined within the measurement area ME, i.e. the detection area where the light-transmitting area 121c is configured. Therefore, even if the continuous occupancy range 121CT is captured in the measurement area ME of multiple images, the number of times the transport object occupancy range identification processing is performed is limited.

[0071] In this embodiment, two specific examples will be described below as the execution of the above-described object occupancy range identification process. In the first example, the image portions 21fy, 121gy, 121gz, 121hy, and 121iy within the measurement area ME are taken as the objects of image processing. Figure 7(a) and (b) illustrate the method of identification. In this case, if the image portions 121gy, 121gz, 121hy, and 121iy corresponding to the four light-transmitting areas are all simultaneously blocked by the transport object CA, it is determined that multiple transport objects CA overlap or are transported in a close-fitting state. This is because the terrain corresponding to the length L in the transport direction F and the width W in the width direction of the transport object CA is such that the light-transmitting areas corresponding to the three image portions 121gy, 121hy, and 121iy are formed within the unit occupied area 121U that is simultaneously blocked by a single transport object CA, while the light-transmitting area corresponding to the other image portion 121gz extends rearward from the aforementioned unit occupied area 121U. Therefore, as Figure 7 As shown in (a), when a single transported item CA passes through, the four image portions 121gy, 121gz, 121hy, and 121iy corresponding to the light-transmitting areas are not all simultaneously blocked. That is, in the example shown, the four light-transmitting areas are arranged in the entire detection area of ​​length Ls along the transport direction F, and this length Ls is longer than the length of the transported item CA along the transport direction F, i.e., the length L of the unit occupied area 121U. On the other hand, if two or more transported items CA are transported in an overlapping or close-fitting state, then as... Figure 7 As shown in (b), all four image portions 121gy, 121gz, 121hy, and 121iy corresponding to the light-transmitting area are simultaneously obscured. This is because the length Lct of the continuous occupancy range 121CT formed by the overlapping transport objects CA1 and CA2 in the transport direction F is longer than the length Ls of the detection area. Therefore, in this example, the configuration is such that it is possible to detect whether the size of the continuous occupancy range 121CT of the transport object CA exceeds the unit occupancy range 121U based on whether all four image portions 121gy, 121gz, 121hy, and 121iy corresponding to the light-transmitting area are simultaneously obscured. If the size of the continuous occupancy range 121CT exceeds the unit occupancy range 121U, an improper judgment is made.

[0072] Furthermore, in this first embodiment, an improper judgment is made only when all four image portions 121gy, 121gz, 121hy, and 121iy corresponding to the light-transmitting areas are confirmed to be completely obscured by image processing, indicating that at least two transport objects CA overlap or are being transported in close proximity. Therefore, it is necessary to capture an image in any of the images obtained by the inspection processing unit (DTU), which is equivalent to the image acquisition unit, showing that all four image portions are completely obscured. In other words, the image must be captured during the period when the continuous occupancy range 121CT that should be judged as improper occupies and obscures the detection area of ​​length Ls formed by the four light-transmitting areas. Therefore, when the range of the entire image portion corresponding to the four light-transmitting areas in the transport direction F is set to Ls = L + ΔL (ΔL > 0), in the length Lct = Ls + ΔLt (ΔLt > 0) of the continuous occupancy range 121CT that is judged as improper in the transport direction F, ΔLt ≥ β = Ts·Vs must be true.

[0073] Next, in the second embodiment, only the image portion 121gv set within a single light-transmitting area 121g is checked as the aforementioned measurement area ME. The continuous occupancy range 121CT of the transport object CA is detected based on whether the entire image portion 121gv is simultaneously obscured by the transport object CA, and whether this continuous occupancy range 121CT exceeds the aforementioned unit occupancy range 121U. The image portion 121gv is defined as the range of length Ls = L + ΔL in the light-transmitting area 121g formed by the aforementioned gap G along the transport direction F. Similarly, in this case, in the length Lct = Ls + ΔLt in the transport direction F of the continuous occupancy range 121CT, ΔLt ≥ β = Ts·Vs must be true.

