Image processing system

Abstract

To reduce time and labor for routing of a power supply cable and time and labor for a noise countermeasure and to shorten the rise time of power supply for light emission, in an image processing system using a robot arm.SOLUTION: The image processing system includes an image processing unit including a light irradiation device for irradiating a workpiece with light, an imaging device for imaging the workpiece, and a light emission control device for supplying power to the light irradiation device, to control its light emission state, the robot arm for supporting the image processing unit at the top end, so that a position and an attitude are changeable, and an information processing device installed on the base end side of the robot arm and supplying the power to the light emission control device.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to an image processing system. [Background technology]

[0002] In recent years, image inspection systems using robot arms have come to be increasingly used in visual inspections of, for example, large workpieces. Known image inspection systems of this kind include a system in which a lighting device and an imaging device are attached to the tip of a robot arm, and the lighting device and imaging device are controlled by a lighting controller and an information processing device arranged on the base end side (e.g., a pedestal portion) of the robot arm. The lighting controller and the information processing device are often connected to the lighting device and imaging device via a cable arranged to run along the arm of the robot arm. Using such an image inspection system, it is possible to image-inspect a part or all of the surface of a workpiece by irradiating the workpiece with inspection light and capturing an image. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2008-046103 A Summary of the Invention [Problem to be solved by the invention]

[0004] In the future, it is expected that in the image inspection using the robot arm described above, not only inspections using simple lighting devices will be required, but also inspections using lighting devices that require multi-channel control, such as photometric stereo devices and phase shift lighting devices. When using such lighting devices that require multi-channel control, the number of power supply cables connecting the lighting devices and the lighting controller increases, and it takes a lot of effort to manage them.

[0005] In addition, the large number of motors used in the robot arm generates a lot of noise. Therefore, in order to run many power supply cables along the robot arm, it is necessary to take thorough measures against noise to prevent malfunctions, which is also time-consuming.

[0006] Furthermore, since the distance between the lighting device and the lighting controller is long, the inductance of the power supply cable itself becomes large, which causes another problem of a long rise time for the power supply for light emission.

[0007] The present invention has been made to solve all of the above-mentioned problems in one fell swoop, and its main objective is to reduce the effort required for handling power supply cables and the effort required for noise countermeasures in an image processing system using a robot arm, and to shorten the rise time of power supply for light emission. [Means for solving the problem]

[0008] That is, the image processing system of the present invention is characterized by comprising an image processing unit having a light irradiation device that irradiates light onto a workpiece, an imaging device that images the workpiece, and a light emission control device that supplies power to the light irradiation device and controls its light emission mode, a robot arm that supports the image processing unit at its tip so that its position and posture can be changed, and an information processing device that supplies power to the light emission control device.

[0009] With this configuration, the light emission control device that supplies power to the light irradiation device is supported at the tip of the robot arm together with the light irradiation device, so even when a light irradiation device that requires multi-channel control is used, there is no need to install multiple power supply cables connecting the light irradiation device and the light emission control device along the robot arm, which reduces the effort required for handling the power supply cables and the effort required for noise countermeasures. Furthermore, since the power supply cable connecting the light irradiation device and the light emission control device can be shortened, the inductance of the power supply cable itself can be reduced and the rise time of the power supply for light emission can be shortened.

[0010] A specific embodiment in which the effects of the present invention are prominently exhibited is one in which the light irradiation device includes a plurality of light irradiators, and the light emission control device supplies power to the plurality of light irradiators in individual modes and controls the light emission modes thereof.

[0011] In the image processing system, it is preferable that the information processing device and the light emission control device, and the light emission control device and the imaging device are connected by communication cables capable of supplying power. In this way, the light emission control device can function as a hub, enabling power supply and communication between the information processing device and the imaging device, thereby reducing the number of cables running through the robot arm and reducing the effort required for handling them and the effort required for noise control.

[0012] It is preferable that the information processing device includes an upper-level trigger control unit that outputs a trigger signal to the light emission control device, and the light emission control device includes a lower-level trigger control unit that outputs a trigger signal to the imaging device, and that upon receiving the trigger signal output from the upper-level trigger control unit, the lower-level trigger control unit outputs a trigger signal to the imaging device. In this way, the function of the trigger control unit that outputs a trigger signal to the imaging device is distributed between the information processing device and the light emission control device, thereby reducing the computational processing load of each device.

