Identification apparatus for foam-molded products and identification method for foam-molded products

Abstract

To accurately identify information attached to a foam-molded product.SOLUTION: An identification apparatus 10 comprises: acquiring means 12 for acquiring image data of an uneven shape 52 formed on the surface of a foam-molded product 50; a storage unit for storing associated data in which image data of the uneven shape having a molding defect is set as specific image data and the specific image data is associated with identification information; and specifying means for specifying the identification information corresponding to the image data of the uneven shape 52 acquired by the acquiring means 12 based on the associated data.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to an identification device and a method for identifying a foam-molded product. [Background technology]

[0002] In foam-molded products, it is sometimes difficult to distinguish the type of product by appearance. Therefore, in order to identify foam-molded products, it has been proposed to embed an electronic identification medium in the foam-molded product (see, for example, Patent Document 1). However, in Patent Document 1, embedding the electronic identification medium during molding of the foam-molded product is time-consuming. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 5357647 Summary of the Invention [Problem to be solved by the invention]

[0004] Therefore, if a symbol for identifying the product type is molded on the surface of the foam-molded product, the symbol may be chipped or have voids or other molding defects that make it difficult to read the symbol.

[0005] The present invention has been proposed in consideration of the above-mentioned problems associated with the conventional technology, and aims to provide an identification device and an identification method for foam-molded products that can accurately identify information attached to foam-molded products. [Means for solving the problem]

[0006] A first aspect of the identification device for foam-molded products according to the present invention is as follows: An acquisition means for acquiring image data of the uneven shape formed on the surface of the foam molded product; a storage unit that stores associated data in which image data of the uneven shape having a molding defect is set as specific image data and the specific image data is associated with identification information; The present invention also includes a specification unit that specifies the identification information corresponding to the image data of the uneven shape acquired by the acquisition unit based on the associated data.

[0007] A second aspect of the identification device for foam-molded products according to the present invention is the same as the first aspect, The specific image data may include image data in which voids or chips exist in the uneven shape.

[0008] A third aspect of the identification device for foam-molded products according to the present invention is the same as the first and second aspects, The acquisition means includes: An illumination means for irradiating the uneven shape with light from an oblique direction; The imaging device may further include an imaging means arranged in front of the uneven shape irradiated with the light, and configured to capture a two-dimensional image of the uneven shape.

[0009] A fourth aspect of the identification device for foam-molded products according to the present invention is any one of the first aspect, the second aspect, and the third aspect, A reading means for reading an identifier attached to a container in which the foam-molded product is contained; The information processing device may further comprise a determination means for determining whether the identifier information read by the reading means and the identification information specified by the specification means are appropriate.

[0010] A first aspect of the method for identifying a foam-molded product according to the present invention is to Acquire image data of the uneven shape formed on the surface of the foam molded product; The gist of the method is that image data of the uneven shape having a molding defect is set as specific image data, and the identification information corresponding to the acquired image data of the uneven shape is identified based on associated data in which the specific image data and identification information are associated. Effect of the Invention

[0011] According to the foam-molded product identification device of the present invention, information attached to the foam-molded product can be identified with high accuracy. According to the method for identifying a foam-molded article of the present invention, the information attached to the foam-molded article can be identified with high accuracy. [Brief description of the drawings]

[0012] [Figure 1] 1 is a schematic diagram showing an identification device according to an embodiment of the present invention; [Diagram 2] FIG. 2 is a perspective view showing an example of the uneven shape of an expansion molded product. [Diagram 3] FIG. 2 is a perspective view showing an example of an uneven shape having a molding defect in an expansion molded product. [Figure 4] FIG. 2 is a block diagram illustrating electrical connections of the identification device according to the embodiment. [Diagram 5] 1 is a diagram showing the positional relationship between an acquisition unit and a foam-molded product in the identification device of the embodiment. FIG. [Figure 6] FIG. 2 is a diagram showing a flow of identification of a foam-molded product using the identification device of the embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] Next, the identification device and the identification method for foam-molded products according to the present invention will be described below with reference to preferred embodiments and the accompanying drawings. Note that the embodiments and drawings described below are merely examples of the present invention, and are not intended to limit the present invention to these configurations, and may be modified as appropriate without departing from the scope of the present invention. EXAMPLES

[0014] The identification device 10 according to the embodiment identifies identification information from an uneven shape 52 formed on the surface of a foam-molded product 50, and identifies whether the foam-molded product 50 is suitable or not based on the identification information. As shown in Fig. 1, the identification device 10 identifies each of a plurality of foam-molded products 50 contained in a container 60 arranged at an image capturing position of a table 40. The table 40 has a stopper 42 that moves between a restricting position where the container 60 protrudes from a mounting surface and a retracted position where the container 60 retracts from the mounting surface, and the container 60 is positioned at the image capturing position by the stopper 42 in the restricting position. The stopper 42 is controlled by a control device 14 (see Fig. 4) of the identification device 10, which will be described later.

