System for checking number of bound steel materials and method for checking number of bound steel materials

Abstract

To provide a system for checking the number of bound steel materials and a method for checking the number of bound steel materials with which the number of steel materials in one bundle can be more accurately checked.SOLUTION: A system for checking the number of bound steel materials comprises: a counting processing apparatus that acquires a photographed image obtained by photographing the bundle of steel materials from an imaging apparatus, and determines a count number that is the number of steel materials included in a bundle to be collated through image processing on the acquired photographed image; and a collation processing apparatus that acquires the count number, acquires a registered number that is the number of steel materials to be included in the bundle to be collated, from a bundle information database in which information on the bundle of steel materials is registered, and performs collation processing as to whether the count number and the registered number match each other. When both the numbers do not match in the collation processing, the system causes the imaging apparatus to photograph the bundle to be collated again, and the collation processing apparatus performs the collation processing again on a count number determined from the photographed image obtained by photographing the bundle again.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a bundling number confirmation system for confirming the number of steel materials bundled in a bundle of steel materials.

Background Art

[0002] In the manufacturing process of steel materials such as steel bars, for example, after hot rolling, they are cooled and conveyed to inspection equipment, and inspections are performed by ultrasonic flaw detectors and the like. Then, the steel materials that have passed the inspection are bundled in multiple pieces and shipped.

[0003] Regarding the bundle of bundled steel materials, it is preferable to confirm whether they are bundled in the correct number. For example, when bundling a plurality of steel materials with a bundling device after inspection, the operator visually counts the number of pieces to be transferred to the bundling device to confirm the number of pieces in one bundle.

[0004] Also, as a method for confirming the number after bundling, for example, the weight of one bundle (calculated value) calculated based on the weight of one steel material and the number of pieces that should be included in one bundle is compared with the actual weight of one bundle obtained by weighing after bundling to confirm the consistency of the number.

[0005] Also, a method has been proposed in which a round bar is imaged with a camera and the number is confirmed by image processing (Patent Document 1).

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0007] In the case of the method of visually checking the number of steel materials when transferring them to the above-mentioned bundling device, there is a possibility of counting errors because the check is performed manually. Also, in the case of the method of checking by the consistency of the weight after bundling, the number of bundled pieces cannot be directly confirmed.

[0008] Moreover, the method of Patent Document 1 is intended to count a plurality of round bars arranged in a transport line, and it is difficult to apply it to counting the number of steel materials included in one bundled group.

[0009] Therefore, an object of the present embodiment is to provide a steel material bundling number confirmation system and a steel material bundling number confirmation method that can more accurately confirm the number of steel materials in one bundle.

Means for Solving the Problems

[0010] The embodiment of the present application has been made to solve the above problems, and the gist is as follows.

[0011] (1) A counting processing device that acquires a captured image of the end portion of a bundle of bundled steel materials from an imaging device and obtains a counted number, which is the number of steel materials included in the bundle to be collated, by performing image processing on the acquired captured image; A collation processing device that acquires the counted number from the counting processing device, acquires a registered number, which is the number of steel materials that should be included in the bundle to be collated, from a bundle information database in which information about the bundle of steel materials is registered, and performs a collation process to determine whether the acquired counted number matches the registered number; A steel material bundling number confirmation system comprising: In the case where the numbers do not match in the collation process, the imaging device is caused to re-capture the bundle to be collated, and the collation processing device performs the collation process again for the counted number obtained by the counting processing device from the re-captured captured image. A steel material bundling number confirmation system characterized by this.

[0012] (2) In the collation process performed on the counted number obtained from the photographed image by the re - photography, when the numbers do not match, the counting device acquires the photographed image in which an operator has photographed the bundle to be collated using the operator's imaging device, obtains the counted number from the acquired photographed image, and the collation processing device performs the collation process on the counted number obtained from the photographed image by the operator's imaging device. The steel material bundle number confirmation system according to (1) above, characterized in that.

[0013] (3) In the collation process, when the numbers match, the steel material bundle number confirmation system according to (1) or (2) above, characterized in that a shipping label to be used for shipping the bundle to be collated is issued to a labeler.

[0014] (4) In the tracking screen of the steel material in the manufacturing process, the steel material bundle number confirmation system according to (1) above, characterized in that the collation result of the collation process is displayed in association with information about the bundle.

[0015] (5) The information displayed on the tracking screen includes information indicating the position of the bundle, the identification number of the bundle, the registered number, the counted number, and a display of the match or mismatch of the numbers as the collation result. The steel material bundle number confirmation system according to (4) above, characterized in that.