[0074] In either the first or second embodiment described above, the length Ls of the detection area and the length L in the transport direction F of the unit occupied area 121U must satisfy the relationship Ls > L, so that a normal judgment can be obtained based on the transmission of a portion of the length Ls in the transport direction F of the detection area formed by the arrangement of light-transmitting areas. On the other hand, when a certain continuous occupied area 121CT that should be judged as improper is assigned, the value of ΔLt = Lct - Ls must be assigned according to the prescribed transport speed Vs, such that the shooting interval Ts satisfies ΔLt ≥ β = Ts·Vs, so that the continuous occupied area 121CT should be judged as improper. Conversely, when the shooting interval Ts is set relative to the prescribed transport speed Vs, if the continuous occupied area 121CT such that ΔLt ≥ β = Ts·Vs holds, then improper judgment can be reliably made. Therefore, it is summarized as follows.

[0075] A. The range within which reliable and normal judgments can be made: Lct < Ls

[0076] B. The range within which improper judgments can be reliably made: Lct ≥ Ls + β

[0077] C. The range that constitutes either a normal judgment or an inappropriate judgment: Ls ≤ Lct < Ls + β

[0078] From the above results, it can be seen that the judgment accuracy (resolution) is β = Ts·Vs. Furthermore, in the region C mentioned above, image processing can also be performed on the image components (surface morphology of the transport object CA) based on reflected light obtained through frontal side illumination (including ambient lighting), as described later, to make a judgment.

[0079] In any of the above embodiments, since the criterion for judgment is whether the size of the overall continuous occupancy range 121CT (the length in the conveying direction F in the example figure) exceeds the unit occupancy range 121U, improper judgments are made not only when multiple conveyed items CA overlap each other, but also when multiple conveyed items CA are conveyed close together. This is because even if multiple conveyed items CA do not overlap each other, if they are conveyed in a close-to-close state, the probability of these conveyed items CA overlapping each other sooner or later increases. This means that improper judgments can be made not only when multiple conveyed items CA are close together, but also when the gap between multiple conveyed items CA in the conveying direction F is less than a predetermined value. This can be achieved by identifying the overall occupancy range 121CT as the continuous occupancy range, not only when the occupancy range of the conveyed items is continuous, but also when the occupancy range is arranged at intervals less than a predetermined value. Alternatively, it can be set to exclude cases where the range of the entire continuous occupancy range 121CT is equivalent to a natural multiple of the unit occupancy range 121U from the improper judgment, thereby only judging improperness when the transported items CA overlap, and not judging improperness when the transported items CA are merely adjacent to each other.

[0080] In this embodiment, the transported object CA is mostly an electronic component (e.g., a cube with rounded corners) having a roughly cubic shape (e.g., a chip resistor, chip inductor, chip capacitor, etc.), but there is no particular limitation. However, in this embodiment, since no cover block or culvert structure is used as described above, it is particularly effective for fine and thin transported objects CA. In this embodiment, the occupancy range of the transported object CA on the transport path 121 is determined by image processing, and the size of the overall occupancy range, i.e., the continuous occupancy range 121CT, is compared with the occupancy range of one transported object CA, i.e., the unit occupancy range 121U. When the size of the continuous occupancy range 121CT exceeds the unit occupancy range 121U, an inappropriate judgment is made that some kind of action needs to be taken.

[0081] Furthermore, according to the detection method for the continuous occupancy range 121CT in the above embodiments, the range in the transport direction F of the measurement area ME must necessarily include the detection area of ​​the length Ls. Here, it is also possible to consider setting this detection area as the actual measurement area ME. Alternatively, it is also possible to consider setting only the light-transmitting area within the measurement area ME that requires image processing as the detection area. Therefore, the length LD in the transport direction F of the measurement area ME is larger than the length Ls in the transport direction F of the detection area. On the other hand, the range in the transport direction F of the measurement area ME includes the continuous occupancy range 121CT (the same size as the unit occupancy range 121U) that should be judged as normal when disposed in the detection area. However, as shown in FIG6, it is not necessary to include all of the continuous occupancy range 121CT (which exceeds the size of the unit occupancy range 121U) that should be judged as improper. It is sufficient that the size of the continuous occupancy range 121CT can be identified based on the unit occupancy range 121U. In addition, in the above embodiments, image processing is not performed on the entire measurement area ME, but only on the image portion corresponding to the light-transmitting area within the detection area. Therefore, the burden of image processing is reduced, and high-speed processing can be achieved. Furthermore, since the detection area is fixed, the detection position of the transported object CA when performing the transported object occupancy range identification process is also roughly fixed, so that even when various controls are performed based on the identification results, their timing can be easily unified.

