Inspection system
The inspection system automates the quality inspection of products by using a side imaging unit to capture images of rotating products on a conveyance line, enabling efficient and accurate detection of quality defects, thus reducing labor and costs.
Patent Information
- Application Number
- JP2023198367
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2023-11-22
- Publication Date
- 2025-06-03
AI Technical Summary
Existing inspection systems for product quality, such as confectionery, rely heavily on manual visual checks, which are labor-intensive and costly, and lack automation to efficiently detect quality defects.
An inspection system comprising a conveyance line, a side imaging unit, a movement adjustment unit, a control unit, and a determination unit, where the side imaging unit captures images of the product rotating on the conveyance line, and the determination unit assesses the product's quality based on these images.
The system effectively automates the inspection process, reducing labor and costs while maintaining high accuracy in detecting quality defects, such as surface bonding issues and content leakage, in products like confectionery.
Smart Images
Figure 2025084454000001_ABST
Abstract
Description
Technical Field
[0001] Embodiments of the present invention relate to an inspection system.
Background Art
[0002] In the production of products such as confectionery, from the viewpoints of improving the quality value of the products and suppressing the decline of the brand name, etc., inspections related to quality such as appearance inspection are carried out at the final stage of the production process. In the inspection related to the quality of products, for example, an object to be inspected is conveyed on a conveyance line, and an inspector or the like visually checks whether or not a quality defect has occurred in the conveyed object. In the inspection related to the quality of products as described above, from the viewpoints of reducing the labor of inspectors and the costs required for inspection, etc., it is required to automate the inspection as much as possible.
Prior Art Documents
Patent Documents
[0003]
Patent Document 1
Summary of the Invention
Problems to be Solved by the Invention
[0004] The problem to be solved by the present invention is to provide an inspection system capable of automating the inspection related to the quality of products.
Means for Solving the Problems
[0005] According to an embodiment, an inspection system includes a conveyance line, a side imaging unit, a movement adjustment unit, a control unit, and a determination unit. The conveyance line conveys a target product, and the side imaging unit can image the target product being conveyed on the conveyance line from one side in the width direction intersecting the conveyance direction. The movement adjustment unit rotates the target product being conveyed on the conveyance line about an axis along the height direction intersecting both the conveyance direction and the width direction. The control unit controls the imaging operation of the side imaging unit to cause the side imaging unit to image the target product at a plurality of time points while the target product is rotating about the axis by the movement adjustment unit. The determination unit determines regarding the quality of the target product based at least on the captured image of the target product by the side imaging unit.
Advantages of the Invention
[0006] According to the present invention, it is possible to provide an inspection system capable of automating the inspection regarding the quality of a product.
Brief Description of the Drawings
[0007]
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Modes for Carrying Out the Invention
[0008] The inspection system (1) of the embodiment includes a conveyance line (2), a side imaging unit (16), a movement adjustment unit (12), a control unit (21), and a determination unit (22). The conveyance line (2) conveys the target product (3), and the side imaging unit (16) can image the target product (3) being conveyed on the conveyance line (2) from one side in the width direction intersecting the conveyance direction. The movement adjustment unit (12) rotates the target product (3) being conveyed on the conveyance line (2) about an axis (C) along the height direction intersecting both the conveyance direction and the width direction. The control unit (21) controls the imaging operation of the side imaging unit (16) to cause the side imaging unit (16) to image the target product (3) at a plurality of time points while the target product (3) is rotating about the axis (C) by the movement adjustment unit (12). The determination unit (22) determines the quality of the target product (3) based at least on the captured image of the target product (3) by the side imaging unit (16). Thereby, while maintaining high inspection accuracy, it becomes possible to automate the inspection regarding the quality of the target product (3) which is a product.
[0009] In the inspection system (1) of the embodiment, the movement adjustment unit (12) includes a plate member (12) extending in a state inclined with respect to both the conveyance direction and the width direction. The plate member (12) rotates the target product (3) about the axis (C) along the height direction by moving the target product (3) along the plate member (12) on the conveyance line (2) in a state where the target product (3) is in contact with the plate member (12). Thereby, while the target product (3) is in contact with the plate member (12), the target product (3) rotates appropriately about the axis (C) due to the reaction force from the plate member (12).
[0010] The inspection system (1) of the embodiment further includes a detection unit (17), and the detection unit (17) detects that the target product (3) being conveyed on the conveyance line (2) has started to contact the plate member (12). Thereby, it becomes possible to appropriately determine whether or not the target product (3) has started to contact the plate member (12), and it becomes possible to appropriately adjust the timing for imaging the target product (3) by the side imaging unit (16).
[0011] In the inspection system (1) of the embodiment, the detection unit (17) includes an upward imaging unit (17) capable of imaging the object (3) being conveyed from above in the height direction, and the upward imaging unit (17) includes the position where the object (3) starts to contact the plate member (12) within the imaging range. The detection unit (17) detects that the object (3) has started to contact the plate member (12) based on the imaging result of the imaging range by the upward imaging unit (17). The control unit (21) controls the imaging operation of the upward imaging unit (17) to cause the upward imaging unit (17) to image the object (3) being conveyed, and the determination unit (22) determines the quality of the object (3) based on the captured image of the object (3) by the side imaging unit (16) and the captured image of the object (3) by the upward imaging unit (17). Thereby, the accuracy of the inspection regarding the quality of the object (3) is further improved. From the imaging result by the upward imaging unit (17), it becomes possible to appropriately determine whether or not the object (3) has started to contact the plate member (12).