[0015] The foam-molded product 50 is obtained by foam-molding a foaming resin material in a mold, and the uneven shape 52 is formed during foam molding using the mold. The uneven shape 52 may be formed only with concaves that are recessed from the surface of the foam-molded product 50 as shown in FIG. 2(a), or may be formed only with convex parts that protrude from the surface of the foam-molded product 50 as shown in FIG. 2(b), or may be formed by combining concaves and convex parts. The uneven shape 52 represents the identification information of the foam-molded product 50 by symbols including numbers, letters, signs, and marks represented by the uneven shape 52, and may be a combination of multiple symbols or a single symbol. It is preferable that the uneven shape 52 be a combination of multiple symbols from the viewpoints of preventing misrecognition and the amount of information. It is to be noted that the identification information includes one or more pieces of information such as the type of the foam-molded product 50, the intended use, and the shipping destination.

[0016] 3, in the foam-molded product 50, molding defects 54 caused by insufficient foaming of the foaming resin material, molding shrinkage, etc. may extend to the uneven shape 52. For example, if molding defects 54 such as chips or voids exist in the uneven shape 52, the uneven shape 52 may be chipped or extra unevenness may be formed around the uneven shape 52, making the uneven shape 52 unclear.

[0017] 1, a container 60 contains a plurality of foam-molded products 50 with the surface having the uneven shape 52 facing upward. An identifier 62 is attached to the side surface of the container 60. A two-dimensional code such as a barcode or a QR code (registered trademark) is used as the identifier 62. The identifier 62 is read by a reading means 16 (to be described later) of the identification device 10 at the imaging position.

[0018] As shown in Figure 1, the identification device 10 includes an acquisition means 12 for acquiring image data of the uneven shape 52 of a foam molded product 50, a control device 14 for performing various processes based on the image data acquired by the acquisition means 12, and a reading means 16 for reading an identifier 62 attached to a container 60 in which the foam molded product 50 is contained.

[0019] As shown in FIG. 4, the acquisition means 12 includes an illumination means 18 that irradiates the uneven shape 52 of the foam-molded article 50 with light, and an imaging means 20 that captures a two-dimensional image of the uneven shape 52 of the foam-molded article 50.

[0020] As shown in Fig. 5, the lighting means 18 is disposed diagonally above the multiple foam-molded products 50 contained in the container 60 disposed at the imaging position. The lighting means 18 irradiates light onto the uneven shape 52 of the foam-molded product 50 from an oblique direction. The lighting means 18 irradiates light widely onto the entire upper surfaces of the multiple foam-molded products 50 contained in the container 60 disposed at the imaging position. The lighting means 18 is turned on by a sensor (not shown) that detects the container 60 disposed at the imaging position, and is turned off when the container 60 is not detected by the sensor. As the lighting means 18, for example, an LED light, a fluorescent lamp, an incandescent lamp, a neon lamp, a mercury lamp, or the like can be used.

[0021] As shown in FIG. 5, the imaging means 20 is disposed above the illumination means 18 on the upper side of the plurality of foam-molded products 50 contained in the container 60 disposed at the imaging position. The imaging means 20 is disposed in front of the uneven shape 52 irradiated with light from the illumination means 18. The imaging means 20 images an area including all of the plurality of foam-molded products 50 contained in the container 60 disposed at the imaging position, and captures a two-dimensional image including the uneven shape 52 of the plurality of foam-molded products 50. The imaging means 20 is connected to a control unit 24 (see FIG. 4) of the control device 14 via a wired or wireless electric communication line, and captures images under the control of the control unit 24, and transmits the captured two-dimensional image to the control unit 24. For example, a digital camera or a digital video camera can be used as the imaging means 20.

[0022] 4, the control device 14 includes a storage unit 22 that stores various information, and a control unit 24 that executes a predetermined process based on the image data acquired by the acquisition means 12 and the information (associated data) stored in the storage unit 22. As the control device 14, a known calculator (computer) in which the storage unit 22 and the control unit 24 are electrically connected to each other can be used.

[0023] The storage unit 22 stores various information such as product type information associated with the information of the identifier 62, quantity information associated with the product type information, and identification information associated with the product type information. The storage unit 22 also stores associated data in which image data of the uneven shape 52 having the molding defect 54 is regarded as specific image data and the specific image data is associated with the identification information. The associated data also includes data in which image data of the uneven shape 52 having no molding defect 54 is associated with the identification information. The storage unit 22 can be a storage device such as a hard disk drive or a solid state drive (SSD).