[0082] Next, the determination of the transport control situation when the transport control is performed through any of the above embodiments and the control method relative to the transported object CA will be explained. Figure 9 Figures (a) to (e) illustrate the steps for controlling and processing two overlapping transport objects CA1 and CA2 transported in a prescribed configuration, based on image data from the captured image GPX or the image area GPY obtained from the camera device 130CM. Furthermore, the processing is performed in the same manner as illustrated when the preceding and following transport objects CA are transported close together. Additionally, the processing is essentially the same as illustrated when transporting continuously at intervals less than a predetermined value. Figure 9 As shown in (a), in this example, the conveyor CA2 is conveyed in the conveying path 121 in an overlapping state, with the front of the conveyor CA2 resting on the rear of the conveyor CA1. In the example, the conveyor CA1 is located within the measurement area ME, with its front end reaching a portion of the detection area, and a portion of the light-transmitting area 121g extending along the conveying direction F is blocked. At this time, the previously supplied conveyor CA0 is placed on the receiving unit 21a, and the light-transmitting area 21f is blocked. Then, as... Figure 9As shown in (b), the conveyed items CA1 and CA2 advance further along the conveying path 121, the light-transmitting area 121i is blocked, and the blocked portion of the light-transmitting area 121g also moves forward in the conveying direction F, increasing its blocking range. At this point, the conveyed item CA0 continues to exist within the receiving section 21a, but begins to move by stepping the indexing table 21 at a predetermined cycle. Therefore, as... Figure 9 As shown in (c), before the conveyed items CA1 and CA2 approach the end, the receiving section 21a becomes empty, and the light-transmitting area 21f becomes unshielded. Thus, it is detected that the receiving section 21a is in a state capable of receiving the conveyed items. Furthermore, at this point in time, if the conveyed item CA0 is still positioned on the receiving section 21a, the conveyed items CA1 and CA2 are discharged from the conveying path 121 to the receiving surface 122a of the recovery path 122 by airflow blown from the jet nozzle SP. This discharge state using the jet nozzle SP continues until the receiving section 21a becomes in a receiving state (the light-transmitting area 21f becomes unshielded).

[0083] Then, in Figure 9 At the position shown in (d), the transported items CA1 and CA2 are judged using the methods described in the above embodiments. In the example shown, since the size of the continuous occupied area 121CT exceeds the unit occupied area 121U, it is judged as improper. Therefore, as Figure 9 As shown in (e), the conveyed item CA2 located in the rear portion of the continuous occupied range 121CT is discharged from the conveying path 121 to the recovery path 122 by the airflow blown from the jet nozzle OP. At this time, since the jet nozzle OP opens directly behind the conveyed item CA1 and blows out the airflow directly, it is preferable to set the blowing time in such a way that a discharge force is applied to the front or center of the conveyed item CA2. In this way, as shown, the conveyed item CA2 either leaves the conveying path 121 with its front part before its rear part, or maintains its initial conveying posture and moves in the width direction orthogonal to the conveying direction F. Therefore, it is not discharged in the posture shown by the dotted line in the figure. At this time, the conveyed item CA1 continues to move along the conveying direction F on the conveying path 121, while the conveyed item CA2, which is subjected to the airflow, moves in the width direction. Therefore, in Figure 9 At the time point shown in (e), the conveyor CA1 separates from the conveyor CA2, thus reducing the possibility of the conveyor CA2 being caught in the movement. On the other hand, if the conveyor CA2 is excluded in the manner shown by the dotted line in the figure, the possibility of it colliding with the conveyor CA1 increases, which may obstruct the supply of the conveyor CA1 to the receiving unit 21a.

[0084] In the conveyor occupancy range identification process of the present invention, it is not limited to the situation described above, where the light-transmitting area 121c is detected based on image data within the measurement area ME to determine whether the conveyor CA is blocked due to its occupation, thereby determining the occupancy range of the conveyor CA. For example, the occupancy range of the conveyor CA can also be determined by processing an image captured solely based on reflected light from the conveyor path 121. For example, the position range of the conveyor CA in the image can also be detected by patterning processing or the like, and the aforementioned occupancy range determination can be made accordingly.