[0012] The inspection system (1) of the embodiment further includes a guide member (11), and the guide member (11) is disposed upstream of the plate member (12) in the conveyance line (2). The guide member (11) guides the object (3) toward the plate member (12) to bring the object (3) into contact with the plate member (12). Thereby, in the conveyance line (2), the object (3) being conveyed appropriately contacts the plate member (12) and appropriately rotates about the axis (C).
[0013] The inspection system (1) of the embodiment further includes an exclusion unit (25), and the exclusion unit (25) can exclude the target product (3) from the transport line (2) on the downstream side with respect to the plate member (12). When the determination unit (22) determines that the target product (3) is of poor quality, the control unit (21) controls the operation of the exclusion unit (25) to cause the exclusion unit (25) to exclude the target product (3) determined to be of poor quality from the transport line (2), and based on the timing when the detection unit (17) detects the start of the contact of the target product (3) with the plate member (12), adjusts the timing for excluding the target product (3) by the operation of the exclusion unit (25). Thereby, when a target product (3) of poor quality occurs, the exclusion unit (25) operates at an appropriate timing, and the target product (3) is excluded at an appropriate timing.
[0014] Hereinafter, the embodiment will be described with reference to the drawings.
[0015] FIG. 1 schematically shows an example of an inspection system 1 according to the embodiment. The inspection system 1 in FIG. 1 performs an inspection regarding the quality of a product in the final stage of the production process in the production of products such as confectionery, and performs, for example, an appearance inspection of the product. By the inspection using the inspection system 1, it is confirmed whether or not a quality defect such as an appearance defect has occurred in the produced product. Hereinafter, the product to be inspected by the inspection system 1 is also referred to as a "target product".
[0016] In one example, confectionery is inspected as the target product by the inspection system 1. In this case, by the inspection using the inspection system 1, it is confirmed whether or not any of surface bonding defects such as peeling of the skin, leakage of contents such as filling, gaps, chips, peeling, discoloration, and burning has occurred as a quality defect of the confectionery.
[0017] As shown in FIG. 1, the inspection system 1 includes a conveying line 2. The conveying line 2 is formed of, for example, a belt conveyor. In the conveying line 2, the target product 3 to be inspected is conveyed. In an example of FIG. 1, in the conveying line 2, a plurality of target products 3 are conveyed with an interval. In the conveying line 2, the conveying direction of the target product 3 is the downstream side (arrow X1 side), and the side opposite to the conveying direction is the upstream side (arrow X2 side).
[0018] Further, in the conveying line 2, a width direction (directions indicated by arrow Y1 and arrow Y2) that intersects (is orthogonal or substantially orthogonal) to the conveying direction, and a height direction that intersects (is orthogonal or substantially orthogonal) to both the conveying direction and the width direction are defined. And in the conveying line 2, one side in the height direction is the upper side, and the side opposite to the upper side in the height direction is the lower side. In FIG. 1, the conveying line 2 is shown in a state viewed from the upper side in the height direction. Also, in the conveying line 2, the upper side in the height direction coincides or substantially coincides with the vertically upper side, and the lower side in the height direction coincides or substantially coincides with the vertically lower side.
[0019] In the inspection system 1, the target product 3 is carried into the conveying line 2 through the carry-in line 5. The carry-in line 5 is formed of, for example, a belt conveyor. In an example of FIG. 1, in the carry-in line 5, a plurality of target products 3 are conveyed with an interval, and the plurality of target products 3 are conveyed toward the conveying line 2 (arrow F1). In the carry-in line 5, the side toward the conveying line 2 is the conveying direction and the downstream side, and the side away from the conveying line 2 is the upstream side.
[0020] Even in the loading line 5, a width direction that intersects (is orthogonal or substantially orthogonal) to the conveyance direction, and a height direction that intersects both the conveyance direction and the width direction are defined. And even in the loading line 5, one side in the height direction is the upper side, and the side opposite to the upper side in the height direction is the lower side. The upper side in the height direction of the loading line 5 coincides or substantially coincides with the upper side in the height direction of the conveyance line 2, and coincides or substantially coincides with the vertically upper side. And the lower side in the height direction of the loading line 5 coincides or substantially coincides with the lower side in the height direction of the conveyance line 2, and coincides or substantially coincides with the vertically lower side. In FIG. 1, the loading line 5 is shown in a state viewed from the upper side in the height direction.
[0021] At the upstream end of the conveyance line 2, the target article 3 from the loading line 5 is loaded from a direction intersecting the conveyance direction in the conveyance line 2. In an example of FIG. 1, the target article 3 is loaded at the upstream end of the conveyance line 2 from a direction orthogonal or substantially orthogonal to the conveyance direction in the conveyance line 2. Therefore, the loading line 5 loads the target article 3 from one side in the width direction of the conveyance line 2 into the conveyance line 2, and in an example of FIG. 1, loads the target article 3 into the conveyance line 2 from the arrow Y1 side.