[0024] The identification device 10 acquires image data of the uneven shape 52 having a molding defect 54 by the acquisition means 12 as specific image data, associates the uneven shape 52 included in this specific image data with the identification information, and generates associated data by machine learning. Also, the acquisition means 12 acquires image data of the uneven shape 52 in various patterns such as the uneven shape 52 arranged horizontally, the uneven shape 52 arranged vertically, and the uneven shape 52 upside down, and generates associated data by learning the uneven shape 52 included in this image data with the identification information.

[0025] As shown in FIG. 4, the control unit 24 is configured as a microprocessor centered on a CPU 26, and is electrically connected to a ROM 28 that stores various control programs for controlling the memory unit 22, and a RAM 30 that temporarily stores various information such as image data acquired by the acquisition means 12 and information on the identifier 62 read by the reading means 16.

[0026] The control unit 24 corresponds to the specifying means of the present invention, and specifies identification information corresponding to the image data of the uneven shape 52 acquired by the acquisition means 12, based on the associated data stored in the storage unit 22. The control unit 24 specifies the identification information of all the uneven shapes 52 included in the image data acquired by the acquisition means 12, based on the associated data, and distinguishes the identification information for each of the uneven shapes 52 of the multiple foam-molded products 50 contained in the container 60. In other words, the control unit 24 also specifies the number of foam-molded products 50 contained in the container 60 based on the number of pieces of identification information specified from the image data.

[0027] The control unit 24 corresponds to the determination means of the present invention, and determines whether the information of the identifier 62 read by the reading means 16 matches the identification information specified from the image data of the uneven shape 52 acquired by the acquisition means 12. Specifically, the control unit 24 determines whether the specified identification information is the variety information associated with the information of the identifier 62. The control unit 24 also determines whether the number of the specified identification information matches the quantity information included in the variety information associated with the information of the identifier 62.

[0028] When the information of the identifier 62 matches the identification information, the control unit 24 controls the stopper 42 to move from the restricted position to the retracted position. When the information of the identifier 62 does not match the identification information, the control unit 24 keeps the stopper 42 in the restricted position. Also, an error may be notified by a notification means such as a display unit or a speaker (not shown).

[0029] The flow of identifying foam-molded products 50 using the above-mentioned identification device 10 will be described with reference to Fig. 6. A container 60 containing multiple foam-molded products 50 is placed at the imaging position of the table 40. At this time, by positioning the container 60 against the stopper 42 protruding at the regulating position, the multiple foam-molded products 50 contained in the container 60 can be placed in front of the imaging means 20 in accordance with the imaging range of the imaging means 20. In addition, when the container 60 is detected by a sensor (not shown), light is irradiated from the illumination means 18 obliquely toward the upper surfaces of the multiple foam-molded products 50.

[0030] The identifier 62 attached to the container 60 is read by the reading means 16 (step S100). As a result, the control unit 24 identifies the product type information corresponding to the information of the read identifier 62. The imaging means 20 images the plurality of foam-molded products 50 from above, and acquires image data including the uneven shapes 52 attached to the upper surfaces of the foam-molded products 50 (step S101). The control unit 24 identifies the identification information of all the uneven shapes 52 included in the image data acquired by the acquisition means 12, based on the associated data stored in the storage unit 22 (step S102).

[0031] The related data associates image data of uneven shapes 52 in various orientations with identification information, so that even if the orientations of the uneven shapes 52 in multiple foam-molded products 50 are not uniform, as shown in Figure 1, it is possible to identify the identification information of each uneven shape 52 from the image data of multiple uneven shapes 52 with different orientations.

[0032] The control unit 24 judges whether the information of the identifier 62 read by the reading means 16 matches the identification information specified from the image data of the uneven shape 52 acquired by the acquisition means 12 (step S103). If the specified identification information matches the product type information associated with the information of the identifier 62 and the number of the specified identification information matches the quantity information included in the product type information associated with the information of the identifier 62, the control unit 24 judges that there is no incorrect product (step S104: YES). The control unit 24 lowers the stopper 42 to the retracted position, and the foam-molded product 50 contained in the container 60 is shipped (step S105).

[0033] The control unit 24 determines that there is a defective product when at least one of the cases applies where the specified identification information does not match the product type information associated with the information of the identifier 62 or the quantity of the specified identification information does not match the quantity information included in the product type information associated with the information of the identifier 62 (step S104: NO). In this case, an inspector visually inspects the foam-molded product 50 (step S106), and if there is no problem, the foam-molded product 50 contained in the container 60 is shipped, but if there is a problem, it is not shipped.