[0085] In this embodiment, the transported object CA, conveyed by the vibrating conveyor 10 on the vibrating conveyor path 121, is the object of inspection. Meanwhile, the camera devices 130CM (CM1, CM2) are positioned in a non-vibrating location (on the base 100). Therefore, in the image data of the captured image GPX or image area GPY, the conveyor path 121, which vibrates with a predetermined amplitude in a back-and-forth motion towards the conveying direction F, is positioned at a location that has shifted according to the change in vibration phase during the capture of the image data. Therefore, to detect and judge the appearance of the transported object CA at a fixed position based on the conveyor path 121, it is necessary to move the position of the measurement area ME within the image synchronously with the vibration of the conveyor 120 at the same amplitude according to the capture time. For example, vibration with an amplitude of 0.1 mm and a vibration frequency of 300 Hz is applied to the conveyor 120.

[0086] Therefore, in this embodiment, the position of the measurement area ME can be corrected based on the position correction mark set on the conveyor 120, so that it matches the vibration position of the conveyor 120 at the time of the captured image GPX or image area GPY. This position correction mark is not particularly limited as long as it is a mark that is easy and reliable for position detection; however, by setting it as a monochrome (same grayscale) mark that can be reliably identified as a blob in the image and whose center of gravity position can be stably detected, the accuracy of position detection can be improved. Furthermore, the position correction mark may not be intentionally set, but rather a part that originally exists on the conveying device and can be detected by image processing, such as an edge, corner, bolt head, or air nozzle formed on the conveyor 120. However, it is preferable to place it in a position that will not be obscured by the conveyed material CA. In the example shown, the position correction mark is the aforementioned marking portion 121y. The marking portion 121y is formed by a recess on the end edge of the conveyor body 120, but is not limited to the end edge. Furthermore, any identifiable structure such as a hole, cavity, or protrusion is acceptable. In this embodiment, since the outline of the marking portion 121y is clearly reflected on the image by the illumination light BLa from the rear-side illumination device 140BL, positional correction based on the position of the marking portion 121y can be easily and reliably performed.

[0087] In this embodiment, for the aforementioned position correction, the position of the measuring area ME relative to the conveyor path 121 is independent of the phase timing of the vibration during imaging and is always located at the same position relative to the conveyor path 121. Therefore, since the measuring area ME is always positioned in a certain relationship with the position of the air blown from the exhaust nozzle OP to remove the air from the improperly judged conveyor CA1 and CA2, and the position of the air blown from the exhaust nozzle SP to stop the supply of conveyor CA in an improper state at the supply destination, the removal force applied to the conveyor CA based on the judgment result of the conveyor occupancy range discrimination processing and the result of whether the receiving unit 21a can receive it can always be applied at approximately the same time.

[0088] Furthermore, it is preferable that the timing of the airflow blowing from the jet nozzle OP can be set so that when a judgment is made incorrect in a specific image, the blowing time begins after a predetermined time, based on the time the image was captured. In this case, generally, the timing setting can be based on the judgment time or the time the image being judged was acquired. However, it is preferable that the blowing time is automatically corrected according to the position of the conveying direction F of the conveyor CA1 in the measurement area ME of the image (the position after position correction mentioned above). In this way, it is easy and reliable to set the airflow from the jet nozzle OP to act only on the conveyor CA2 and not on the conveyor CA1. In addition, it is preferable that the starting time of the airflow blowing from the jet nozzle SP is also automatically corrected according to the position of the conveying direction F of the conveyor CA1 (the position after position correction mentioned above), in the same way.

[0089] In this embodiment, an image of the transported item CA on the transport surface 121b is obtained by the camera device 130CM, and the size of the continuous occupancy range 121CT of the transported item CA is determined based on the unit occupancy range 121U by processing within the measurement area ME of the image. Since the transported items CA are transported on the transport surface 121b in a posture that easily overlaps with each other in a direction orthogonal to the transport surface 121b, the overlap state of the transported items CA can be easily determined based on the occupancy range in the image. In particular, by aligning the shooting direction of the camera device 130CM with the aforementioned direction of easy overlap, image processing becomes easier, and the recognition accuracy is improved.

