Movement degree measuring apparatus, movement degree measuring method and movement degree measuring system

Abstract

To measure the movement degree of a belt conveyor with a simple configuration.SOLUTION: A movement degree measuring apparatus which measures the movement degree of a belt conveyor based upon a captured image of the belt conveyor comprises a processor and a memory, and is configured to: acquire the captured image through cooperation between the processor and the memory; divide an area for measuring the movement degree of the belt conveyor in the captured image into a plurality of unit block images; recognize markers arranged at predetermined intervals on the belt conveyor from the plurality of respective unit block images; detect the positions of the markers in the plurality of unit block images; and calculate the movement degree of the belt conveyor based upon detection results.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a progress measurement device, a progress measurement method, and a progress measurement system. [Background technology]

[0002] Conventionally, the progress of belt conveyors used in factories and the like has been measured, and the measurement results have been used in production activities, etc. For example, Patent Document 1 discloses a control device that uses an encoder provided on the belt conveyor to measure the transport distance of the belt conveyor. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 10-324418 Summary of the Invention [Problem to be solved by the invention]

[0004] However, in order to measure the progress of a belt conveyor using an encoder, it may be necessary to modify the equipment in order to directly connect the belt conveyor to the encoder, which may require costs in terms of both time and money to measure the progress of the belt conveyor using an encoder.

[0005] The present disclosure has been devised in view of the above-described conventional situation, and aims to measure the progress of a belt conveyor with a simple configuration. [Means for solving the problem]

[0006] The present disclosure provides a progress measurement device that measures the progress of a belt conveyor based on an image of the belt conveyor, the progress measurement device comprising a processor and a memory, wherein the processor and the memory work together to acquire the image, divide an area of ​​the image for measuring the progress of the belt conveyor into a plurality of unit block images, recognize markers arranged at predetermined intervals on the belt conveyor from each of the plurality of unit block images, detect the positions of the markers in each of the plurality of unit block images, and calculate the progress of the belt conveyor based on the detection results.

[0007] The present disclosure also provides a progress measurement method for measuring the progress of a belt conveyor based on an image of the belt conveyor, which includes acquiring the image, dividing an area of ​​the image for measuring the progress of the belt conveyor into a plurality of unit block images, recognizing markers arranged at predetermined intervals on the belt conveyor from each of the plurality of unit block images, detecting the positions of the markers in each of the plurality of unit block images, and calculating the progress of the belt conveyor based on the detection results.

[0008] The present disclosure also provides a progress measurement system comprising a camera that captures an image of a belt conveyor to generate an image, and a progress measurement device that measures the progress of the belt conveyor based on the image, wherein the progress measurement device acquires the image from the camera, divides an area of ​​the image for measuring the progress of the belt conveyor into a plurality of unit block images, recognizes markers arranged at predetermined intervals on the belt conveyor from each of the plurality of unit block images, detects the positions of the markers in each of the plurality of unit block images, and calculates the progress of the belt conveyor based on the detection results.

[0009] The present disclosure also provides a program for executing a progress measurement method for measuring the progress of a belt conveyor based on an image of the belt conveyor, the program causing a computing device to acquire the image, divide an area of ​​the image for measuring the progress of the belt conveyor into a plurality of unit block images, recognize markers arranged at predetermined intervals on the belt conveyor from each of the plurality of unit block images, detect the positions of the markers in each of the plurality of unit block images, and calculate the progress of the belt conveyor based on the detection results.

[0010] Any combination of the above components, and conversion of the expression of the present disclosure into a method, device, system, storage medium, computer program, etc., are also valid aspects of the present disclosure. [Effects of the Invention]

[0011] According to the present disclosure, the progress of a belt conveyor can be measured with a simple configuration. [Brief explanation of the drawings]

[0012] [Figure 1] A block diagram showing an overview of a progress measurement system according to a first embodiment. [Figure 2] FIG. 1 is a schematic diagram showing an example of cutting out a captured image according to the first embodiment; [Figure 3] FIG. 1 is a schematic diagram illustrating an example of division and conversion of a captured image according to the first embodiment; [Figure 4] FIG. 1 is a schematic diagram illustrating a sheet counter according to a first embodiment; [Figure 5] Flowchart showing progress measurement processing according to the first embodiment DETAILED DESCRIPTION OF THE INVENTION

[0013] Hereinafter, with reference to the accompanying drawings as appropriate, detailed descriptions will be provided of specific embodiments of a progress measurement device, a progress measurement method, and a progress measurement system according to the present disclosure. However, unnecessary detailed descriptions may be omitted. For example, detailed descriptions of well-known matters and redundant descriptions of substantially identical configurations may be omitted. This is to avoid unnecessary redundancy in the following description and to facilitate understanding by those skilled in the art. Note that the accompanying drawings and the following description are provided to enable those skilled in the art to fully understand the present disclosure, and are not intended to limit the subject matter recited in the claims.

[0014] (Embodiment 1) FIG. 1 is a block diagram showing an overall overview of a progress measurement system 1 according to a first embodiment. The progress measurement system 1 includes a belt conveyor BC1, a camera CAM1, a progress measurement device 10, and a progress utilization device 30. In the progress measurement system 1, the camera CAM1 captures an image of the belt conveyor BC1 to generate a captured image. The progress measurement device 10 then acquires the captured image of the belt conveyor BC1 from the camera CAM1 and measures the progress of the belt conveyor BC1 based on the acquired captured image. The progress measurement results obtained by the progress measurement device 10 are utilized by the progress utilization device 30. Note that the progress utilization device 30 may be omitted from the configuration of the progress measurement system 1 shown in FIG. 1.