[0016] (6) The steel material bundle number confirmation system according to (1) above, characterized in that photographing is performed on a bundle on a weighing machine that weighs steel materials in the manufacturing process using the imaging device.

[0017] (7) An image - processing on the photographed image obtained by acquiring a photographed image of the end part of the bundle of bundled steel materials is performed to obtain a counted number, which is the number of steel materials included in the bundle to be collated. The counted number is acquired, a registered number, which is the number of steel materials that should be included in the bundle to be collated, is acquired from a bundle information database in which information about the bundle of steel materials is registered, and a collation process is performed to determine whether the acquired counted number matches the registered number. A method for confirming the number of bundled steel materials, When the numbers do not match in the verification process, the imaging device is caused to re-take an image of the bundle to be verified, and the verification process is performed again for the counted number obtained from the re-taken captured image. A method for confirming the number of bundled steel materials, characterized by this.

[0018] (8) In the verification process performed on the counted number obtained from the captured image by the re-take, when the numbers do not match, an operator uses an operator imaging device to acquire a captured image of the bundle to be verified, obtains the counted number from the acquired captured image, and performs the verification process on the counted number obtained from the captured image by the operator imaging device. The method for confirming the number of bundled steel materials according to (7) above, characterized by this.

[0019] (9) When the numbers match in the verification process, a shipping label used for shipping the bundle to be verified is issued to a labeler. The method for confirming the number of bundled steel materials according to (7) or (8) above, characterized by this.

[0020] (10) On a tracking screen of steel materials in a manufacturing process, the verification result of the verification process is displayed in association with information regarding the bundle. The method for confirming the number of bundled steel materials according to (7) above, characterized by this.

[0021] (11) The information displayed on the tracking screen includes information indicating the position of the bundle, an identification number of the bundle, the registered number, the counted number, and a display of whether the numbers match or do not match as the verification result. The method for confirming the number of bundled steel materials according to (10) above, characterized by this.

[0022] (12) An image is taken of a bundle on a weighing machine that weighs steel materials in a manufacturing process by the imaging device. The method for confirming the number of bundled steel materials according to (7) above, characterized by this.

Advantages of the Invention

[0023] According to one aspect of the embodiment, it is possible to provide a steel material bundling number confirmation system and a steel material bundling number confirmation method that can more accurately confirm the number of steel materials in a bundle.

Brief Description of the Drawings

[0024]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Modes for Carrying Out the Invention

[0025] Hereinafter, embodiments will be described with reference to the drawings. FIG. 1 is a diagram showing an example of a manufacturing process for performing the bundling number confirmation process of the steel material of the present embodiment. FIG. 2 is a system configuration diagram for executing the bundling number confirmation process of the steel material of the present embodiment.

[0026] In the present embodiment described below, the “network” includes various networks configured by wire or wireless, and includes, for example, the Internet, LAN (local area network), WAN (wide area network), mobile communication network, and the like.

[0027] The bound steel material bound number confirmation system 1 of this embodiment (hereinafter simply referred to as "system 1") performs a process of counting the number of bound steel materials (bound number) for a bundle of steel materials cut to a predetermined length after rolling in a manufacturing process of steel materials such as bar steel, etc., bound by a bundling device in a predetermined number. Then, for example, it compares the registered number, which is the number of bound steel materials that should be included in each bundle in the manufacturing process and is registered in a process computer 200, with the counted number counted in the bound number confirmation system 1, determines whether the bundle to be collated has the correct bound number, and outputs the result.

[0028] The manufacturing process for implementing the bound number confirmation process shown in FIG. 1 will be described. The manufacturing process in FIG. 1 is, for example, a process on the downstream side of the rolling process, and includes an inspection table 10, a conveyor 12, a bundling device 14, a weighing machine 16, an extraction conveyor 18, a conveyor 20, etc. The inspection table 10 is a place where the steel material 80 cooled after the rolling process is conveyed and various inspections are performed. Specifically, for example, straightening by a straightening machine, surface inspection by a surface defect inspection device, internal inspection by an ultrasonic flaw detector, etc. are performed. The bundling device 14 bundles the steel materials that have passed the inspection on the inspection table 10. When a predetermined number of steel materials 82 are transferred from the inspection table 10 to the conveyor 12 and collected, they are conveyed to the bundling device 14 and bundled with a bundling material. The weighing machine 16 weighs the bundle 84 of the bundled steel materials. The extraction conveyor 18 is a conveyor that conveys the bundle of steel materials weighed by the weighing machine 16. Also, when there is a bundle with an incorrect bound number, etc., the operator performs a process of checking or removing the bundle on the extraction conveyor 18. Further, on the extraction conveyor 18, the operator 28 attaches a shipping label etc. issued from the labeler 26 to the bundle. The conveyor 20 conveys the bundle with a shipping label etc. attached to a warehouse etc. Note that the bundle may be conveyed by another means such as a crane instead of the conveyor 20.