[0013] A specific embodiment of the image processing system is one in which the image processing unit further includes an attachment member integrally connected to the light irradiation device, the imaging device, and the light emission control device, and the image processing unit is supported at the tip of the robot arm by attaching the attachment member to a mounting portion provided at the tip of the robot arm.

[0014] In the image processing system, it is preferable that the image processing unit includes a separation mechanism, located on the tip side of the attachment member, for detachably separating the light emission control device from the light irradiation device and the imaging device. In this way, it is possible to remove and replace only the light irradiation device and the image capture device without replacing the light emission control device, and it is possible to perform optimal photography according to the shape of the workpiece. Moreover, it is possible for the user to keep costs down by using one light emission control device as is and not needing to purchase a new one.

[0015] Furthermore, it is preferable that the image processing system further includes a forced air cooling mechanism for generating an air flow within the housing of the light irradiation device or the light emission control device for cooling, and that the forced air cooling mechanism includes a compressor provided on the base end side of the robot arm and a cooling airline connecting the compressor to the inside of the housing of the light irradiation device or the inside of the housing of the light emission control device. In this way, the light irradiation device and the light emission control device can be cooled without having to attach heat dissipation fins or cooling fans, making it possible to make these devices smaller and lighter. This reduces the weight of the image processing unit itself supported at the tip of the robot arm, making it possible to select a small robot arm with a relatively small payload capacity. This reduces the cost of the robot arm, reduces the space required for its operation, and shortens the takt time.

[0016] When such a forced air-cooling mechanism is provided, it is preferable that the robot arm is provided with a mechanism for blowing or sucking in air for a specified operation from the tip of the arm, and that a compressor is shared between this mechanism and the forced air-cooling mechanism. In this way, the compressor can be used for both purposes, thereby reducing costs. Effect of the Invention

[0017] According to the present invention configured in this manner, in an image processing system using a robot arm, the effort required for managing the power supply cable and the effort required for noise countermeasures can be reduced, and the rise time of the power supply for light emission can be shortened. [Brief description of the drawings]

[0018] [Figure 1] 1 is a diagram showing a schematic diagram of an overall configuration of an image processing system according to an embodiment of the present invention; [Diagram 2] FIG. 2 is a functional block diagram of the image processing system according to the embodiment. [Diagram 3] FIG. 2 is a diagram showing a connection state of a communication cable and a power supply cord in the image processing unit of the embodiment. [Figure 4] FIG. 4 is a diagram showing a schematic diagram of a connection state of cooling air lines in the image processing unit of the embodiment. [Diagram 5] FIG. 13 is a diagram illustrating an overall configuration of an image processing system according to another embodiment. [Figure 6] FIG. 13 is a diagram illustrating an overall configuration of an image inspection system according to another embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] An image processing system 100 according to an embodiment of the present invention will be described below with reference to the drawings.

[0020] As shown in FIG. 1, the image processing system 100 of this embodiment includes a light irradiation device 11, an imaging device 12, a robot arm 2 that supports the light irradiation device 11 and the imaging device 12 so that their position and posture can be changed, a light emission control device 13 that outputs a light emission command signal to the light irradiation device 11, and an information processing device 3. The image processing system 100 inspects part or all of the surface of the workpiece by irradiating the workpiece with light, capturing an image of the workpiece, and processing the captured image.

[0021] The light irradiation device 11 irradiates the workpiece with light using, for example, an LED. The light irradiation device 11 of this embodiment includes a plurality of light irradiators capable of individually controlling the light emission mode. Here, each light irradiator is a line type or a bar type that irradiates a straight line or a strip of light, but is not limited thereto.

[0022] The imaging device 12 includes a light receiving optical system such as a lens, and an imaging element that receives and senses the light that has passed through the light receiving optical system. The imaging device 12 of this embodiment is called a line camera, but is not limited to this.