[0022] Also, the inspection system 1 includes a housing 6. The upstream end of the conveyance line 2, that is, the portion where the target article 3 is loaded from the loading line 5 into the conveyance line 2 is located inside the housing 6. The conveyance line 2 extends from inside the housing 6 to the outside of the housing 6, and the downstream end of the conveyance line 2 is located outside the housing 6. Therefore, the target article 3 is conveyed toward the downstream side in the loading line 5 and thus loaded into the housing 6, and in the housing 6, it is loaded from the loading line 5 into the conveyance line 2. And the target article 3 is conveyed toward the downstream side in the conveyance line 2 and thus unloaded from the housing 6.
[0023] The internal space of the housing 6 is surrounded by the housing 6 or the like in a state where light or the like from outside the housing 6 does not enter or hardly enters. However, a slight gap is formed between the housing 6 and the conveying line 2 and between the housing 6 and the loading line 5 in a state where the housing 6 does not contact the conveying line 2 and the loading line 5. Thereby, the influence of the housing 6 on the conveyance of the object 3 through the loading line 5 and the conveying line 2 is suppressed.
[0024] FIG. 2 schematically shows the inside of the conveying line 2 and the housing 6 as viewed from one side (arrow Y2 side) in the width direction of the conveying line 2. In FIG. 2, a state of viewing from the side opposite to the side where the loading line 5 is located, that is, a state of viewing from the side opposite to the side where the object 3 is loaded from the loading line 5 is shown. In FIG. 2, the arrow Z1 side is the upper side in the height direction of the conveying line 2, and the arrow Z2 side is the lower side in the height direction of the conveying line 2.
[0025] As shown in FIGS. 1 and 2, a guide member (guide plate) 11, plate members 12, 13 are arranged on the conveying line 2. The guide member 11 and the plate member 12 are located inside the housing 6. Further, in an example of FIGS. 1 and 2, in the plate member 13, a part is arranged inside the housing 6 and the remaining part is arranged outside the housing 6. Further, the guide member 11 is located on the upstream side of the conveying line 2 with respect to the plate member 12, and the plate member 13 is located on the downstream side of the conveying line 2 with respect to the plate member 12. Therefore, on the conveying line 2, the guide member 11, the plate member 12, and the plate member 13 are arranged in this order from the upstream side. Note that the guide member 11 and the plate members 12, 13 do not move even when the object 3 is being conveyed on the conveying line 2.
[0026] The target product 3 carried from the loading line 5 to the conveying line 2 abuts against the guide member 11. When the target product 3 abuts against the guide member 11, at the upstream end of the conveying line 2, the carried target product 3 is suppressed from moving beyond the guide member 11 to the side where the loading line 5 is located. Since the target product 3 does not move to the side opposite to the side where the loading line 5 is located beyond the guide member 11, the target product 3 conveyed in the conveying line 2 abuts against the plate member 12.
[0027] Therefore, the guide member 11 guides the carried target product 3 in a state where the target product 3 abuts against the plate member 12 in the conveying line 2. That is, the guide member 11 guides the target product 3 toward the plate member 12 so that the target product 3 abuts against the plate member 12. In one example, the guide member 11 guides the carried target product 3 toward a specific position of the plate member 12, and the target product 3 starts to abut against the plate member 12 at the specific position. That is, the guide member 11 guides the target product 3 in a state where the target product 3 starts to abut against the plate member 12 at the specific position.
[0028] The plate member 12 extends in a state of being inclined with respect to both the conveying direction and the width direction of the conveying line 2. As described above, in the conveying line 2, the target product 3 abuts against the plate member 12 by being guided by the guide member 11. In one example of FIGS. 1 and 2, the target product 3 abuts against the plate member 12 from the side opposite to the side where the loading line 5 is located in the width direction of the conveying line 2.
[0029] In the conveying line 2, when the target article 3 abuts against the plate member 12, the target article 3 moves along the plate member 12 while being in contact with the plate member 12. And while the target article 3 is in contact with the plate member 12, that is, while the target article 3 is moving along the plate member 12, due to the reaction force from the plate member 12, the target article 3 rotates (arrow R1) about the axis C along the height direction of the conveying line 2. That is, while the target article 3 is in contact with the plate member 12, the target article 3 rotates about the axis of the axis C. For this reason, the plate member 12 serves as a movement adjustment unit that rotates the conveyed target article 3 about the axis C along the height direction. Here, the axis C corresponds to the central axis of the target article 3.
[0030] During the period when the target article 3 is in contact with the plate member 12, the amount of rotation of the target article 3 about the axis of the axis C changes corresponding to the conveying speed in the conveying line 2, the dimensions of the plate member 12, the inclination angle of the plate member 12 with respect to the conveying direction, etc. In one example, during the period when the target article 3 is in contact with the plate member 12, the target article 3 rotates about the axis C by a rotation amount of 3 / 4 rotation or more. That is, from the start to the end of the contact of the target article 3 with the plate member 12, the target article 3 rotates by a rotation amount of 3 / 4 rotation or more.