[0029] In this embodiment, in the manufacturing process, a camera 22 which is a part of the configuration of the system 1 is arranged. Also, it is preferable to use a tablet terminal 24 which is a photographing device for manually taking pictures.

[0030] The camera 22 is an imaging device that photographs a bundled steel material. The camera 22 detects that the bundle 84 has been conveyed to the weighing machine 16 by the sensor 22a, and photographs the bundle 84 on the weighing machine 16. The camera 22 photographs the end portions of the steel materials in the bundle 84. In the present embodiment, the camera 22 photographs the front end portion of the steel material in the conveyance direction from the bundling device 14 to the weighing machine 16.

[0031] The position of the steel material photographed by the camera 22 is not necessarily limited to being on the weighing machine 16. However, since the steel material once stops on the weighing machine 16 when being weighed, the steel material can be photographed in a stationary state. That is, a clear image suitable for counting by the image processing described later can be photographed, so that the number of bundled items can be appropriately counted. Also, by performing the photographing during weighing, it is not necessary to stop the conveyance line only for the purpose of photographing, and the number can be confirmed without reducing the manufacturing efficiency.

[0032] The camera 22 is not particularly limited as long as it includes an image sensor such as a CCD (Charge Coupled Device) and an imaging optical system such as a lens. However, it is preferable to have a zoom function and an autofocus function that can automatically focus on the end portion of the bundle 84. The camera 22 uses a zoom function or the like to photograph an appropriate image in which the end portion of the steel material is in focus.

[0033] The sensor 22a may be any sensor that can detect that the bundle 84 has been conveyed onto the weighing machine 16. For example, an optical sensor such as a photoelectric sensor can be used. Also, the sensor 22a may be arranged separately from the camera 22.

[0034] Also, the camera 22 has a communication unit 22b that transmits the photographed image to the counting processing device 50. The communication unit 22b may be directly connected to the counting processing device 50 for communication, or may be connected via a network, and may be connected either by wire or wirelessly.

[0035] For the captured image captured by the camera 22, image processing can be performed in the system 1, and the number of bundles can be counted. The counted number of bundles, i.e., the count number, is used in the verification process for verifying whether the bundle is tied with the correct number of ties. For example, it is used for comparison with the registered number, which is the correct number of ties pre-registered in the professional controller 200.

[0036] The tablet terminal 24 is an imaging device for an operator to manually capture an image of a bundle. When the count number is different from the correct number as a result of the verification process, it can be used for manual imaging to re-count the bundle. For example, when the number does not match in the first verification process using the captured image by the camera 22 and also does not match in the second verification process after re-capturing by the camera 22, manual imaging using the tablet terminal 24 can be performed.

[0037] The tablet terminal 24 has a camera 24a and a communication unit 24b. The camera 24a performs imaging, and the communication unit 24b performs communication for transmitting the captured image to the counting processing device 50. The communication unit 24b may be directly connected to and communicate with the counting processing device 50, or may be connected via a network, and may be connected either by wire or wirelessly.

[0038] Note that the device used for manual re-imaging is not limited to the tablet terminal 24, and any device that can capture an image of a bundle and transmit the captured image to the counting processing device 50 may be used. For example, a smartphone or a digital camera equipped with a communication function may also be used.

[0039] The results of the collation process using the captured image by the camera 22 and the results of the collation process using the captured image by the tablet terminal 24 can be displayed on the terminal 250 connected to the professional computer 200 via the network. In the present embodiment, the collation result is displayed on the steel material tracking screen in the manufacturing process. Thereby, for example, when there is a bundle in which the number is inconsistent even in the re-collation process based on the captured image by the tablet terminal 24, the operator can immediately confirm the result of the inconsistency on the terminal 250 and take necessary measures such as removing the bundle from the conveying line.