[0015] The belt conveyor BC1 is installed, for example, in a factory. The belt conveyor BC1 is introduced, for example, into a production line in a factory to transport items, etc. Markers (for example, marker M1) are placed on the belt conveyor BC1 at predetermined intervals. The markers are placed perpendicular to the transport direction of the belt conveyor BC1, in other words, the traveling direction. In this embodiment, the belt conveyor BC1 is described as including multiple panels (for example, panel P1) as a transport surface on which transported items, etc. are placed. In this case, the items, etc. transported by the belt conveyor BC1 are placed on the panels. Also, when the belt conveyor BC1 is configured to include multiple panels, the boundaries between the panels correspond to the markers. Note that the belt conveyor BC1 may be configured to include, for example, a single flat belt or a single flat piece of rubber, instead of multiple panels. In this case, marks may be provided on the belt or rubber, for example, at predetermined intervals, and the marks may serve as markers. Note that the marks may include figures, letters, or symbols.

[0016] Camera CAM1 is installed, for example, in a factory and captures an image of a belt conveyor BC1 also installed in the factory. Camera CAM1 is configured with at least a lens (not shown) and an image sensor (not shown) as optical elements. The lens receives light reflected by an object within the angle of view of the area captured by camera CAM1 and forms an optical image of the object on the light-receiving surface (i.e., the imaging surface) of the image sensor. The image sensor is, for example, a solid-state imaging element such as a Charged Coupled Device (hereinafter referred to as "CCD") or a Complementary Metal Oxide Semiconductor (hereinafter referred to as "CMOS"). The image sensor converts the optical image formed on the imaging surface via the lens into an electrical signal every predetermined time (e.g., 1 / 30 (second)). For example, if the predetermined time is 1 / 30 (second), the frame rate of camera CAM1 is 30 fps. Camera CAM1 may also generate image data (video data) by performing predetermined signal processing on the electrical signal every predetermined time. The image data is a still image, and the video data is a moving image. The camera CAM1 outputs the image data (video data) to the progress measurement device 10. Hereinafter, the image data and video data will be referred to as a captured image.

[0017] The progress measurement device 10 is configured using a general-purpose computer device such as a personal computer or a server computer. The progress measurement device 10 includes a processor 11, a memory 12, a display device 13, and a communication interface device 14. The components of the progress measurement device 10 are communicably connected via an internal bus 16. Hereinafter, the progress measurement device 10 may also be referred to as a computing device.

[0018] The processor 11 is configured using, for example, a central processing unit (hereinafter referred to as "CPU"), a digital signal processor (hereinafter referred to as "DSP"), or a field programmable gate array (hereinafter referred to as "FPGA"). The processor 11 functions as a controller that manages the overall operation of the progress measurement device 10. The processor 11 performs control processing to oversee the operation of each part of the progress measurement device 10, data input / output processing between each part of the progress measurement device 10, data arithmetic processing, and data storage processing. The processor 11 operates according to a program stored in the memory 12. The processor 11 uses the memory 12 during operation, and temporarily stores data generated or acquired by the processor 11 in the memory 12. The processor 11 realizes the functions of the image division unit 20, the image conversion unit 21, the position detection unit 22, and the progress calculation unit 23 by using the programs and data stored in the memory 12.

[0019] An image dividing unit 20, which is an example of a dividing unit, cuts out and divides a portion of the captured image acquired from the camera CAM1. An image conversion unit 21, which is an example of a conversion unit, converts and corrects each of the images divided by the image dividing unit 20. A position detection unit 22, which is an example of a detection unit, recognizes markers on the belt conveyor BC1 in each of the images converted by the image conversion unit 21 and detects the positions of the recognized markers. A progress calculation unit 23, which is an example of a calculation unit, calculates the progress of the belt conveyor BC1 based on the positions of the markers detected by the position detection unit 22.

[0020] The memory 12 is configured using, for example, Random Access Memory (hereinafter referred to as "RAM") and Read Only Memory (hereinafter referred to as "ROM"), and temporarily stores programs necessary for the operation of the progress measurement device 10, as well as data generated during operation. The RAM is, for example, a work memory used during the operation of the progress measurement device 10. The ROM, for example, stores and holds in advance programs for controlling the progress measurement device 10.

[0021] The display device 13 is a device that displays information, images, etc. Examples of the display device 13 include a liquid crystal display, an organic electroluminescence (hereinafter referred to as "EL") display, and the like.

[0022] The input device 14 is configured by, for example, a keyboard, a mouse, etc. The input device 14 accepts input from the user who operates the progress measurement device 10.

[0023] The communication interface device 15 is an interface device that enables the progress measurement device 10 to communicate wirelessly or wired with the camera CAM1 and the progress utilization device 30. The communication interface device 15 may communicate via a network. The communication method used by the communication interface device 15 is, for example, a Wide Area Network (hereinafter referred to as "WAN"), a Local Area Network (hereinafter referred to as "LAN"), Long Term Evolution (hereinafter referred to as "LTE"), mobile communications such as 4G and 5G, power line communications, short-range wireless communications (e.g., Bluetooth (registered trademark) communications), or communications for mobile phones.

[0024] The progress utilization device 30 acquires the measurement result of the progress of the belt conveyor BC1 from the progress measurement device 10 and utilizes the measurement result. An example of the progress utilization device 30 is an image inspection device.

[0025] Next, a flow of measuring the progress of the belt conveyor BC1 by the progress measurement device 10 will be described with reference to Figures 2, 3, and 4. Figure 2 is a schematic diagram showing an example of clipping of a captured image IMG1 according to the first embodiment.

[0026] The progress measurement device 10 acquires a captured image IMG1 from a camera CAM1. The captured image IMG1 shows a belt conveyor BC1. The belt conveyor BC1 includes a plurality of panels (for example, panel P2). Here, the description will be given assuming that the boundaries between the panels are markers (for example, marker M2). In the example of FIG. 2, the belt conveyor BC1 transports a vehicle 40 in a traveling direction X of the belt conveyor BC1.