[0090] Furthermore, in this embodiment, by performing image processing on the image portion 21fy of the light-transmitting area 21f of the receiving unit 21a, it is possible to detect whether the supply destination can receive the material, thus accurately identifying the cessation of the supply of the transported item CA. In particular, since detection can be performed based on an image identical to the image used in the above-mentioned transported item occupancy area identification process, the imaging unit can be simply configured, and image processing can be performed quickly and in parallel. Moreover, when determining whether the receiving unit 21a can receive the material, the same back-side illumination effect as the light-transmitting area within the measurement area ME can be obtained.

[0091] In this embodiment, since the shading status of the light-transmitting areas 21f, 121g, 121h, and 121i can be clearly detected by the illumination light BLa from the back-side illumination device 140BL, it is less susceptible to the effects of reduced contrast in the measurement area ME, thus reducing image processing burden and improving detection accuracy. However, the image captured by the camera device 130CM is not limited to back-side illumination (transmitted light); it can also be front-side illumination (reflected light), or a combination of both. In this case, it is preferable to define the range of the light-transmitting area 121c (light-transmitting area), thereby making it easier to extract not only the lines (contour information) of the shooting range but also the surface morphology through image processing. For example, in this embodiment, since it is not necessary to identify the shape of the conveyed object CA in the width direction, by making the light-transmitting area 121c narrower than the width of the conveyed object CA, the area of ​​the light-transmitting area 121c can be defined without reducing the effect. In particular, from the perspective of determining the position of the conveyed material CA in the conveying direction F, it is preferable to configure it as a slit extending in the conveying direction F, as described above as the light-transmitting area 121g. In this case, it is even more preferable to extend it continuously within the measurement area ME. At this time, by extracting the surface morphology captured in the image, it is possible to further distinguish the overlapping state of the conveyed material CA in detail and change the method of applying the rejection force if the judgment is incorrect. Alternatively, if it is confirmed from the surface morphology that it is not an overlapping state, it is possible to avoid incorrect judgment. Regarding the limitation of the light-transmitting area, for example, it is also preferable to set the light-transmitting area 121c as having a plurality of dispersed light-transmitting areas arranged as described above as the light-transmitting area sections 121g, 121h, and 121i.

[0092] In this embodiment, various data used in the identification processing of the transported object CA, such as the type and size of the transported object CA, improper judgment conditions, reference image data of the transported object CA, continuous occupation range determination conditions, unit occupation range values, and brightness thresholds during binarization in image processing, are stored in the main storage device MM, etc., and are appropriately read out and used during each processing. In addition, settings for determining the shooting time of the camera device 130CM (CM1, CM2), setting the image acquisition conditions when acquiring the captured image GPX or image area GPY, setting the method for determining the position correction of each measurement area using the vibration of the transport path 121, setting the form of various setting screens and display screens, and control methods such as the airflow for screening or supplying stop, such as the airflow blowing time and pressure value, are also processed in the same way.

[0093] In this embodiment, image files (GPX or GPY images) that are stored sequentially in the main storage device MM and have been captured in a time sequence can be selected, read, and displayed. Furthermore, a device is provided for performing various operations on the selected image files.

[0094] The image file stored in the main storage device MM is generated by the processing unit MPU automatically recording image data of multiple captured images (GPX) or image areas (GPY) obtained in the operating mode. While all image data can be stored in the main storage device MM if there is available space, it is preferable to always store the image file from the latest predetermined period (e.g., 1 hour) or the latest predetermined number of images (e.g., 1000 images) even if there is no available space in the main storage device MM.

[0095] While displaying previously recorded captured images (GPX) or image areas (GPY) as described above, image measurement processing, consisting of the aforementioned transport object detection processing and transport object identification processing (generally the aforementioned transport processing), can be performed again on the image data through appropriate operation. As one of the display mode control functions, for multiple captured images (GPX) or image areas (GPY) stored in the same file, it is possible to switch to other image data captured previously through appropriate operation. Alternatively, multiple captured images (GPX) or image areas (GPY) within the same image file can be displayed continuously, while image measurement processing relative to the displayed image data is performed in parallel.