[0040] Next, the system configuration of the bundle number confirmation system 1 of the present embodiment will be described with reference to FIG. 2. The system 1 includes a counting processing device 50, a collation processing device 100, a professional computer 200, a terminal 250, a conveying system PLC 300, a labeler 26, a camera 22, a tablet terminal 24, and the like. As the professional computer 200 and the conveying system PLC 300, existing devices used for information processing and equipment control in the steel material manufacturing process can be utilized.

[0041] The counting processing device 50 acquires a captured image from the camera 22 or the tablet terminal 24, and performs a process of counting the number of steel materials included in the captured bundle by image processing on the captured image of the bundle, and obtains the counted number of the target bundle. As the counting processing device 50, a general-purpose computer can be used. The counting processing device 50 includes a control unit 52, a storage unit 54, a count processing program 56, a communication unit 58, and the like.

[0042] The control unit 52 controls various processes of the counting processing device 50, and in this embodiment, particularly performs the count processing of the number of bound books by image processing. The control unit 52 includes a processor and a memory. The processor is a circuit that executes a control program stored in the storage unit 54 and the like to execute various processes, and is, for example, a CPU (central processing unit) or an MPU (micro processing unit). The memory is, for example, a semiconductor memory, such as a RAM (random access memory) that provides a temporary work area for the processor and a ROM (read only memory) that stores the control program of the processor. Note that the control unit 52 may include an ASIC (application specific integrated circuit) that realizes some or all of the functions realized by executing the program stored in the storage unit 54 and the like.

[0043] The storage unit 54 stores an OS and other control programs for controlling the processes of the counting processing device 50. The storage unit 54 also stores the count processing program 56. The storage unit 54 may be, for example, a hard disk drive (HDD) or other magnetic storage device, an optical storage device, a semiconductor storage device such as a flash memory, or any combination thereof.

[0044] The count processing program 56 is a program for realizing the function of performing image processing on the captured image of the bundle acquired from the camera 22 and the like and counting the number of bound books of the bundle when executed by the control unit 52. As the count processing program 56, a known counting program capable of counting a predetermined object included in the image by image processing can be used.

[0045] The communication unit 58 is an interface for communicating with the collation processing device 100, the camera 22, and the tablet terminal 24. The communication unit 58 may be directly connected to and communicate with the collation processing device 100 or the like, or may be connected via a network, and may be connected by either wired or wireless means.

[0046] Next, the collation processing device 100 acquires the counted number of bundles to be collated from the counting processing device 50, compares it with the registered number, which is the correct number of bound bundles of the said bundle registered in advance, and performs a collation process to determine whether the correct number of books is bound in the bundle to be collated. Further, the collation processing device 100 transmits the collation result to the procon 200, or outputs a signal based on the collation result to the carrier system PLC 300 or the labeler 26.

[0047] The collation processing device 100 includes a control unit 102, a storage unit 108, a collation processing program 110, a communication unit 112, and the like.

[0048] The control unit 102 controls various processes of the collation processing device 100, and particularly performs the above-mentioned collation process in this embodiment. The control unit 102 includes a processor 104, a memory 106, and the like. The processor 104 is a circuit that executes control programs stored in the storage unit 108 and the like to execute various processes, and is, for example, a CPU (central processing unit) or an MPU (micro processing unit). The memory 106 is, for example, a semiconductor memory, and is a RAM (random access memory) that provides a temporary work area for the processor, a ROM (read only memory) that stores the control program of the processor, and the like. Note that the control unit 102 may include an ASIC (application specific integrated circuit) that realizes some or all of the functions realized by executing the programs stored in the storage unit 108 and the like.

[0049] The storage unit 108 stores an OS and other control programs for controlling the processes of the collation processing device 100. The storage unit 108 also stores the collation processing program 110. The storage unit 108 may be, for example, a hard disk drive (HDD) or other magnetic storage device, an optical storage device, a semiconductor storage device such as a flash memory, or any combination thereof.

[0050] The verification processing program 110 is a program for realizing the verification processing function for a bundle to be verified when executed by the control unit 102. The flow of the verification processing will be described later.

[0051] The communication unit 112 is an interface for communicating with the counting processing device 50, the personal computer 200, the conveyance system PLC 300, the labeler 26, etc. The communication unit 112 may be directly connected to and communicate with the counting processing device 50, the personal computer 200, etc., or may be connected via a network, and may be connected either by wire or wirelessly. Also, they may be connected by different communication methods.