[0031] Also, in one example of FIGS. 1 and 2, in the conveying line 2, after the target article 3 finishes contacting the plate member 12, it contacts the plate member 13. The target article 3 contacts the plate member 13 from the side where the loading line 5 is located in the width direction of the conveying line 2. In one example of FIGS. 1 and 2, the plate member 13 extends in a state of being inclined with respect to both the conveying direction and the width direction of the conveying line 2.
[0032] When the target item 3 comes into contact with the plate member 13, the target item 3 moves along the plate member 13 while being in contact with the plate member 13. And while the target item 3 is in contact with the plate member 13, the target item 3 rotates (arrow R2) about the axis C along the height direction of the conveyance line 2 due to the reaction force from the plate member 13. Here, the plate member 13 is inclined to the side opposite to the side where the plate member 12 is inclined with respect to the conveyance direction of the conveyance line 2. For this reason, while the target item 3 is in contact with the plate member 13, the target item 3 rotates about the axis C in the direction opposite to the rotation when it is in contact with the plate member 12.
[0033] Also, in the inspection system 1, a light source 15 and imaging units 16, 17 are arranged inside the housing 6. The light source 15 irradiates light inside the housing 6, for example, irradiates white light. As a result, inside the housing 6, the target item 3 being conveyed is irradiated with light from the light source 15. Also, each of the imaging units 16, 17 is composed of, for example, a camera or a video camera or the like.
[0034] The imaging unit 16 can image the target item 3 being conveyed on the conveyance line 2 from one side in the width direction of the conveyance line 2. For this reason, the imaging unit 16 becomes a side imaging unit that can image the target item 3 being conveyed from the side. In an example of FIGS. 1 and 2, the imaging unit 16 images the target item 3 from the side opposite to the side where the carry-in line 5 is located in the width direction of the conveyance line 2. The imaging range by the imaging unit 16 includes the plate member 12. For this reason, when the target item 3 is in contact with the plate member 12, the imaging unit 16 can image the target item 3 rotating about the axis C.
[0035] The imaging unit 17 can image the target product 3 being conveyed on the conveyance line 2 from above in the height direction of the conveyance line 2. For this reason, the imaging unit 17 serves as an upward imaging unit that can image the conveyed target product 3 from above. The imaging range by the imaging unit 17 includes the position where the target product 3 starts to contact the plate member 12. For this reason, when the target product 3 starts to contact the plate member 12 or immediately thereafter, the imaging unit 17 can image the target product 3 in contact with the plate member 12. In one example, the target product 3 starts to contact the plate member 12 at a specific position, and the specific position where the target product 3 starts to contact the plate member 12 is included in the imaging range of the imaging unit 16.
[0036] FIG. 3 schematically shows the control system etc. of the inspection system 1 in a block diagram. As shown in FIGS. 1 and 3 etc., the inspection system 1 includes a processing device 20. The processing device 20 is composed of, for example, a computer such as a server, and includes one or more processors or integrated circuits, and a storage medium such as one or more memories. The processor or integrated circuit of the processing device 20 includes any one of a CPU (Central Processing Unit), an ASIC (Application Specific Integrated Circuit), a microcomputer, an FPGA (Field Programmable Gate Array), and a DSP (Digital Signal processor), etc.
[0037] The processing device 20 includes a control unit 21 and a determination unit 22. The control unit 21 and the determination unit 22 execute a part of the processing performed by the processor etc. of the processing device 20. Further, the processing device 20 includes a data storage unit 23. The data storage unit 23 functions as a storage medium and can store data in the data storage unit 23. Note that the processing described later performed by the control unit 21 and the determination unit 22 of the processing device 20 may be performed in cooperation by a plurality of processing devices such as a plurality of computers. Also, the processing described later performed by the control unit 21 and the determination unit 22 of the processing device 20 may be performed by a server etc. in a cloud environment.
[0038] In addition, the inspection system 1 is provided with an exclusion unit 25. The exclusion unit 25 can exclude the target product 3 from the transport line 2 on the downstream side of the transport line 2 with respect to the plate members 12 and 13. In the present embodiment, by operating the exclusion unit 25, the target product 3 with quality defects is excluded from the transport line 2. The target product 3 excluded from the transport line 2 by the exclusion unit 25 is not transported downstream with respect to the exclusion unit 25. In one example, the exclusion unit 25 excludes the target product 3 from the transport line 2 by pressing the target product 3. In another example, the exclusion unit 25 excludes the target product 3 from the transport line 2 by injecting gas toward the target product 3 and using the pressure of the injected gas.
[0039] Also, as shown in FIG. 3, the inspection system 1 includes a user interface 26. The user interface 26 includes an operation member, and the operation member is composed of, for example, any one of a keyboard, a mouse, a remote control, and a switch. With the operation member, an operation related to the inspection of the target product 3 can be input by an inspector or the like. Further, the user interface 26 includes a notification unit that notifies information related to the inspection. With the notification unit, information related to the inspection is notified by any one of screen display and voice.