[0027] The image dividing unit 20 sets an area to be cut out from the captured image IMG1. The area cut out by the image dividing unit 20 from the captured image is an area used for measuring the progress of the belt conveyor BC1. In the example of FIG. 2, the image dividing unit 20 sets and cuts out area E1 as an area for measuring the progress of the belt conveyor BC1. As a result, an area image IMG2 is generated. Area E1 is captured in the area image IMG2. The area for measuring the progress of the belt conveyor BC1 is set so that the area includes multiple panels of the belt conveyor BC1. Furthermore, when an article or the like is being transported on the belt conveyor BC1, the area is set so that a portion of the panel on which the article is placed that is not obstructed by the article is included in the area E1. In the example of FIG. 2, area E1 is set so that a portion of the panel on which the vehicle 40 is placed that is not obstructed by the vehicle 40 is included in the area E1. The area for measuring the progress of the belt conveyor BC1 may be set by a user operating the progress measurement device 10.

[0028] Although FIG. 1 illustrates an example in which the progress measurement system 1 includes one camera CAM1, the progress measurement system 1 may include multiple cameras. The image division unit 20 may set an area for measuring the progress of the belt conveyor BC1 for each of the images of the belt conveyor BC1 captured by each of the multiple cameras. For example, if the progress measurement system 1 includes two cameras, each capturing an image of a different part of the belt conveyor BC1, the image division unit 20 may set an area to be cut out for measuring the progress of the belt conveyor BC1 from each of the images captured by the two cameras. For example, the area set in the image captured by one of the two cameras may barely capture the panel of the belt conveyor BC1 due to the camera's angle of view or the items being transported. Even in such a case, if the panel is almost always captured in the area set in the image captured by the other camera, the progress measurement device 10 can use that area for subsequent progress measurement processing. In this way, by setting an area for progress measurement for each of the images captured by multiple cameras, even if it is difficult to measure the progress of the belt conveyor BC1 using an image captured by one camera, progress measurement can be performed using a camera other than that camera.

[0029] FIG. 3 is a schematic diagram illustrating an example of division and conversion of a captured image IMG1 according to the first embodiment. As described with reference to FIG. 2, the captured image IMG1 is cut out into an area image IMG2 by the image division unit 20. The image division unit 20 divides the area image IMG2 into a plurality of unit block images. In the example of FIG. 3, the image division unit 20 divides the area image IMG2 into six unit block images IMG3, IMG4, IMG5, IMG6, IMG7, and IMG8. This generates a plurality of unit block images. How the area image is divided, in other words, the division process, may be preset by, for example, a user. However, the image division unit 20 performs division so that each unit block image includes at least one marker. In the example of FIG. 6, the area image IMG2 is divided into six, but this is not limiting. It is assumed that each unit block image has the same size.

[0030] The unit block image IMG3, unit block image IMG4, unit block image IMG5, unit block image IMG6, unit block image IMG7 and unit block image IMG8 show the divided area E2, divided area E3, divided area E4, divided area E5, divided area E6 and divided area E7, respectively.

[0031] The image conversion unit 21 converts and corrects each of the unit block images. The image conversion unit 21 converts each of the unit block images so that the number of markers in the unit block image is reduced to one and the panels displayed in the unit block images are rectangular. The image conversion unit 21 converts each of the unit block images so that the positions of the markers in each of the converted unit block images are substantially the same in all of the converted unit block images. The positions of the markers will be described later. The conversion by the image conversion unit 21 may include deformations such as enlargement, reduction, and stretching, as well as projective transformation. The image conversion unit 21 also corrects the color and brightness of the converted image. For example, the image conversion unit 21 may change the luminance or brightness of the converted image. The specific conversion and correction processes may be set in advance by, for example, a user. For example, the user may set the conversion process while visually confirming that the positions of the markers in each of the converted unit block images are substantially the same in all of the converted unit block images.

[0032] Two markers, M3 and M4, are shown in the unit block image IMG3. The image conversion unit 21 converts and corrects the unit block image IMG3 so that the number of markers in the unit block image IMG3 becomes one and the panel shown in the unit block image IMG3 becomes rectangular, thereby generating a conversion unit block image IMG3a. One marker M4 is shown in the conversion unit block image IMG3a. Similarly, the image conversion unit 21 converts and corrects each of the unit block images IMG4, IMG5, IMG6, IMG7, and IMG8, ​​thereby generating a conversion unit block image IMG4a, a conversion unit block image IMG5a, a conversion unit block image IMG6a, a conversion unit block image IMG7a, and a conversion unit block image IMG8a, respectively.

[0033] Two markers, M5 and M6, appear in the unit block image IMG4. One marker, M6, appears in the transformation unit block image IMG4a obtained after transformation of the unit block image IMG4.

[0034] Two markers, M7 and M8, appear in the unit block image IMG5. One marker, M8, appears in the transformation unit block image IMG5a obtained after transformation of the unit block image IMG5. Furthermore, the vehicle 40, which was partially depicted in the unit block image IMG5, does not appear in the transformation unit block image IMG5a. This is because the image transformation unit 21 has performed a transformation such that the vehicle 50 does not appear in the image.

[0035] Two markers, M9 and M10, appear in the unit block image IMG6. One marker, M10, appears in the transformation unit block image IMG6a obtained after transformation of the unit block image IMG6. Furthermore, the transformation unit block image IMG5a shows the vehicle 40, which was partially shown in the unit block image IMG5.

[0036] Two markers, M11 and M12, appear in the unit block image IMG7. One marker, M12, appears in a transformation unit block image IMG7a obtained after transformation of the unit block image IMG7.

[0037] Two markers, M13 and M14, appear in the unit block image IMG8. One marker, M14, appears in a transformation unit block image IMG8a obtained after transformation of the unit block image IMG8.