[0023] The robot arm 2 supports the light irradiation device 11 and the imaging device 12 at the tip of its arm section 21 and sets their postures and positions. The robot arm 2 of this embodiment is a so-called vertical articulated robot, and is configured so that the postures and positions of the light irradiation device 11 and the imaging device 12 can be set with, for example, six degrees of freedom. Note that the robot arm 2 of this embodiment is an industrial robot, but is not limited to this and may be a collaborative robot.

[0024] The robot arm 2 has an air blowing mechanism for blowing air from the tip of the arm portion 21 to perform a predetermined operation (for example, removing dust, etc.). The air blowing mechanism includes a compressor 71 provided on the base end side of the robot arm 2 (more specifically, inside the box-shaped base 22), and an operation airline 72 that guides the air compressed by the compressor 71 to the tip of the robot arm 2. The operation airline 72 is installed along the arm portion 21 of the robot arm 2, with one end on the upstream side connected to the compressor 71 and one end on the downstream side opening near the tip of the arm portion 21. The operation airline 72 is composed of an air tube or a hose. The compressor 71 of this embodiment is a bidirectional type that can be switched between a pressurization mode and a suction mode. The air blowing mechanism of this embodiment also functions as a suction mechanism that sucks air from the tip of the arm portion 21 by switching the compressor 71 from the pressurization mode to the suction mode.

[0025] The light emission control device 13 supplies power to the multiple light irradiators included in the light irradiation device 11 and controls the light emission modes thereof, and is also called an illumination controller or a power supply device. This light emission control device 13 is a multi-channel type having multiple channels for supplying power to each light irradiator. As shown in Fig. 3, the light emission control device 13 supplies power to the multiple light irradiators in individual modes via power supply cords 4 connected to each of the multiple channels, and can control the light emission modes thereof.

[0026] The information processing device 3 is connected to the light emission control device 13 and the imaging device 12 via a cable 5. The information processing device 3 is a computer equipped with various input devices such as a mouse and a keyboard, a CPU, a memory, a display, and the like. The information processing device 3 performs at least the functions of a power supply unit 31 that supplies power to the light emission control device 13 and the imaging device 12, a trigger control unit 32 that outputs a trigger signal for synchronizing the light emission timing of the light emission control device 13 with the shutter timing of the imaging device 12, a light emission setting storage unit 33 that stores light emission parameters set for each channel of the light emission control device 13, a communication unit 34 that performs data communication of captured images and the like with the imaging device 12, and an image processing unit 35 that processes the acquired captured images, as shown in FIG. 2, by the CPU and its peripheral devices working together according to a predetermined program stored in the memory. The information processing device 3 is installed on the base end side of the robot arm 2 (specifically, inside the pedestal 22).

[0027] In the image processing system 100 of this embodiment, the light emission control device 13 is supported at the tip of the robot arm 2 together with the light irradiation device 11 and the imaging device 12. More specifically, in the image processing system 100 of this embodiment, the light irradiation device 11, the imaging device 12, and the light emission control device 13 are connected to each other and integrated into an image processing unit 1. This image processing unit 1 has a dedicated attachment member 14 that is detachably attached to a mounting portion 211 provided at the tip of the robot arm 2, and is attached to and supported at the tip of the robot arm 2 using this attachment member 14.

[0028] In this embodiment, the information processing device 3 and the light-emitting control device 13 are connected by one communication cable 5 (hereinafter also referred to as the upstream communication cable 5) capable of supplying power. Specifically, this upstream communication cable 5 is called an Ethernet cable compatible with the PoE standard, and through this upstream communication cable 5, power supply (PoE power supply) from the information processing device 3 to the light-emitting control device 13, data communication between the information processing device 3 and the light-emitting control device 13, and trigger control from the information processing device 3 to the light-emitting control device 13 can be performed. The light-emitting control device 13 also complies with the PoE standard. This upstream communication cable 5 is attached along the arm portion 21 of the robot arm 2.

[0029] 3, the light emission control device 13 and the imaging device 12 are also connected by a power-supplying communication cable 6 (specifically, an Ethernet cable conforming to the PoE standard. Hereinafter, also referred to as a downstream communication cable), and power supply, data communication, and trigger control can be performed between the information processing device 3 and the imaging device 12 via the light emission control device 13. The imaging device 12 also conforms to the PoE standard.