[0040] The control unit 21 controls the respective imaging operations of the imaging units 16 and 17 and the operation of the exclusion unit 25. Also, in a state where the target product 3 is being transported on the transport line 2, the transport line 2 is constantly imaged by the imaging unit 17, which is an upper imaging unit, and the control unit 21 constantly monitors the transport line 2 based on the captured image from the imaging unit 17. Then, the control unit 21 controls the respective imaging operations of the imaging units 16 and 17 and the operation of the exclusion unit 25 in accordance with the monitoring result of the transport line 2. Note that, in one example, in a state where the target product 3 is being transported on the transport line 2, the transport line 2 may be constantly imaged by both of the imaging units 16 and 17, and the control unit 21 may constantly monitor the transport line 2 based on the captured images from the imaging units 16 and 17.
[0041] Figure 4 schematically shows, in a flowchart, an example of the control of the imaging operations of the imaging units 16 and 17 performed by the control unit 21. The processing of the example in Figure 4 is performed for one target product 3, and each time one target product 3 is carried into the conveying line 2, the processing of the example in Figure 4 is performed. When starting the processing of the example in Figure 4, the control unit 21 acquires a captured image by the imaging unit 17 which is an upper imaging unit (S41).
[0042] Then, the control unit 21 determines whether or not the conveyed target product 3 has started to contact the plate member 12 based on the captured image by the imaging unit 17 (S42). At this time, the control unit 21 performs the determination based on whether or not the target product 3 exists in the captured image and the position of the target product 3 in the captured image and the like by performing image processing on the captured image by the imaging unit 17. In one example, the target product 3 starts to contact the plate member 12 at a specific position. Then, based on the target product 3 being positioned in a specific range of the captured image, it is determined that the conveyed target product 3 has started to contact the plate member 12. Therefore, in this example, the imaging unit 17 functions as a detection unit that detects that the conveyed target product 3 has started to contact the plate member 12. And based on the imaging result of the imaging range by the imaging unit 17 which is an upper imaging unit, it is detected that the target product 3 has started to contact the plate member 12.
[0043] When the target product 3 is not in contact with the plate member 12 (S42 - No), the process returns to S41, and the control unit 21 sequentially performs the processes after S41. For this reason, it waits until the target product 3 contacts the plate member 12. On the other hand, when the target product 3 starts to contact the plate member 12 (S42 - Yes), the control unit 21 causes the imaging unit 17 which is an upper imaging unit to image the target product 3 in contact with the plate member 12 (S43). Thereby, the control unit 21 acquires a captured image of the target product 3 in contact with the plate member 12 taken from the upper side. Then, the control unit 21 stores the captured image captured by the imaging unit 17 in the data storage unit 23. Also, the imaging by the imaging unit 17 of the captured image to be stored is performed at the time when the target product 3 starts to contact the plate member 12 or immediately thereafter.
[0044] Also, when the target article 3 starts to contact the plate member 12 (S42-Yes), the control unit 21 causes the imaging unit 16, which is a side imaging unit, to image the target article 3 in contact with the plate member 12 (S44 to S47). In the present embodiment, while the target article 3 is rotating about the axis C due to the contact with the plate member 12, the control unit 21 causes the imaging unit 16 to image the target article at a plurality of time points. Thereby, the control unit 21 acquires a plurality of captured images of the conveyed target article 3 taken from the side at different angular positions with respect to each other in the circumferential direction of the axis C (the circumferential direction of the target article 3). Then, the control unit 21 stores the plurality of captured images captured by the imaging unit 16 in the data storage unit 23.
[0045] Here, time t is defined such that time t becomes 0 when the start of the contact of the target article 3 with the plate member 12 is detected. In this case, at the time when the captured image is captured by the imaging unit 17 and stored, time t is 0 or approximately 0. In an example of FIG. 4, the control unit 21 causes the imaging unit 16 to image the target article 3 at the timing of time t = ta (S44). Then, the control unit 21 causes the imaging unit 16 to image the target article 3 at the timings of time t = ta + 1 / 3×tb, time t = ta + 2 / 3×tb, and time t = ta + tb, respectively (S45, S46, S47). In one example, time ta may be 0 or approximately 0. In this case, at the time when the target article 3 starts to contact the plate member 12 or immediately thereafter, the imaging of S44 by the imaging unit 16 is performed, and the imaging of S44 by the imaging unit 16 is performed at the same or approximately the same timing as the imaging of S43 by the imaging unit 17.
[0046] Also, time tb corresponds to the required time for the target article 3 to rotate by a rotation amount of 3 / 4 rotations in the state where the target article 3 is in contact with the plate member 12. Therefore, in an example of FIG. 4, after the imaging of S44 is performed, each time the target article 3 rotates by 1 / 4 rotation until the target article 3 rotates by 3 / 4 rotations, the target article 3 is imaged by the imaging unit 16. Thereby, four captured images of the target article 3 taken from the side at intervals of 90° or approximately 90° in the circumferential direction of the axis C are acquired.
[0047] In an example of FIG. 4, while the target product 3 is in contact with the plate member 12, captured images of the target product 3 by the imaging unit 16, which is a side imaging unit, are acquired at four time points. However, while the target product 3 is in contact with the plate member 12, the captured images of the target product 3 by the imaging unit 16 may be acquired at two or three time points, or may be acquired at five or more time points. In one example, while the target product 3 is in contact with the plate member 12, the target product 3 is imaged by the imaging unit 16 at two time points, and two captured images of the target product 3 taken from the side at intervals of 180° or approximately 180° around the axis C are acquired. In another example, while the target product 3 is in contact with the plate member 12, the target product 3 is imaged by the imaging unit 16 at three time points, and three captured images of the target product 3 taken from the side at intervals of 120° or approximately 120° around the axis C are acquired.