[0096] Next, refer to Figure 11 The overall operation procedure of this embodiment will be explained. Figure 11This is a simplified flowchart of the processing performed by the processing unit (DTU) and the processing unit (MPU) according to the action program. When the action program is started, firstly, the above-mentioned image capture and image measurement processing are performed, and the conveyor device 10 (feeder 11 and linear feeder 12) is driven by the controllers CL11 and CL12. Then, when the debugging setting corresponding to the aforementioned debugging operation is OFF, image measurement processing is performed on the captured image GPX or image area GPY. If the final judgment result is OK, as long as no debugging operation has been performed, the image measurement processing of the next captured image GPX or image area GPY is directly implemented. For example, at the screening position based on the judgment of defective and good products of conveyed item CA, the screening position based on the judgment of improper posture and standard posture, or the flipping position, the airflow control of the jet nozzle is used to remove conveyed item CA judged as defective or judged as improperly oriented from the conveyor path 121 or to flip its posture based on the images captured by cameras CM1, CM2, etc. Furthermore, in the screening position (measurement area ME) based on the determination of the occupancy range of the conveyed material CA in the aforementioned end portion 121e, an exclusion force is also applied to the continuously occupied range 121CT that is improperly determined, as described above, based on the image obtained by the camera device 130CM.

[0097] In this way, by controlling the conveyed items CA on the conveyor path 121, only good quality and well-positioned conveyed items are supplied downstream in an orderly manner. Furthermore, in the end section 121e, the overlap state or probability of the conveyed items CA can be determined, and each conveyed item CA is supplied to the receiving section 21a in a way that ultimately prevents improper supply. In this case, as long as no subsequent debugging operation is performed, the determination of the next captured image GPX or image area GPY can be directly implemented.

[0098] When the aforementioned debugging operation is performed and the debugging setting becomes ON, the above-mentioned routine is discontinued, the drive of the conveyor 10 is stopped, and image measurement processing also stops. Then, if appropriate operations are performed in this state, the state where image files can be selected, as described above, is achieved. At this time, the selected and displayed image file is an image file containing multiple captured images (GPX) or image areas (GPY) recorded in the previous operating mode. If this image file is selected directly and appropriate operations are performed, the process transitions to the re-execution mode. In this mode, the display, detection, and judgment of the image can be performed again based on the image file containing the control actions that have been performed as described above. That is, if a malfunction occurs in the control of the conveyor CA of the conveyor 10, in order to eliminate the malfunction, the image measurement processing is first re-executed based on past image data to investigate the problem in the image measurement processing. If the problem is identified, the settings (set values) for detection or judgment can be changed or adjusted accordingly, and the results of the adjustment and improvement operation can be confirmed by re-executing the image measurement processing based on past image data. Then, when the appropriate recovery operation is performed, the debugging setting is restored to OFF, image measurement processing restarts, and the conveyor 10 is restarted. Additionally, the display screen returns to the operating mode display screen.

[0099] In the embodiment described above, in addition to the various effects mentioned above, by continuously capturing images at predetermined shooting intervals using the camera device 130CM and performing image measurement processing on the image data within the measurement area ME, it is possible to detect and determine the transported items CA disposed within the measurement area ME in any captured image. Therefore, it is not necessary to generate trigger signals for detecting the position of each transported item as in the prior art. The range LD in the transport direction F of the measurement area ME is pre-set to always include all transported items CA passing through the transport path 121 based on the relationship between the transported item's transport speed Vs and the shooting interval Ts. Furthermore, by determining the occupancy range of the transported items CA contained in the image, i.e., the continuous occupancy range 121CT, based on the unit occupancy range 121U, information related to the overlap state or probability of the transported items CA can be reliably extracted. Therefore, even with high-speed or high-density transport of transported items, improper supply towards the supply destination of the transported items CA can be prevented, enabling efficient supply. Furthermore, since it is only necessary to detect the continuous occupancy range of the transported object CA on the transport path 121 and compare it with the unit occupancy range, image measurement processing for determining the overlap state or probability of the transported object CA can be performed at high speed and with high accuracy.

[0100] In this embodiment, a light-transmitting area 121c, as shown in FIG. 6, is provided on the conveying surface 121b constituting the conveying path 121. This light-transmitting area 121c is formed by a through-hole or gap G that penetrates the conveying surface 121b and opens on the back side. A back-side lighting device 140BL faces the back side of this through-hole or gap G. The through-hole or gap and the back-side lighting device 140BL constitute the aforementioned back-side lighting unit. Furthermore, as a back-side lighting unit, any transmitted light that passes through the light-transmitting area 121c and faces the imaging unit is sufficient; even if it is not a dedicated lighting device like the one shown in the figure, ambient lighting that ensures direct or indirect illumination, such as indoor lighting, is acceptable.