[0052] Next, the personal computer 200 is a higher-level control device that controls and manages the facilities of the entire manufacturing process. For example, the personal computer 200 controls the conveyance system PLC 300 and manages the tracking system that tracks the steel materials and bundles conveyed in the manufacturing process. The personal computer 200 includes a control unit 202, a storage unit 208, a communication unit 212, etc. The configuration and functions of each unit are common to the verification processing device 100, etc. The personal computer 200 is communicably connected to the verification processing device 100, the conveyance system PLC 300, the labeler 26, etc. via a network.

[0053] The storage unit 208 stores the bundle information database (DB) 210. The bundle information DB 210 is a database that manages information about the bundles bundled by the bundling device 14 in the manufacturing process of FIG. 1. FIG. 3 shows an example of the data configuration of the bundle information DB 210. The bundle information DB 210 is composed of information such as the identification number of each bundle, the registered number, the counted number, and the verification result. In addition, it can include information such as the color of the color-coded label indicating the steel type attached to the end face of the steel material.

[0054] The bundle identification number is a number assigned to each bundle. The identification number is displayed on a shipping label attached to the bundle or a seal attached to the steel material, etc., and is used to identify the bundle. The registered quantity is the number of items to be bundled in each bundle, and is registered in advance in the bundle information DB210. The counted quantity is the number of bundled items counted by the counting processing device 50 from the captured image. The collation result is the result of the collation processing device 100 collating the counted quantity with the registered quantity. For example, when they match, it can be displayed as "OK", and when they do not match, it can be displayed as "NG".

[0055] Note that, as will be described later, after the first collation result is inconsistent, if re - shooting by the camera 22 and re - counting and re - collation are performed, or if manual shooting using the tablet terminal 24 and re - counting and re - collation are performed, the counted quantity and collation result thereof can be further registered in the bundle information DB210.

[0056] Also, the pro - con 200 creates a tracking screen that can confirm the collation result for the bundles in the manufacturing process based on the information of the tracking process and the information of the bundle information DB210. The tracking screen is displayed on the terminal 250 or the like. In this embodiment, on the tracking screen, information related to the bundle such as the identification number and the collation result of that bundle are displayed in association, and the operator can immediately confirm the collation result.

[0057] An example of a tracking screen displaying the collation result is shown in FIG. 4. On the tracking screen 252 of FIG. 4, information indicating the position of the bundle on the weighing machine 16 and the extraction conveyor 18, the identification number which is information for identifying the bundle, the registered quantity, the counted quantity, the collation result, etc. are displayed. The operator can view the tracking screen 252 and confirm the collation result, etc. for the bundles at each position on the weighing machine 16 and the extraction conveyor 18. FIGS. 4(a) and (b) show an example of the tracking screen 252 (FIG. 4(a)) when there is a bundle with NG, and a screen (FIG. 4(b)) where the collation result has switched to OK by re - shooting and re - collation.

[0058] For example, in Fig. 4(a), the bundle at the 10th position of the extraction conveyor 18 (the bundle with the identification number A-1052 in Fig. 4), which is the position where it is to be transferred next from the weighing machine 16, has a registered number of 5, but the counted number is 6, resulting in a discrepancy. As a collation result, NG is displayed. Also, the bundle at the 9th position (A-1051) one downstream from it and the bundle (A-1050) one further downstream have counted numbers that match the registered numbers and are displayed as OK. And in Fig. 4(b), this is an example where the number of the bundle (the bundle of A-1052) that was NG was corrected from 6 to 5 as a result of re-photographing and re-collating described later, and the display of NG changed to the display of OK. Also, information such as the collation result of the next bundle (A-1053) conveyed to the weighing machine 16 is newly displayed.

[0059] The tracking screen 252 may simply display the latest collation result at that time. Also, for the steel materials on the extraction conveyor 18, the collation result based on the captured image of the camera 22 or the collation result based on the captured image of the tablet terminal 24 may be distinguished and displayed. Also, when the collation result is NG, a warning may be displayed on the tracking screen 252. Also, regarding the information of the bundle that becomes NG on the tracking screen 252, it may be displayed in a different display method from the information of the OK bundle, such as changing the color or flashing the display.