[0038] The position detection unit 22 recognizes markers included in each of the unit block images converted by the image conversion unit 21, i.e., each of the conversion unit block images. The position detection unit 22 may recognize the markers based on, for example, the color or shape of the marker. The position detection unit 22 may also use a known image recognition technique to recognize the markers. Although not shown in the figure, the following description will be given assuming that each of the conversion unit block images is displayed on the display device 13 (see FIG. 4). The position detection unit 22 displays lines superimposed on the recognized markers. For example, the position detection unit 22 recognizes a marker M6 from the conversion unit block image IMG4a and displays a line L2 superimposed on the marker M6. The position detection unit 22 also recognizes a marker M8 from the conversion unit block image IMG5a and displays a line L3 superimposed on the marker M8. The position detection unit 22 also recognizes a marker M10 from the conversion unit block image IMG6a and displays a line L4 superimposed on the marker M10. Furthermore, the position detection unit 22 recognizes the marker M12 from the transformation unit block image IMG7a, and displays the line L5 superimposed on the marker M12.

[0039] If the belt conveyor BC1, or more specifically, the panel, is discolored due to dirt or has foreign matter attached thereto, the position detection unit 22 may mistakenly recognize the discoloration or foreign matter as a marker. In the example of FIG. 3, the position detection unit 22 mistakenly recognizes the discolored portion D1 in the conversion unit block image IMG3a as a marker and displays a line L1 superimposed on the discolored portion D1. Furthermore, the position detection unit 22 mistakenly recognizes the discolored portion D2 in the conversion unit block image IMG8a as a marker and displays a line L6 superimposed on the discolored portion D2. It is preferable that the markers be correctly recognized when measuring the progress of the belt conveyor BC1. Therefore, it is preferable that the image conversion unit 21 converts and corrects the unit block images so that discoloration or foreign matter is removed from the converted and corrected images.

[0040] Also, for example, in the conversion unit block image IMG6a, the position detection unit 22 can recognize the marker M10. However, there is a possibility that the position detection unit 22 may mistakenly recognize the vehicle 40 as the marker. Therefore, it is preferable that the image conversion unit 21 converts the unit block image so that an article to be transported, such as the vehicle 40, reflected in the unit block image is excluded from the image.

[0041] The position detection unit 22 detects the position of a marker recognized in a conversion unit block image in the conversion unit block image. More precisely, the position of the marker is the position of the marker relative to the traveling direction X of the belt conveyor BC1 of the conversion unit block image in which the marker is displayed. When detecting the position of the marker, the position detection unit 22 calculates a value corresponding to the marker position. The value corresponding to the marker position is the ratio of the position of the marker relative to the traveling direction X of the belt conveyor BC1 of the conversion unit block image in which the marker is displayed. Here, the value corresponding to the marker position is expressed as a percentage from 0% to 100%, and is described as increasing from the rear to the front in the traveling direction of the belt conveyor BC1. Note that the position of the marker can be interpreted as the position of a line displayed superimposed on the recognized marker. Therefore, for example, the position of the marker displayed in the conversion unit block image IMG3a is not the position of marker M4, but the position of line L1 displayed superimposed on the discolored portion D1 that was mistakenly recognized as a marker.

[0042] Here, when converting each unit block image, the image conversion unit 21 converts each unit block image so that the position of the marker in each conversion unit block image is almost the same in all conversion unit block images. Therefore, the positions of the markers recognized in each conversion unit block image will be almost the same unless the position detection unit 22 erroneously recognizes the marker.

[0043] In the example of FIG. 3, the position detection unit 22 calculates that the value corresponding to the marker in the conversion unit block image IMG3a, more precisely, the position of the line L1 displayed superimposed on the discolored portion mistakenly recognized as a marker, is 10%. The position detection unit 22 also calculates that the value corresponding to the position of the marker M6 in the conversion unit block image IMG4a, in other words, the position of the line L2, is 40%. The position detection unit 22 also calculates that the value corresponding to the position of the marker M8 in the conversion unit block image IMG5a, in other words, the position of the line L3, is 35%. The position detection unit 22 also calculates that the value corresponding to the position of the marker M10 in the conversion unit block image IMG6a, in other words, the position of the line L4, is 45%. The position detection unit 22 also calculates that the value corresponding to the position of the marker M12 in the conversion unit block image IMG7a, in other words, the position of the line L5, is 40%. Furthermore, the position detection unit 22 calculates that the value corresponding to the position of the marker in the transformation unit block image IMG8a, more precisely, the line L6 displayed superimposed on the discolored portion mistakenly recognized as a marker, is 70%. The value corresponding to the position of the marker calculated by the position detection unit 22 may be displayed on the display device 13.

[0044] The position detection unit 22 calculates the average value of the values ​​corresponding to the marker positions in each of the transformation unit block images, excluding the image with the largest and smallest values ​​corresponding to the marker positions. In the example of FIG. 3, the transformation unit block image with the largest value corresponding to the marker position is transformation unit block image IMG8a, which has a value of 70% corresponding to the position of line L6. The transformation unit block image with the smallest value corresponding to the marker position is transformation unit block image IMG3a, which has a value of 10% corresponding to the position of line L1. The position detection unit 22 calculates the average value of the values ​​corresponding to the marker positions in each of the transformation unit block images IMG4a, IMG5a, IMG6a, and IMG7a, excluding transformation unit block images IMG3a and IMG8a. In other words, the position detection unit 22 calculates the average of 40%, 35%, 45%, and 40%, and obtains a calculation result of 40%. The average value of the values ​​corresponding to the positions of the multiple markers calculated by the position detection unit 22 may be referred to as the overall position of the markers. The progress calculation unit 23 calculates the progress of the belt conveyor BC1 using the overall positions of the markers calculated by the position detection unit 22, etc.