[0048] FIG. 5 schematically shows, in a flowchart, an example of the processing related to the determination of the quality of the target product 3 performed by the control unit 21 and the determination unit 22. The processing in the example of FIG. 5 is performed for one target product 3, and each time one target product 3 is carried into the conveying line 2, the processing in the example of FIG. 5 is performed. Also, the processing in the example of FIG. 5 is performed using the captured images of the target product 3 captured by the imaging units 16 and 17 in the processing in the example of FIG. 4 after the processing in the example of FIG. 4 is performed.
[0049] When starting the process of an example in FIG. 5, the determination unit 22 acquires a captured image of the target product 3 by the imaging unit 17 which is an upward imaging unit (S51). At this time, for example, the determination unit 22 acquires the captured image of the target product 3 captured in S43 of the process of an example in FIG. 4. Further, the determination unit 22 acquires captured images of the target product 3 at a plurality of time points by the imaging unit 16 which is a side imaging unit (S52). At this time, for example, the determination unit 22 acquires the captured images of the target product 3 captured in each of S44 to S47 of the process of an example in FIG. 4. Then, the determination unit 22 determines whether or not a quality defect has occurred in the target product 3 using the captured image of the target product 3. At this time, the determination unit 22 determines whether or not a quality defect of the target product 3 is confirmed in each of the captured images acquired in S51 and S52 (S53).
[0050] In one example, the determination in S53 is performed by AI determination (artificial intelligence determination) using a machine learning model. In this case, for example, a machine learning model is generated by learning a model by deep learning using learning data composed of a plurality of data sets. Then, the generated machine learning model is stored in the data storage unit 23. In each of the plurality of data sets of the learning data, for the target product 3 for which an inspection on quality has already been performed, a captured image from above, and a plurality of captured images of the target product 3 captured from the side at different angular positions with respect to each other around the axis C of the axis are shown. Also, in each of the plurality of data sets, the actual inspection result in the quality inspection for the target product 3 for which an inspection has already been performed is shown. Therefore, in the generation of the machine learning model, the model is learned by supervised learning in which the inspection result shown in each data set is given as the correct answer.
[0051] Note that in the determination of S53, a machine learning model may not be used. In one example, the determination unit 22 mechanically determines, for each of the captured images of the target product 3 obtained, whether a quality defect of the target product 3 is confirmed based on a dot pattern, a color tone ratio, etc. In this case, a threshold value is set for parameters related to the dot pattern and the color tone ratio, etc. of the captured image of the target product 3, and the determination is made based on whether the parameter exceeds the threshold value or not. The threshold value for parameters related to the dot pattern and the color tone ratio, etc. is set, for example, by an operation input by an inspector or the like at the user interface 26.
[0052] If no quality defect of the target product 3 is confirmed in any of the obtained captured images (S53 - No), the determination unit 22 determines that no quality defect has occurred in the target product 3 to be inspected. Then, without the target product 3 being excluded from the conveyance line 2 by the exclusion unit 25, the process of the example in FIG. 5 ends.
[0053] On the other hand, if a quality defect of the target product 3 is confirmed in any of the obtained captured images (S53 - Yes), the determination unit 22 determines that a quality defect has occurred in the target product 3 to be inspected. Then, the control unit 21, the determination unit 22, etc. calculate the timing for excluding the target product 3 determined to have a quality defect from the conveyance line 2 (S54). Thereby, the timing for excluding the target product 3 with a quality defect by the exclusion unit 25 is determined. In the present embodiment, the timing for excluding the target product 3 is determined based on the timing when the imaging unit 17, which is an upper imaging unit, detects the start of contact of the target product 3 determined to have a quality defect with the plate member 12.
[0054] In one example, the timing at which the target article 3 is to be excluded due to a quality defect is determined as the time point when a time tc has elapsed since the start of contact of the target article 3 with the plate member 12 was detected. In this case, the time tc is longer than the time ta + tb described above. Then, the control unit 21 controls the operation of the exclusion unit 25 to exclude the target article 3 with a quality defect from the conveyance line 2 at the timing calculated in S54 (S55). At this time, the control unit 21 causes the exclusion unit 25 to exclude the target article 3, for example, by transmitting a command signal serving as an exclusion command to the exclusion unit 25. Therefore, in the present embodiment, the control unit 21 and the like adjust the timing at which the target article 3 with a quality defect is excluded by the operation of the exclusion unit 25 based on the timing at which the start of contact of the target article 3 with the plate member 12 is detected.
[0055] Note that, in one example of FIG. 5, the determination unit 22 determines whether or not a quality defect is confirmed for all of the captured images of the target article 3 that have been acquired, but the present invention is not limited to this. In one example, when a quality defect is confirmed in any one of the captured images of the target article 3 that have been acquired, the determination unit 22 determines that the target article 3 has a quality defect and ends the determination process. At this time, even if the determination as to whether or not a quality defect is confirmed for one or more of the captured images of the target article 3 that have been acquired has not been performed, the determination unit 22 determines that the target article 3 has a quality defect and ends the determination process.