[0034] The above-mentioned identification device 10 and identification method use image data of the uneven shape 52 having a molding defect 54 as specific image data, and identify the identification information corresponding to the image data of the uneven shape 52 acquired by the acquisition means 12 based on the associated data in which the specific image data and the identification information are associated and stored in the storage unit 22. In this way, since the specific image data of the uneven shape 52 having a molding defect 54 is associated with the identification information in the associated data, even if the uneven shape 52 is in an incomplete state due to chipping due to the molding defect 54, the identification information can be accurately identified from the image data of the uneven shape 52 acquired by the acquisition means 12. Therefore, even if it is difficult to completely prevent molding defects 54 in a foam-molded product 50, it is possible to form the uneven shape 52 on the surface of the foam-molded product 50 and inspect the foam-molded product 50 using the uneven shape 52 that may be unclear due to the molding defect 54.

[0035] Even if the foam-molded products 50 are of different types, if their external shapes are almost the same, it may be impossible to distinguish the types by visual inspection. According to the above-mentioned identification device 10 and identification method, it is possible to specify identification information from image data of the uneven shape 52 of the foam-molded product 50 acquired by the acquisition means 12, so that the efficiency of inspecting the foam-molded product 50 can be significantly improved.

[0036] Since the specific image data includes image data showing voids or chips in the uneven shape 52 of the foam molded product 50, even if the uneven shape 52 is incomplete due to chipping caused by a molding defect 54, identification information can be accurately determined based on related data from the image data of the uneven shape 52 acquired by the acquisition means 12.

[0037] The acquisition means 12 includes an illumination means 18 that irradiates the uneven shape 52 with light from an oblique direction, and an imaging means 20 that is disposed in front of the uneven shape 52 irradiated with light and captures a two-dimensional image of the uneven shape 52. By irradiating the uneven shape 52 with light from an oblique direction using the illumination means 18, the contrast of the uneven shape 52 can be emphasized, and at this time, by capturing a two-dimensional image of the uneven shape 52 from the front using the imaging means 20, clear image data of the uneven shape 52 can be acquired. Therefore, the identification information can be accurately identified based on the associated data from the image data of the uneven shape 52 acquired by the acquisition means 12.

[0038] By determining whether the information of the identifier 62 read by the reading means 16 matches the identification information specified from the image data acquired by the acquisition means 12, the foam-molded product 50 can be inspected with greater accuracy.

[0039] (Example of change) The present invention is not limited to the above-mentioned items, and may be, for example, as follows: It should be noted that the present invention is not limited to the specific descriptions of the examples and the following modified examples. (1) In the embodiment, the identification device and the identification method are applied to the inspection of foam-molded products. However, the present invention is not limited to this application, and the identification device and the identification method may be applied to other cases, such as sorting foam-molded products by type. (2) In the embodiment, image data of the uneven shape was acquired while the foam molded product was stopped at the imaging position. However, this is not limited to this, and image data of the uneven shape may be acquired from a foam molded product that moves the imaging position. [Explanation of symbols]

[0040] 10 identification device, 12 acquisition means, 16 reading means, 18 lighting means, 20 imaging means, 22 storage unit, 24 control unit, 50 foam molded product, 52 uneven shape

Claims

1. An acquisition means for acquiring image data of the uneven shape formed on the surface of the foam molded product; a storage unit that stores associated data in which image data of the uneven shape having a molding defect is set as specific image data and the specific image data is associated with identification information; and an identification means for identifying the identification information corresponding to the image data of the uneven shape acquired by the acquisition means based on the associated data.

2. The device for identifying foam-molded products according to claim 1 , wherein the specific image data includes image data in which voids or chips exist in the uneven shape.

3. The acquisition means includes: An illumination means for irradiating the uneven shape with light from an oblique direction; 2. The identification device for foam-molded products according to claim 1, further comprising: an imaging means arranged in front of the uneven shape irradiated with the light, for capturing a two-dimensional image of the uneven shape.

4. A reading means for reading an identifier attached to a container in which the foam-molded product is contained; 2. The identification device for foam-molded products according to claim 1, further comprising a determination means for determining whether the identifier information read by the reading means is appropriate to the identification information specified by the specifying means.

5. Acquire image data of the uneven shape formed on the surface of the foam molded product; A method for identifying a foam-molded product, in which image data of the uneven shape having a molding defect is designated as specific image data, and the identification information corresponding to the acquired image data of the uneven shape is identified based on associated data in which the specific image data and identification information are associated.

Images