[0045] When calculating the overall position of the marker, the position detection unit 22 excludes the image with the maximum and minimum values ​​corresponding to the marker position from among the transformation unit block images. Therefore, the image division unit 20 divides the area image into at least three unit block images. The more the area image is divided, the higher the accuracy of the calculation result of the overall position of the marker.

[0046] Next, calculation of the progress of the belt conveyor BC1 by the progress calculation unit 23 will be described with reference to Fig. 4. Fig. 4 is a schematic diagram for explaining the sheet number counter according to the first embodiment.

[0047] In FIG. 4, a conversion unit block image IMG9a-1 is displayed on the display device 13. For ease of explanation, an example is shown in which one conversion unit block image IMG9a-1 is displayed on the display device 13. However, the display device 13 may display as many conversion unit block images as the number of divisions of the area image. The conversion unit block image IMG9a-1 shows panels P3 and P4. A line L7 is displayed superimposed on a marker M15 between panels P3 and P4. Here, the value corresponding to the position of the marker M15 is 95%. At this time, the position of the marker M15 in the conversion unit block image IMG9a-1 is located within a first range R1. The first range R1 is a range of a predetermined length from a first end T1, where the belt conveyor BC1 terminates its movement, to a second end T2, where the belt conveyor BC1 begins its movement, in the conversion unit block image. This predetermined length may be set in advance by the user.

[0048] As the belt conveyor BC1 moves forward, the conversion unit block image IMG9a-1 displayed on the display device 13 transitions to a conversion unit block image IMG9a-2. The conversion unit block image IMG9a-1 and the conversion unit block image IMG9a-2 display the same divided area. By looking at the display device 13, the user can confirm the progress of the belt conveyor BC1 in the same divided area.

[0049] Panels P4 and P5 are shown in the conversion unit block image IMG9a-2. This is because, as the belt conveyor BC1 moves in the direction of travel X, panel P3 moves out of the image range and panel P5 moves in. Since the conversion unit block image includes one marker, when marker M15 moves out of the image, marker M16 appears in the image. A line L8 is displayed superimposed on marker M16 between panels P4 and P5. Here, the value corresponding to the position of marker M16 is 5%. At this time, the position of marker M16 in the conversion unit block image IMG9a-2 is located within a second range R2. The second range R2 is a range of a predetermined length from the second end T2, where the belt conveyor BC1 starts moving, to the first end T1, where the belt conveyor BC1 ends moving, in the conversion unit block image. This predetermined length may be set in advance by the user.

[0050] For ease of explanation, the value corresponding to the position of marker M15 in conversion unit block image IMG9a-1 and the value corresponding to the position of marker M16 in conversion unit block image IMG9a-2 are assumed to be the overall positions of the markers. As shown in the example of FIG. 4, when the overall position of the marker disappears from the first range R1 and appears in the second range R2 as the belt conveyor BC1 advances, the progress calculation unit 23 increments the number counter. The number counter indicates how many panels have passed through the conversion unit block image. More precisely, the number counter indicates how many panels have passed through the divided area depicted by the conversion unit block image.

[0051] The first range R1 has been described as a range of a predetermined length from the first end T1, where the movement of the belt conveyor BC1 ends, to the second end T2, where the movement of the belt conveyor BC1 begins, in the transformation unit block image. This can be interpreted as follows: That is, the first range R1 is a range of a preset value or more and 100% or less. For example, the first range R1 may be a range of 95% or more and 100% or less. The first range R1 may be set in advance by the user.

[0052] Also, the second range R2 was described as a range of a predetermined length from the second end T2 where the belt conveyor BC1 starts moving in the conversion unit block image to the first end T1 where the belt conveyor BC1 ends moving. This can be interpreted as follows: That is, the second range R2 is a range of 0% or more and a preset value or less. For example, the second range R2 may be a range of 0% or more and 5% or less. The second range R2 may be set in advance by the user.

[0053] For example, in a configuration in which the number counter is incremented when the total position of the marker is calculated as 100% and then calculated as 0%, the number counter may not be incremented correctly due to the influence of the frame rate of camera CAM1, etc. However, by setting the first range R1 and the second range R2 as ranges with a certain width, the number counter will be incremented correctly even if, for example, the total position of the marker is calculated as 97% and then calculated as 4%.

[0054] Additionally, it has been explained that the progress calculation unit 23 increments the number counter when the overall position of the marker disappears from the first range R1 and appears in the second range R2. However, this is not limited thereto. The progress calculation unit 23 may increment the number counter when the overall position of the marker disappears from the first range R1 and appears in the second range R2 within a predetermined time after entering the first range R1. This is because, for example, if the belt conveyor BC1 is moving at a constant speed, the overall position of the marker should move into the second range R2 within a predetermined time after entering the first range R1. The predetermined time may be determined, for example, based on the traveling speed of the belt conveyor BC1.

[0055] The progress calculation unit 23 calculates the progress of the belt conveyor using the following formula (1). Here, L is the distance between the markers, c is the number counter, and a is the overall position of the markers. In other words, the distance between the markers is the length of one panel in the traveling direction X. Hereinafter, the progress of the belt conveyor may be referred to as the conveyor progress.

[0056]

number

[0057] For example, if the length of the panel is 1 m, the number counter since the conveyor progress measurement started is 3, and the total position of the marker is 40%, the progress calculation unit 23 calculates that the conveyor progress since the conveyor progress measurement started is 3.4 m.

[0058] Next, the flow of processing by the progress measurement device 10 will be described with reference to Fig. 5. Fig. 5 is a flowchart showing the progress measurement processing according to the first embodiment.