[0060] Also, when the verification result is NG and then becomes OK in subsequent verification processes, the information of that bundle may be displayed on the tracking screen 252 in a display method different from the case where the result of the first verification is OK. For example, when it becomes OK through reshooting, the verification result OK can be displayed in a different color. Similarly, the corrected counted number may be displayed in a different color, or the entire row of the bundle information that has switched to OK may be displayed in a different color. By using different displays for bundles that have once become NG, the operator can easily grasp that the bundle has been reshot, re-verified, and become OK, or that the counted number has been corrected. Furthermore, when NG changes to OK through reshooting by the camera 22 and when it changes to OK through manual reshooting by the tablet terminal 24, they may be displayed in different colors so that they can be distinguished. Note that as different display methods, in addition to the color of the characters, other methods such as changing the font, changing the color of the frame, or filling the inside of the frame may be used, as long as it is a display method that can distinguish the difference in the verification results.

[0061] The terminal 250 for displaying the tracking screen may be any device as long as it can view the tracking screen. For example, a general-purpose computer, a tablet terminal, a smartphone, a display device, etc. may be used.

[0062] The conveyance system PLC 300 is a conveyance control device that controls conveyance equipment such as the conveyor 12 and the extraction conveyor 18. In this embodiment, when the result of reshooting and re-verification on the weighing machine 16 is inconsistent (NG), the conveyance system PLC 300 controls the conveyor on the line to transfer the steel material from the weighing machine 16 to the extraction conveyor 18, and then can stop the movement of the next bundle (for example, the transfer from the bundling machine 14 to the weighing machine 16). This is for stopping the movement of the bundle and taking a picture of the bundle on the extraction conveyor 18 with the tablet terminal 24.

[0063] The labeler 26 issues a shipping label or the like to be used for shipping the bundle to be collated. The labeler 26 acquires an instruction from the collation processing device 100 that requests the output of a shipping label for the bundle with a matching collation result. The instruction includes information that can identify the bundle to be collated, and a shipping label is output based on that information. The labeler 26 can also use information such as the bundle information DB 210 managed by the procon 200 to acquire the necessary information and output a shipping label. The output label is attached to the target bundle by the operator 28. The above is the system configuration of the bundle number confirmation system 1 of this embodiment.

[0064] Next, the flow of the bundle number confirmation method executed by the bundle number confirmation system 1 will be described. FIG. 5 is a flowchart showing the flow of the bundle number confirmation method of this embodiment. The processing of each step is executed by the control unit (circuit such as a CPU) of the corresponding device unless otherwise specified.

[0065] First, when the sensor 22a of the camera 22 detects a bundle on the weighing machine 16, the camera 22 captures an image of the front end surface of the bundle (step 101).

[0066] Next, the counting processing device 50 acquires a captured image from the camera 22 and counts the number of steel materials included in the bundle in the captured image by executing the counting processing program 56 to obtain the counted number of the bundle (step 102).

[0067] Next, the collation processing device 100 performs a collation process between the counted number and the registered number (step 103). Specifically, the collation processing device 100 acquires the counted number of the bundle photographed on the weighing machine 16 from the counting processing device 50. Also, the collation processing device 100 acquires the registered number of the bundle on the weighing machine 16 from the bundle information DB 210 of the procon 200. Then, a collation process is performed to determine whether the counted number matches the registered number (the first time). Note that the procon 200 can identify the bundle on the weighing machine 16 by the tracking system and output the registered number associated with the identification information of the bundle to the collation processing device 100 in the bundle information DB 210.

[0068] If, as a result of the determination, the counted number matches the registered number (Yes in step 104), the collation processing device 100 outputs a matching collation result (OK) to the procon 200, and the procon 200 registers the collation result in the bundle information DB 210. Further, the procon 200 causes the collation result (OK) to be displayed in the column for the collation result of the bundle to be collated on the tracking screen 252 of the terminal 250 or the like (step 105).

[0069] Also, the collation processing device 100 outputs a signal to the conveyance system PLC 300, and the conveyance system PLC 300 controls the extraction conveyor 18 or the like based on the acquired signal to transfer the bundle from the weighing machine 16 (step 106).

[0070] Also, the collation processing device 100 transmits a signal requesting the issuance of a shipping label for the target bundle to the labeler 26, and the labeler 26 issues a shipping label for the target bundle (step 107). The bundle with the shipping label attached by the operator 28 is conveyed to a warehouse for shipping or the like. Thereafter, the process returns to step 101, and the collation process for the bundles is sequentially repeated.

[0071] Note that steps 105, 106, and 107 do not necessarily have to be in this order, and may be executed in parallel or in a different order.

[0072] On the other hand, if the numbers do not match in the determination in step 104 (No in step 104), the collation processing device 100 outputs a non-matching collation result (NG) to the procon 200, and the procon 200 registers the collation result in the bundle information DB 210. Further, the procon 200 causes the non-matching (NG) to be displayed in the column for the collation result of the bundle to be collated on the tracking screen 252 of the terminal 250 (step 108).