[0030] In this embodiment, not only the information processing device 3 but also the light emission control device 13 is provided with a function as a trigger control unit (lower trigger control unit) that outputs a trigger signal. When a trigger signal (upper trigger signal) output from the trigger control unit 32 (referred to as upper trigger control unit) of the information processing device 3 is received, the lower trigger control unit is configured to output a trigger signal (lower trigger signal) to the imaging device 12. That is, the lower trigger signal output by the lower trigger control unit is a plurality of signals for controlling the shutter timing of the imaging device 12, and the upper trigger signal output by the upper trigger control unit 32 is a signal for controlling the start timing at which the lower trigger control unit outputs a plurality of lower trigger signals. In other words, the upper trigger control unit 32 performs rough trigger control, and the lower trigger control unit performs finer trigger control. In this way, by distributing the function as a trigger control unit that outputs a trigger signal to the imaging device 12 between the information processing device 3 and the light emission control device 13, the load of the calculation process of each device can be reduced.

[0031] The image processing system 100 of this embodiment also has a forced air-cooling mechanism for cooling the light irradiation device 11 and the light emission control device 13. This forced air-cooling mechanism forcibly cools the insides of the light irradiation device 11 and the light emission control device 13 by generating an air flow within each of the housings of the light irradiation device 11 and the light emission control device 13. Specifically, the forced air-cooling mechanism includes a compressor 81 provided on the base end side of the robot arm 2, and a cooling air line 82 connecting the compressor 81 to the inside of the housing of the light irradiation device 11 and the inside of the housing of the light emission control device 13. The cooling air line 82 is configured using an air tube or a hose.

[0032] The cooling airline 82 has two airlines: an arm side airline 821 provided on the robot arm 2 side of the connection between the robot arm 2 and the image processing unit 1, and an image processing unit side airline 822 provided on the image processing unit 1 side of the connection.

[0033] The arm-side airline 821 is installed so as to pass through the inside of the arm part 21 of the robot arm 2, one end of which is connected to the compressor 81, and the other end of which is opened to the mounting part 211 at the tip of the robot arm 2. As shown in FIG. 4, the image processing unit side airline 822 has one end which is opened to the end face of the attachment member 14, and the other end which is connected to the ventilation holes provided in the housing of the light irradiation device 11 and the housing of the light emission control device 13. When the attachment member 14 of the image processing unit 1 is attached to the mounting part 211 of the robot arm 2, the arm-side airline 821 and the image processing unit side airline 822 are connected, and the compressor 81 is communicated with the space in the housing of the light irradiation device 11 and the space in the housing of the light emission control device 13. In this embodiment, the compressor 81 is configured to suck air, so that an air flow is generated in the housing of the light irradiation device 11 and the housing of the light emission control device 13.

[0034] In this embodiment, the compressor is shared between the air blowing mechanism and the forced air cooling mechanism, and the operating air line 72 and the cooling air line 82 are connected to the common compressors 71, 81.

[0035] According to the image processing system 100 of the present embodiment configured as described above, the light emission control device 13 that supplies power to the light irradiation device 11 is supported at the tip of the robot arm 2 together with the light irradiation device 11. Therefore, even when a light irradiation device 11 that requires multi-channel control is used, it is not necessary to lay a large number of power supply cords 4 connecting the light irradiation device 11 and the light emission control device 13 along the robot arm 2. This reduces the effort required for handling the power supply cord 4 and the effort required for noise countermeasures. Furthermore, since the power supply cord 4 connecting the light irradiation device 11 and the light emission control device 13 can be shortened, the inductance of the power supply cord 4 itself can be reduced, and the rise time of the power supply for light emission can be shortened.

[0036] The present invention is not limited to the above-described embodiment. For example, the image processing unit 1 of another embodiment may be provided with a separation mechanism 15 for detachably separating the light emission control device 13 from the light irradiation device 11 and the image capture device 12 at the tip side of the attachment member 14. In this case, the light irradiation device 11 and the image capture device 12 may be integrally connected to form a unit. In this way, only the light irradiation device 11 and the image capture device 12 can be removed and replaced without replacing the light emission control device 13, and optimal photography can be performed according to the shape of the work. Moreover, the user can use one light emission control device 13 as it is and does not need to purchase a new one, thereby reducing costs.