[0059] The progress measurement device 10 acquires a captured image from the camera CAM1 (step S100). The captured image acquired by the progress measurement device 10 in step S100 is used to cut out an area for progress measurement from the captured image, divide the cut-out area, and set up conversion of unit block images. Therefore, in step S100, the progress measurement device 10 may acquire, or may acquire, a captured image that has been recorded in advance and stored in an external device (not shown). In the captured image acquired by the progress measurement device 10 in step S100, it is preferable that the belt conveyor BC1 is not carrying any articles. This is to ensure that various settings such as division and conversion can be performed as smoothly as possible.

[0060] The image dividing unit 20 of the progress measurement device 10 sets an area to be cut out in the captured image acquired in step S100 for measuring the progress of the belt conveyor (step S101). For example, the image dividing unit 20 sets an area E1 in the captured image IMG1 as in the example of Fig. 2. The setting of the cut-out area in step S101 may be performed by, for example, a user operation.

[0061] The image dividing unit 20 sets a process for dividing the area image generated based on the area set in step S101 into a plurality of unit block images (step S102). This sets the number of divisions into the area image, the dimensions of one unit block image, etc. The setting of the division process in step S102 may be performed by, for example, a user operation.

[0062] The image conversion unit 21 sets a conversion process for the unit block image generated based on the division method set in step S102 (step S103). As a result, the conversion unit block image generated based on the setting includes one marker, and the panel displayed in the conversion unit block image becomes rectangular. The setting of the conversion process in step S103 may be performed by a user operation, for example.

[0063] The image conversion unit 21 sets the color and brightness correction process for the conversion unit block image (step S104). This improves the visibility of the conversion unit block image displayed on the display device 13. The correction process setting in step S104 may be set by, for example, a user operation.

[0064] The settings before measuring the progress of the belt conveyor are completed by the processing from step S100 to step S104. The progress of the belt conveyor is measured by the processing from step S105 onwards.

[0065] The progress calculation unit 23 initializes the length of the panel, in other words, the distance between the markers and the number counter (step S105). The progress calculation unit 23 sets the value of L in the above-mentioned formula (1), i.e., the distance between the markers, and also sets the value of c, i.e., the number counter, to 0. The distance between the markers may be stored in memory 12 in advance, for example, or may be set by a user operation.

[0066] The progress measurement device 10 acquires a captured image from the camera CAM1 (step S106).

[0067] The image division unit 20 cuts out an area image from the captured image acquired in step S106 based on the area cut-out setting in step S101, and divides the area image into multiple unit block images based on the division processing setting in step S102 (step S107).

[0068] The image conversion unit 21 converts each of the plurality of unit block images generated in step S107 based on the settings for the conversion process in step S103 (step S108), thereby generating a plurality of conversion unit block images.

[0069] The image conversion unit 21 performs correction on each of the plurality of conversion unit block images generated in step S108 based on the correction process settings made in step S104 (step S109).

[0070] The position detection unit 22 recognizes the markers in each of the plurality of transformation unit block images corrected in step S109 and detects the positions of the recognized markers (step S110), thereby calculating values ​​corresponding to the positions of the markers in each of the plurality of transformation unit block images.

[0071] When the position detection unit 22 has calculated the values ​​corresponding to the positions of the markers in each of the plurality of transformation unit block images in step S110, the position detection unit 22 calculates the overall position of the marker (step S111). The position detection unit 22 calculates, as the overall position of the marker, the average value of the values ​​corresponding to the positions of the markers in each of the plurality of transformation unit block images, excluding the image with the maximum and minimum values ​​corresponding to the positions of the markers.

[0072] The position detection unit 22 determines whether the overall position of the marker calculated in step S111 has disappeared from the first range R1 and appeared in the second range R2 (step S112). While the process of measuring the progress of the belt conveyor is being executed, the processes from step S106 to step S114 are repeated. In step S112, the position detection unit 22 compares the overall position of the marker calculated in step S111 in the previous loop with the overall position of the marker calculated in step S111 in the current loop. Then, the progress calculation unit 23 determines whether the overall position of the marker has disappeared from the first range R1 and appeared in the second range R2. Therefore, in the first loop, the position detection unit 22 determines that the overall position of the marker calculated in step S111 has disappeared from the first range R1 and does not appear in the second range R2.

[0073] If the position detection unit 22 determines that the overall position of the marker calculated in step S111 has disappeared from the first range R1 and does not appear in the second range R2 (step S112; NO), the progress calculation unit 23 calculates the progress of the belt conveyor based on the above-mentioned equation (1) (step S114).

[0074] If the position detection unit 22 determines that the overall position of the marker calculated in step S111 has disappeared from the first range R1 and appeared in the second range R2 (step S112; YES), the progress calculation unit 23 increments the number counter (step S113).Then, the progress calculation unit 23 calculates the progress of the belt conveyor based on the above-mentioned formula (1) (step S114).

[0075] When the progress calculation unit 23 determines to end the measurement of the progress of the belt conveyor (step S115; YES), the progress calculation unit 23 ends this processing flow. For example, the progress calculation unit 23 may determine to end the measurement of the progress of the belt conveyor when the progress of the belt conveyor reaches a predetermined value. Alternatively, the progress calculation unit 23 may determine to end the measurement of the progress of the belt conveyor based on a specific operation by the user.

[0076] When the progress calculation unit 23 determines not to end the measurement of the progress of the belt conveyor (step S115; NO), the process returns to step S106 and repeats the process. For example, the progress calculation unit 23 may determine not to end the measurement of the progress of the belt conveyor if the progress of the belt conveyor has not reached a predetermined value. Alternatively, the progress calculation unit 23 may determine not to end the measurement of the progress of the belt conveyor unless a specific operation is performed by the user.

[0077] In this way, the progress measurement system 1 can measure the progress of the belt conveyor BC1 based on the captured image of the belt conveyor BC1. Therefore, even if the belt conveyor BC1 and an encoder capable of measuring the progress of the belt conveyor BC1 are not connected, for example, it is possible to measure the progress of the belt conveyor BC1 without performing any work for connection. In other words, the progress measurement system 1 enables measurement of the progress of the belt conveyor BC1 with a simple configuration.