[0073] The verification processing device 100 outputs a signal of a verification result of non - matching (NG) to the counting processing device 50, and the counting processing device 50 instructs the camera 22 to re - photograph the bundle based on the signal. Then, the camera 22 performs re - photographing based on the signal (step 109). Note that the verification processing device 100 may directly send an instruction to the camera 22 to re - photograph based on the non - matching result.

[0074] Then, similar to the first count - verification process, the counting processing device 50 acquires the image re - photographed by the camera 22, performs image processing to count the number (step 110), and the verification processing device 100 verifies the counted number and the registered number (second time) and determines whether they match (step 111). If they match (Yes in step 111), the process proceeds to the processes of steps 105 - 107.

[0075] If they do not match (No in step 111), the verification processing device 100 outputs a verification result of non - matching (NG) to the pro - controller 200, and the pro - controller 200 registers the verification result in the bundle information DB210. At this time, the counted number and the verification result may be registered as the second verification result separately from the first verification result. Also, the pro - controller 200 continues to display non - matching (NG) in the verification result column of the tracking screen 252 of the terminal 250 (step 112). Note that it may be displayed on the tracking screen 252 so that it can be understood that it is the result of the second verification process. Also, the verification processing device 100 issues an instruction to the conveyance system PLC 300 to move the bundle that was NG in re - photographing from the weighing machine 16 to a predetermined position (position for manual photographing) on the extraction conveyor 18 (step 113). Also, the verification processing device 100 stops the conveyance of the next bundle from the bundling device 14 to the weighing machine 16 by the conveyance system PLC 300.

[0076] Next, when manual re - imaging is performed on the tablet terminal 24, the counting processing device 50 acquires an image from the tablet terminal 24 (step 114), performs image processing on the captured image to obtain the counted number (step 115). Then, the collation processing device 100 acquires the counted number, collates the acquired counted number with the registered number (the third time), and determines whether they match (step 116). If they match (Yes in step 116), the process proceeds to the processes of steps 105 - 107.

[0077] If they do not match (No in step 116), the collation processing device 100 outputs a collation result (NG) in which the counted number obtained from the re - captured image does not match to the pro - controller 200, and the pro - controller 200 registers the collation result in the bundle information DB210. Also, the pro - controller 200 continues to display the mismatch (NG) in the column of the collation result of the bundle on the tracking screen 252 of the terminal 250 (step 117).

[0078] If there is also a mismatch when manually imaging the bundle, necessary countermeasures such as removing the bundle from the line are taken (step 118), and the process returns to step 101 to resume the collation process for the next bundle.

[0079] The above is the processing flow of the method for confirming the number of bundled steel materials in this embodiment. In the above processing, the instructions (signal transmission) from the collation processing device 100 to the conveyance system PLC 300 and the labeler 26 may be performed via the pro - controller 200. Also, in step 113, when manually re - imaging with the tablet terminal 24, it is assumed that the conveyance of the next bundle from the bundling device 14 to the weigher 16 is stopped by the conveyance system PLC 300, but this is not limited thereto. In parallel with the manual re - imaging, the next bundle may be transferred from the bundling device 14 to the weigher 16, and for the transferred bundle, imaging by the camera 22 on the weigher, the steel material counting process, the collation process, etc. may be performed.

[0080] According to the above-described embodiment, for a bundle in which steel materials are bundled, the number of bundled materials can be confirmed more accurately. By accurately confirming the number of bundled materials, it is possible to more reliably prevent the mixing of foreign materials that should not be bundled in the bundle and the occurrence of bundles with incorrect numbers.

[0081] In addition, in this embodiment, the configuration in which the counting processing device 50 and the collation processing device 100 are separate devices (computers) has been described. However, the present invention is not limited to this, and the functions shown in the embodiment may be realized by a single device (computer), or the functions may be realized by three or more devices.

[0082] Further, in this embodiment, it is assumed that the photographing by the camera 22 is performed on the weighing machine 16. However, the present invention is not limited to this. Any other position may be used as long as it is between the weighing machine 16 and the attachment position of the shipping label on the production line and the position of the bundle can be displayed on the tracking screen 252. Further, the photographing position may be appropriately set according to the layout of the production line.