[0101] In the example shown, the back-side lighting unit is formed by the aforementioned through-hole or gap G. However, a light-transmitting material, such as glass, quartz, sapphire, or acrylic resin, can also be arranged along the conveying surface 121b, thereby forming the back-side lighting unit on the same plane as the conveying surface 121b. In this way, no step portion is formed on the conveying surface 121a by the through-hole 121d, thus not hindering the conveying of the conveyed item CA. In addition, as shown in Figures 6(a) and 6(b), the aforementioned jet nozzles OP and SP are provided with chamfered or rounded deformed corners OPa and SPa at the front edge of the opening in the conveying direction F. Therefore, it is possible to prevent the conveyed item CA from getting stuck at the opening edge of the jet nozzles OP and SP and becoming stuck or causing posture disorder.

[0102] Although the transmitted light from the aforementioned rear-side lighting device 140BL shines from the light-transmitting area 121c toward the camera device 130CM (CM1, CM2), the range of the light-transmitting area 121c is limited. Therefore, when the camera device 130CM captures an image of the conveyed item CA on the conveyor path 121, the ambient lighting (sunlight, factory indoor lighting, etc.) behind the camera device 130CM causes the shapes of the conveyor surfaces 121a, 121b and the surface of the conveyed item CA to appear in the captured image. In this case, a front-side lighting device can also be provided to illuminate the conveyor path 121 and the conveyed item CA from behind the camera device 130CM. If sufficient illumination can be obtained through ambient lighting as described above, a front-side lighting device may not be necessary. This front-side lighting device can also be configured to illuminate from various directions.

[0103] Furthermore, the conveying control system and 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, the occupancy range of the conveyed item CA is detected by processing the image portion of the light-transmitting area 121c obtained using back-side illumination (transmitted light), but the occupancy range of the conveyed item can also be detected by processing the image obtained using conventional front-side illumination (reflected light).

[0104] Furthermore, in the above embodiment, the length of the continuous occupying range 121CT in the transport direction F is compared with the length of the unit occupying range 121U in the transport direction F, which leads to improper judgment. However, in the present invention, the width of the continuous occupying range 121CT can be compared with the width of the unit occupying range 121U, or the area of ​​the continuous occupying range 121CT can be compared with the area of ​​the unit occupying range 121U.

[0105] Furthermore, in the above embodiment, as a basic component of the inspection processing unit DTU, it takes pictures at a predetermined time interval Ts regardless of the arrival time of the transported object CA, but it can also take pictures by triggering the camera device 130CM (CM1, CM2) based on the signal that detects the arrival of the transported object CA.

[0106] Furthermore, in the above embodiment, when determining the size of the continuous occupied area 121CT based on the unit occupied area 121U, the length Lct in the conveying direction F is compared with the lengths L and Ls in the same conveying direction F. However, the overlapping or close contact state of the conveyed objects CA may occur not only in the length of the occupied area in the conveying direction F, but also in the width direction. Therefore, the width of each area can also be used as the comparison object, or both the length and width, or the area of ​​each area itself can be used as the comparison object.

Claims

1. A conveying control system, characterized in that, have: The image acquisition unit repeatedly acquires images of the measurement area (ME) on the transport path (121) of the transported object (CA) by the shooting unit; The transport object occupancy range identification unit detects the continuous occupancy range (121CT) within the measurement area (ME), and determines the size of the continuous occupancy range (121CT) based on the unit occupancy range (121U) equivalent to one transport object (CA). The continuous occupancy range (121CT) refers to the range in which the occupancy area of ​​the transport object (CA) on the transport path (121) is connected as one, or the occupancy area is continuous at intervals less than a specified value. as well as The transport control unit controls the transport status of at least one of the transported items (CA) disposed within the continuous occupancy range (121CT) when the continuous occupancy range (121CT) satisfies the condition of an improper judgment based on the unit occupancy range (121U). The measurement area (ME) is located at the end (121e) of the conveying path (121). The image acquisition unit also includes a transport receiving capability detection unit. The transport receiving capability detection unit acquires an image obtained by the imaging unit, which includes the measurement area (ME) and the receiving unit (21a) that supplies the transport (CA) to the supply destination from the end part (121e). The image is then processed to detect whether the receiving unit (21a) can receive the transport (CA).