[0078] (Modification of the first embodiment) In the above-described first embodiment, an example has been shown in which the position detection unit 22 excludes, from each transformation unit block image, the image with the maximum value and the image with the minimum value corresponding to the marker position when calculating the overall position of the marker. However, this is not limited to this, and the position detection unit 22 may exclude the following images (A1) to (A3) from each transformation unit block image when calculating the overall position of the marker.

[0079] (A1) An image showing a change in the value corresponding to the marker position that deviates from the operation of the belt conveyor BC1. As described with reference to FIG. 4, as the belt conveyor BC1 moves, the positions of the markers and the values ​​corresponding to the marker positions change. In this case, for example, if the value corresponding to the marker position fluctuates wildly, the position detection unit 22 may exclude conversion unit block images showing divided areas including markers whose corresponding values ​​fluctuate wildly from the images used to calculate the overall positions of the markers. Furthermore, for example, if the rate of change of the value corresponding to the marker position is too fast compared to the rate of change expected based on the moving speed of the belt conveyor BC1, the position detection unit 22 may exclude conversion unit block images showing divided areas including markers whose corresponding values ​​change too fast from the images used to calculate the overall positions of the markers. In this case, a specified range may be defined for the rate of change of the value corresponding to the marker position. Furthermore, for example, if the position of the marker continues to change in the direction opposite to the moving direction X of the belt conveyor BC1, the position detection unit 22 may exclude conversion unit block images showing divided areas including the markers from the images used to calculate the overall positions of the markers.

[0080] (A2) Images in which the difference between the recognized marker dimensions and the specified dimensions exceeds the specified range. This is because there is a possibility that a portion other than a marker may be recognized as a marker in the image (A2). For example, a discoloration portion may be mistaken for a marker, as in the discoloration portions D1 and D2 shown in FIG. 3. In this case, the position detection unit 22 may calculate the difference between the width of the discoloration portion recognized as a marker in a certain transformation unit block image in the traveling direction X and the width of the boundary between panels, i.e., the specified width of the marker. If the calculated difference exceeds a specified range, the position detection unit 22 may exclude the transformation unit block image from the images used to calculate the overall position of the marker. The specified range and the specified dimensions of the marker may be set in advance by the user.

[0081] (A3) An image in which the value corresponding to the marker position is a value calculated as a statistical outlier. For example, values ​​corresponding to the marker positions may be stored and accumulated in the memory 12 or the like each time they are calculated. The position detection unit 22 may then calculate the average value and standard deviation of the values ​​corresponding to the marker positions based on past data of values ​​corresponding to the marker positions. If the value corresponding to the marker position calculated in a certain transformation unit block image is more than twice the standard deviation from the average value, the position detection unit 22 may determine the calculated value as an outlier and exclude the transformation unit block image from images used to calculate the overall position of the marker. Furthermore, for example, the position detection unit 22 may calculate the interquartile range of the data based on past data of values ​​corresponding to the marker positions and quartiles based on the data. If the value corresponding to the marker position calculated in a certain transformation unit block image is a value outside the interquartile range, the position detection unit 22 may determine the value as an outlier and exclude the transformation unit block image from images used to calculate the overall position of the marker.

[0082] When calculating the overall position of the marker, the position detection unit 22 not only excludes the images with the largest and smallest values ​​corresponding to the marker position from among the transformation unit block images, but also excludes the above images (A1) to (A3), thereby enabling the progress measurement device 10 to measure the progress of the belt conveyor BC1 with higher accuracy.

[0083] Summary of the Disclosure The above description of the first embodiment discloses at least the following techniques. Note that the components corresponding to the first embodiment are shown in parentheses, but the present invention is not limited to these.

[0084] <Technology 1> A progress measurement device (e.g., progress measurement device 10) is a progress measurement device that measures the progress of a belt conveyor (e.g., belt conveyor BC1) based on an image (e.g., image IMG1) of the belt conveyor, and is equipped with a processor (e.g., processor 11) and a memory (e.g., memory 12).The processor and the memory work together to acquire the image, divide an area (e.g., area E1) of the image for measuring the progress of the belt conveyor into a plurality of unit block images (e.g., unit block image IMG3), recognize markers (e.g., marker M3) arranged at predetermined intervals on the belt conveyor from each of the plurality of unit block images, detect the position of the marker in each of the plurality of unit block images, and calculate the progress of the belt conveyor based on the detection results.

[0085] This allows the progress measurement device to measure the progress of the belt conveyor with a simple configuration.

[0086] <Technology 2> In the progress measurement device described in Technology 1, the progress measurement device may calculate the progress of the belt conveyor based on the position of the marker in each of the multiple unit block images, excluding the image with the largest value and the image with the smallest value corresponding to the position of the marker.

[0087] This allows the progress measurement device to calculate the progress of the belt conveyor without using the image with the largest or smallest value corresponding to the marker position among the multiple unit block images, thereby allowing the progress measurement device to accurately calculate the progress of the belt conveyor using a simple method.

[0088] <Technology 3> In the progress measurement device described in Technology 2, the value corresponding to the position of the marker is the ratio of the position of the marker to the direction of travel of the belt conveyor in the unit block image (e.g., direction of travel X), and the progress measurement device may calculate the progress of the belt conveyor using the average value of the values ​​corresponding to the positions of the marker in each unit block image.

[0089] This allows the progress measurement device to obtain a value corresponding to the position of the marker in the unit block image as a ratio of the position of the marker in the unit block image to the direction of travel of the belt conveyor.Furthermore, the progress measurement device can calculate the progress of the belt conveyor by using the average value of the values ​​corresponding to the positions of the marker in each of the multiple unit block images.