[0037] In another embodiment, only some of the light irradiation device 11, the imaging device 12, and the light emission control device 13 may be attached to the tip of the robot arm 2 via an attachment member 14. For example, as shown in Fig. 6, the light irradiation device 11 and the imaging device 12 may be attached via an attachment member 14, and the light emission control device 13 may be fixed to the tip of the robot arm 2.

[0038] In the above embodiment, the function of performing trigger control over the imaging device 12 is distributed between the information processing device 3 and the light emission control device 13, but this is not limited to the above. In other embodiments, the function of performing trigger control over the imaging device 12 may be performed only by the information processing device 3, not by the light emission control device 13.

[0039] In the above embodiment, the trigger control is performed by the power-supplying communication cables 5 and 6, but this is not limiting. In other embodiments, the information processing device 3 and the light emission control device 13, and the light emission control device 13 and the image capture device 12 may be further connected by a dedicated trigger cable.

[0040] In the above embodiment, the light irradiation device 11 has a plurality of light irradiators, and the light emission control device 13 controls the light emission modes of the plurality of light irradiators, but this is not limiting. In another embodiment, the light emission control device 13 may have one channel and control the light emission mode of a single light irradiator.

[0041] The forced air-cooling mechanism of still another embodiment does not have to generate an air flow inside the housings of the light irradiation device 11 and the light emission control device 13 to perform air cooling. For example, the forced air-cooling mechanism may cool the housings of the light irradiation device 11 and the light emission control device 13 by blowing gas onto them from the outside.

[0042] In addition, in the above embodiment, an appearance inspection based on image processing is given as an example, but it is also applicable to character recognition, positioning, etc. In addition, the information processing device 3 may be installed not on the base end side of the robot arm 2 but at a location away from the robot arm 2, and a connected cable may be connected to the base end side of the robot arm 2. [Explanation of symbols]

[0043] 100 Image Processing System 1. Image processing unit 11...Light irradiation device 12 Imaging device 13 Light Emitting Control Device 2. Robot arm 3. Information Processing Device

Claims

1. An image processing unit including a light irradiation device that irradiates light onto a workpiece, an imaging device that images the workpiece, and a light emission control device that supplies power to the light irradiation device and controls the light emission mode of the light irradiation device; a robot arm that supports the image processing unit at a tip thereof so as to be capable of changing a position and a posture; and an information processing device that supplies power to the light emission control device.

2. The light irradiation device includes a plurality of light irradiators, 2. The image processing system according to claim 1, wherein the light emission control device supplies power to the plurality of light irradiators in individual modes and controls the light emission modes of the light irradiators.

3. 2. The image processing system according to claim 1, wherein the information processing device and the light emission control device, and the light emission control device and the imaging device are connected by communication cables capable of supplying power.

4. the information processing device includes a host trigger control unit that outputs a trigger signal to the light emission control device, the light emission control device includes a lower trigger control unit that outputs a trigger signal to the imaging device, The image processing system according to claim 3 , wherein, upon receiving a trigger signal output from the upper trigger control unit, the lower trigger control unit outputs a trigger signal to the imaging device.

5. the image processing unit further includes an attachment member integrally connected to the light irradiation device, the imaging device, and the light emission control device; 2. The image processing system according to claim 1, wherein the image processing unit is supported at the tip of the robot arm by attaching the attachment member to a mounting portion provided at the tip of the robot arm.

6. The image processing system according to claim 5 , wherein the image processing unit further comprises a separation mechanism, located on a tip side of the attachment member, for detachably separating the light emission control device from the light irradiation device and the image capturing device.

7. A forced air-cooling mechanism for generating an air flow in a housing of the light irradiation device or the light emission control device to perform air cooling, 2. The image processing system according to claim 1, wherein the forced air cooling mechanism comprises a compressor provided on the base end side of the robot arm, and a cooling air line connecting the compressor to a housing of the light irradiation device or a housing of the light emission control device.

8. The robot arm is provided with a mechanism for blowing or sucking air for a predetermined operation from the tip of the arm, 8. The image processing system according to claim 7, wherein a compressor is shared between said mechanism and said forced air cooling mechanism.

Images