[0056] As described above, in the present embodiment, the target article 3 being conveyed on the conveyance line 2 rotates about the axis C along the height direction by the plate member 12 which is the movement adjustment unit. Then, the control unit 21 controls the imaging operation of the imaging unit 16 which is the side imaging unit, so that the imaging unit 16 images the target article 3 at a plurality of time points while the target article 3 is rotating about the axis C. The determination unit 22 determines the quality of the target article 3 based on at least a plurality of captured images of the target article 3 by the imaging unit 16. In the present embodiment, since the determination regarding the quality of the target article 3 is made based on the captured image of the target article 3 by the imaging unit 16 and the like, it is not necessary for an inspector or the like to visually confirm whether or not a quality defect has occurred in the target article 3. Therefore, the inspection regarding the quality of the target article 3 as a product is automated.
[0057] In addition, in this embodiment, the target product 3 is photographed at a plurality of time points while the target product 3 is rotating about the axis C. Therefore, a plurality of photographed images of the target product 3 taken from the side at different angular positions with respect to each other in the circumferential direction of the axis C (the circumferential direction of the target product 3) are used for determining the quality of the target product 3. Accordingly, whether or not a quality defect has occurred in the target product 3 is determined with high accuracy, and the accuracy of the inspection of the quality of the target product 3 is maintained high.
[0058] In addition, in this embodiment, the plate member 12 serving as the movement adjustment unit is extended in a state inclined with respect to both the conveyance direction and the width direction of the conveyance line 2. Then, the plate member 12 moves the target product along the plate member 12 in the conveyance line 2 in a state where the target product 3 is in contact with the plate member 12. Thereby, while the target product 3 is in contact with the plate member 12, the target product 3 appropriately rotates about the axis C due to the reaction force from the plate member 12.
[0059] In addition, in this embodiment, the photographing unit (upper photographing unit) 17 serving as the detection unit detects that the conveyed target product 3 has started to contact the plate member 12. Thereby, it becomes possible to appropriately determine whether or not the target product 3 has started to contact the plate member 12. Then, by adjusting the timing of photographing the target product 3 by the photographing unit 16 based on the detection result by the photographing unit 17, the target product 3 rotating about the axis C is appropriately photographed by the photographing unit 16.
[0060] In addition, in this embodiment, the control unit 21 controls the photographing operation of the photographing unit 17 which is the upper photographing unit to cause the photographing unit 17 to photograph the conveyed target product 3. Then, the determination unit 22 determines regarding the quality of the target product 3 based on the photographed images of the target product 3 by the photographing units 16 and 17. Therefore, regarding the quality of the target product 3, determination is made based on the photographed images of the target product 3 taken from the upper side in addition to the plurality of photographed images of the target product 3 taken from the side. Thereby, the accuracy of the inspection regarding the quality of the target product 3 is further improved.
[0061] Also, in the present embodiment, the imaging unit 17, which is an upward imaging unit, includes in the imaging range the position where the target product 3 starts to contact the plate member 12. Then, the imaging unit 17 serving as the detection unit detects that the target product 3 has started to contact the plate member 12 based on the imaging result of the imaging range by the imaging unit 17. Thereby, it becomes possible to appropriately determine whether or not the target product 3 has started to contact the plate member 12 from the imaging result by the imaging unit 17.
[0062] Also, in the present embodiment, in the conveyance line 2, the guide member 11 is arranged on the upstream side with respect to the plate member 12. Then, the guide member 11 guides the target product 3 toward the plate member 12, thereby bringing the target product 3 into contact with the plate member 12. Thereby, in the conveyance line 2, the conveyed target product 3 appropriately contacts the plate member 12 and appropriately rotates about the axis C.
[0063] Also, in the present embodiment, when it is determined by the determination unit 22 that the target product 3 is of poor quality, the control unit 21 controls the operation of the exclusion unit 25 to exclude the target product 3 determined to be of poor quality from the conveyance line 2. Then, the control unit 21 adjusts the timing at which the target product 3 is excluded by the operation of the exclusion unit 25 based on the timing when the start of the contact of the target product 3 with the plate member 12 is detected. Thereby, when a target product 3 of poor quality occurs, the exclusion unit 25 operates at an appropriate timing, and the target product 3 is excluded at an appropriate timing.
[0064] Also, in an example of the present embodiment, the determination unit 22 determines whether or not a quality defect of the target product 3 is confirmed in each of the captured images by AI determination using a machine learning model. Thereby, in the determination of the quality of the target product 3 by the determination unit 22, the trouble of setting thresholds for parameters related to the dot pattern and color tone ratio, etc. of the captured image of the target product 3 is omitted.
[0065] In the above-described embodiments and the like, the start of the contact of the target product 3 with the plate member 12 is detected by the imaging unit 17 which is an upward imaging unit, but the present invention is not limited to this. In a certain modification, a contact sensor is attached to the plate member 12, and the start of the contact of the target product 3 with the plate member 12 is detected by the contact sensor. In an example, the target product 3 starts to contact the plate member 12 at a specific position, and the contact sensor is attached to the plate member 12 at the specific position where the target product 3 starts to contact the plate member 12.