[0083] Further, the manual re-photographing by the tablet terminal 24 may be omitted. In this case, for example, for a bundle in which the numbers do not match even in the second collation process by re-photographing by the camera 22, the operator can take measures such as removing the bundle from the line.

[0084] Further, the re-photographing by the camera 22 and the collation process obtained from the photographed image may be performed three or more times.

Explanation of Reference Numerals

[0085] 1 Bundled Quantity Confirmation System 14 Bundling Device 16 Weighing Machine 18 Extraction Conveyor 22 Camera 24 Tablet Terminal 26 Labeler 50 Counting Processing Device 100 Collation Processing Device 200 Procon 210 Bundle Information DB 252 Tracking Screen 300 Conveyor System PLC

Claims

1. A counting processing device that acquires a captured image obtained by photographing an end portion of a bundle of finished steel materials from an imaging device, and obtains a counted number, which is the number of steel materials included in the bundle to be collated, by performing image processing on the acquired captured image; A collation processing device that acquires the counted number from the counting processing device, acquires a registered number, which is the number of steel materials that should be included in the bundle to be collated, from a bundle information database in which information regarding the bundle of steel materials is registered, and performs a collation process to determine whether the acquired counted number matches the registered number; A steel material bundling number confirmation system comprising: The steel material bundling number confirmation system is characterized in that when the numbers do not match in the collation process, the imaging device is caused to re-photograph the bundle to be collated, and the collation processing device performs the collation process again for the counted number obtained by the counting processing device from the re-photographed captured image.

2. In the collation process performed on the counted number obtained from the captured image by the re-photographing, when the numbers do not match, the counting processing device acquires a captured image obtained by an operator photographing the bundle to be collated using an operator imaging device, obtains a counted number from the acquired captured image, and the collation processing device performs the collation process on the counted number obtained from the captured image by the operator imaging device. The steel material bundling number confirmation system according to Claim 1.

3. The steel material bundling number confirmation system according to Claim 1 or 2, characterized in that when the numbers match in the collation process, a shipping label to be used for shipping the bundle to be collated is issued to a labeler.

4. The steel material bundling number confirmation system according to Claim 1, characterized in that in a tracking screen of steel materials in a manufacturing process, the collation result of the collation process is displayed in association with information regarding the bundle.

5. The information displayed on the tracking screen includes information indicating the position of the bundle, an identification number of the bundle, the registered number, the counted number, and a display of whether the numbers match or do not match as the collation result. The steel material bundling number confirmation system according to Claim 4.

6. The steel material bundling number confirmation system according to Claim 1, characterized in that photographing is performed on a bundle on a weighing machine that weighs steel materials in a manufacturing process using the imaging device.

7. An imaging device acquires a captured image of an end portion of a bundle of finished steel materials, and obtains a counted number, which is the number of steel materials included in the bundle to be collated, by performing image processing on the acquired captured image. The counted number is acquired, a registered number, which is the number of steel materials that should be included in the bundle to be collated, is acquired from a bundle information database in which information regarding the bundle of steel materials is registered, and a collation process is performed to determine whether the acquired counted number matches the registered number. A method for confirming the number of bundled steel materials, The method for confirming the number of bundled steel materials according to claim 7, characterized in that when the numbers do not match in the collation process, the imaging device is caused to re-capture the bundle to be collated, and the collation process is performed again for the counted number obtained from the re-captured image.

8. In the collation process performed on the counted number obtained from the captured image by the re-capture, when the numbers do not match, an operator acquires a captured image of the bundle to be collated using an operator imaging device, obtains a counted number from the acquired captured image, and performs the collation process on the counted number obtained from the captured image by the operator imaging device. The method for confirming the number of bundled steel materials according to claim 7.

9. The method for confirming the number of bundled steel materials according to claim 7 or 8, characterized in that when the numbers match in the collation process, a shipping label to be used for shipping the bundle to be collated is issued to a labeler.

10. The method for confirming the number of bundled steel materials according to claim 7, characterized in that in a tracking screen of steel materials in a manufacturing process, the collation result of the collation process is displayed in association with information regarding the bundle.

11. The method for confirming the number of bundled steel materials according to claim 10, characterized in that the information displayed on the tracking screen includes information indicating the position of the bundle, an identification number of the bundle, the registered number, the counted number, and a display of whether the numbers match or do not match as the collation result.

12. The method for confirming the number of bundled steel materials according to claim 7, characterized in that the imaging device performs imaging on a bundle on a weighing machine that weighs steel materials in a manufacturing process.

Images