2. The conveying control system as described in claim 1, characterized in that, The transport object occupancy range identification unit determines the occupancy range when viewed from a specific direction on the transport path (121) where two or more transport objects (CA) are more likely to overlap than in other directions.

3. The conveying control system as described in claim 2, characterized in that, The image acquisition unit's shooting direction is the specific direction.

4. The conveying control system as described in any one of claims 1 to 3, characterized in that, The transport control unit applies a rejection force to the portion of the unit occupying range (121U) that is located in the forward direction of the transport direction, compared to the portion that is located in the continuous occupying range (121CT) when the unit occupying range (121U) is assumed to be located in the forward direction of the transport direction.

5. The conveying control system as described in any one of claims 1 to 3, characterized in that, The transported object occupancy range identification unit has a detection area (Ls) within the measurement area (ME). The detection area (Ls) is fixed along the transport direction (F) and is set such that the continuous occupancy range (121CT) that meets the conditions for improper judgment must occupy the detection area (Ls).

6. The conveying control system as described in any one of claims 1 to 3, characterized in that, The image acquisition unit continuously captures images through the shooting unit at predetermined shooting intervals (Ts), and... The measurement area (ME) is pre-set to include all the conveyed objects (CA) passing through the conveying path (121) based on the relationship between the conveying speed (Vs) and the shooting interval (Ts) of the conveyed object (CA).

7. The conveying control system as described in claim 6, characterized in that, The continuous occupancy range (121CT) that meets the conditions for improper judgment must occupy the detection area (Ls) that is fixed along the transport direction (F) and is set within the measurement area (ME); Based on the transport speed (Vs), the shooting interval (Ts) is set such that all the continuous occupancy ranges (121CT) that meet the conditions for improper judgment will be photographed when occupying the detection area (Ls).

8. The conveying control system as described in any one of claims 1 to 3, characterized in that, It also has: A light-transmitting area (121c) is formed within the measurement area (ME) on the conveying surfaces (121a, 121b) of the conveying path (121); and A rear-side illumination unit illuminates light from the rear side of the conveying surfaces (121a, 121b) toward the imaging unit side through the light-transmitting area (121c); The transport object occupancy range discrimination unit uses information representing the range of the light-transmitting area (121c) that is covered by the transport object (CA) or not covered by the light-blocking portion to detect the size of the continuous occupancy range (121CT) within the measurement area (ME) relative to the image data within the measurement area (ME).

9. The conveying control system as described in claim 8, characterized in that, The light-transmitting area (121c) is configured as a slit-shaped part that is longer than the length of the conveyed object (CA) in the conveying direction (F).

10. The conveying control system as described in claim 8, characterized in that, The light-transmitting area (121c) is composed of a group of multiple light-transmitting areas (121g to 121i) arranged in the measurement area (ME).

11. The conveying control system as described in claim 10, characterized in that, The plurality of light-transmitting areas (121g to 121i) of the light-transmitting area (121c) include: a first light-transmitting area (121h) and a second light-transmitting area (121i) formed to be included in the length range of the transport direction of the unit occupied area, and a third light-transmitting area (121g) having a portion that is not covered when the first light-transmitting area (121h) and the second light-transmitting area (121i) are covered in the unit occupied area (121U).

12. The conveying control system as described in any one of claims 1 to 3, characterized in that, The conveying path (121) conveys the conveyed object (CA) by vibrating in a reciprocating manner in the direction of conveying (F) along the conveying direction of the conveyed object (CA). The camera unit is stationary; The position of the measurement area (ME) within the captured image (GPX) is corrected to eliminate positional variations within the captured image (GPX) relative to the transport path (121) caused by vibration of the transport path (121) during capture.

13. The conveying control system as described in claim 12, characterized in that, The transport area identification unit detects the position of a specific part (121y) on the transport path (121) captured in the captured image (GPX) through image measurement processing, and corrects the position of the measurement area (ME) based on the position.

14. A conveying device, characterized in that, have: The conveying control system according to any one of claims 1 to 3; and A conveying mechanism having the conveying path (121).

15. The conveying device as claimed in claim 14, characterized in that, The conveying mechanism has an excitation unit that vibrates the conveying path (121) and an excitation control unit that controls the driving mode of the excitation unit.

Images