[0066] Also, in the above-described embodiments and the like, the imaging of the target product 3 by the imaging unit 17 which is an upward imaging unit is performed in a state where the target product 3 is in contact with the plate member 12, that is, in a state where the target product 3 is rotating about the axis C, but the present invention is not limited to this. In a certain modification, before the target product 3 contacts the plate member 12, the imaging unit 17 images the target product 3 from above. In this case, for example, immediately before the target product 3 starts to contact the plate member 12, the target product 3 is imaged by the imaging unit 17. Also in this modification, while the target product 3 is in contact with the plate member 12, that is, while the target product 3 is rotating about the axis C, the target product 3 is imaged at a plurality of time points by the imaging unit 16 which is a side imaging unit. Then, based on the imaging images of the target product 3 by the imaging units 16 and 17, the quality of the target product 3 is determined.
[0067] Also, in a certain modification, in addition to determining whether or not a quality defect has occurred in the target product 3 as described above based on the imaging image of the target product 3 by the imaging unit 16 and the like, an inspector or the like visually checks whether or not a quality defect has occurred in the target product 3. In this case, for example, visual confirmation by an inspector or the like is performed in a state where the target product 3 is in contact with the plate member 13 on the downstream side with respect to the plate member 12.
[0068] Also, in the above-described embodiments and the like, the target product 3 rotates about the axis C along the height direction by bringing the target product 3 into contact with the plate member 12. However, in the conveying line 2, a movement adjustment unit for rotating the target product 3 about the axis C may be provided. In a certain modification, in the conveying line 2, the target product 3 is rotated about the axis C by an air flow. However, in any case, the target product 3 is photographed by the photographing unit 16 which is a side photographing unit at a plurality of time points while the target product 3 is rotating about the axis C. Then, based at least on the photographed image of the target product 3 by the photographing unit 16, the quality of the target product 3 is determined as described above.
[0069] According to at least one of these embodiments, the movement adjustment unit rotates the conveyed target product about an axis along the height direction that intersects both the conveying direction and the width direction, and the control unit causes the side photographing unit to photograph the target product at a plurality of time points while the target product is rotating about the axis. Then, the determination unit determines the quality of the target product based at least on the photographed image of the target product by the side photographing unit. Thereby, it is possible to provide an inspection system capable of automating the inspection regarding the quality of the product.
[0070] Although some embodiments of the present invention have been described, these embodiments are presented as examples and are not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the gist of the invention. These embodiments and their modifications are included in the scope and gist of the invention, and are also included in the invention described in the claims and its equivalent scope.
Explanation of Reference Numerals
[0071] 1... Inspection system, 2... Conveying line, 3... Target product, 11... Guide member, 12... Plate member (movement adjustment unit), 16... Photographing unit (side photographing unit), 17... Photographing unit (upper photographing unit), 20... Processing device, 21... Control unit, 22... Determination unit, 25... Exclusion unit.
Claims
1. A conveying line for conveying an object; A side imaging unit capable of imaging the object being conveyed on the conveying line from one side in the width direction intersecting the conveying direction; A movement adjustment unit for rotating the object being conveyed on the conveying line about an axis along the height direction intersecting both the conveying direction and the width direction; A control unit that controls the imaging operation of the side imaging unit to cause the side imaging unit to image the object at a plurality of time points while the object is being rotated about the axis by the movement adjustment unit; A determination unit that determines the quality of the object based at least on a captured image of the object by the side imaging unit; An inspection system comprising:
2. The movement adjustment unit includes a plate member extending in a state inclined with respect to both the conveying direction and the width direction, The plate member rotates the object about the axis along the height direction by moving the object along the plate member on the conveying line in a state where the object is in contact with the plate member. The inspection system according to Claim 1.
3. The inspection system according to Claim 2, further comprising a detection unit that detects that the object being conveyed on the conveying line has started to contact the plate member.
4. The detection unit includes an upper imaging unit capable of imaging the object being conveyed from above in the height direction, The upper imaging unit includes, in its imaging range, the position where the object starts to contact the plate member, The detection unit detects that the object has started to contact the plate member based on the imaging result of the imaging range by the upper imaging unit, The control unit controls the imaging operation of the upper imaging unit to cause the upper imaging unit to image the object being conveyed, The determination unit determines the quality of the object based on the captured image of the object by the side imaging unit and the captured image of the object by the upper imaging unit. The inspection system according to Claim 3.
5. The inspection system according to Claim 3 or 4, further comprising a guide member that is disposed upstream of the plate member on the conveying line and guides the object toward the plate member to bring the object into contact with the plate member.
6. The apparatus further includes an exclusion unit capable of excluding the target article from the conveyance line on the downstream side with respect to the plate member. When the determination unit determines that the target article is of defective quality, the control unit controls the operation of the exclusion unit to cause the exclusion unit to exclude the target article determined to be of defective quality from the conveyance line, and adjusts the timing of excluding the target article by the operation of the exclusion unit based on the timing when the detection unit detects the start of the contact of the target article with the plate member. The inspection system according to claim 3 or 4.
Citation Information
Patent Citations
Food inspection support system, food inspection support device, and computer program
JP7317702B2