[0090] <Technology 4> In the progress measurement device described in any one of Techniques 1 to 3, the progress measurement device may define a range of a predetermined length from a first end (e.g., first end T1) where the progress of the belt conveyor ends in the unit block image to a second end (e.g., second end T2) where the progress of the belt conveyor starts as a first range (e.g., first range R1), and a range of a predetermined length from the second end to the first end as a second range (e.g., second range R2), and may calculate the progress of the belt conveyor based on the number of times the position of the marker in the unit block image disappears from the first range and appears in the second range, a predetermined interval, and the position of the marker in the unit block image.

[0091] This allows the progress measurement device to calculate the progress of the belt conveyor based on the number of times the marker has passed through the unit block image, the length between the markers, and the position of the marker in the unit block image.

[0092] <Technology 5> In the progress measurement device according to any one of the first to fourth techniques, the progress measurement device may convert the unit block image so that the number of markers in the unit block image becomes one.

[0093] This allows the progress measurement device to convert the unit block image so that the number of markers in the unit block image becomes one.

[0094] <Technology 6> In the progress measurement device according to any one of the first to fifth techniques, the markers may be boundaries between panels that form the belt conveyor.

[0095] This allows the progress measurement device to treat the boundaries between panels as markers when the belt conveyor is configured to include multiple panels.

[0096] <Technology 7> In the progress measurement device described in Technique 6, the progress measurement device may convert the unit block image so that the panels in the unit block image are rectangular.

[0097] This allows the progress measurement device to convert the unit block image so that the panels within the unit block image become rectangular.

[0098] <Technology 8> The progress measurement method measures the progress of a belt conveyor based on an image of the belt conveyor, by obtaining the image, dividing an area of ​​the image for measuring the progress of the belt conveyor into a plurality of unit block images, recognizing markers arranged at predetermined intervals on the belt conveyor from each of the plurality of unit block images, detecting the positions of the markers in each of the plurality of unit block images, and calculating the progress of the belt conveyor based on the detection results.

[0099] This allows the progress measurement method to achieve the same effect as Technique 1.

[0100] <Technology 9> A progress measurement system (e.g., progress measurement system 1) includes a camera (e.g., camera CAM1) that captures an image of a belt conveyor and generates an image, and a progress measurement device that measures the progress of the belt conveyor based on the image. The progress measurement device obtains the image from the camera, divides an area of ​​the captured image for measuring the progress of the belt conveyor into a plurality of unit block images, recognizes markers arranged at predetermined intervals on the belt conveyor from each of the plurality of unit block images, detects the positions of the markers in each of the plurality of unit block images, and calculates the progress of the belt conveyor based on the detection results.

[0101] This allows the progress measurement system to achieve the same effect as Technique 1.

[0102] <Technology 10> A program for executing a progress measurement method for measuring the progress of a belt conveyor based on an image of the belt conveyor causes a computing device to acquire the image, divide an area of ​​the image for measuring the progress of the belt conveyor into a plurality of unit block images, recognize markers arranged at predetermined intervals on the belt conveyor from each of the plurality of unit block images, detect the positions of the markers in each of the plurality of unit block images, and calculate the progress of the belt conveyor based on the detection results.

[0103] This allows the program to achieve the same effect as Technique 1.

[0104] Although the present embodiment has been described above with reference to the drawings, it goes without saying that the present disclosure is not limited to such examples. It is clear that a person skilled in the art can conceive of various modifications, alterations, substitutions, additions, deletions, and equivalents within the scope of the claims, and it is understood that these also naturally fall within the technical scope of the present disclosure. Furthermore, the components of the above-described present embodiment may be combined in any manner as long as they do not deviate from the spirit of the invention. [Industrial Applicability]

[0105] The present disclosure is useful as a progress measurement device, a progress measurement method, and a progress measurement system. [Explanation of symbols]

[0106] 1 Progress measurement system 10 Progress measuring device 11 processors 12 Memory 13 Display device 14 Input Devices 15 Communication interface device 16 Internal Bus 20 Image division unit 21 Image conversion unit 22 Position detection unit 23 Progress calculation section 30 Progress Utilization Device 40 vehicles CAM1 camera BC1 Belt Conveyor E1 Area E2, E3, E4, E5, E6, E7 divided areas P1, P2, P3, P4, P5 panels M1,M2,M3,M4,M5,M6,M7,M8,M9,M10,M11,M12,M13,M14,M15,M16 marker IMG1 Captured image IMG2 Area image IMG3,IMG4,IMG5,IMG6,IMG7,IMG8 Unit block images IMG3a,IMG4a,IMG5a,IMG6a,IMG7a,IMG8a,IMG9a-1,IMG9a-2 Transformation unit block images L1, L2, L3, L4, L5, L6, L7, L8 lines D1, D2 Discolored area T1 1st end T2 2nd end R1 First range R2 Second range

Claims

1. A progress measurement device for measuring the progress of a belt conveyor based on a captured image of the belt conveyor, A processor and a memory, The processor and the memory cooperate to Acquire the captured image; Dividing an area of ​​the captured image for measuring the progress of the belt conveyor into a plurality of unit block images; Recognizing markers arranged at predetermined intervals on the belt conveyor from each of the plurality of unit block images; Detecting the position of the marker in each of the plurality of unit block images; Calculating the progress of the belt conveyor based on the detection result. Progress measuring device.

2. calculating a progress of the belt conveyor based on the position of the marker in each of the plurality of unit block images, excluding an image having a maximum value and an image having a minimum value corresponding to the position of the marker; 2. The progress measuring device according to claim 1.

3. the value corresponding to the position of the marker is a ratio of the position of the marker to the moving direction of the belt conveyor of the unit block image, calculating a progress of the belt conveyor using an average value of values ​​corresponding to the positions of the markers in each of the plurality of unit block images; 3. A progress measuring device according to claim 1 or 2.

4. a first range is a range of a predetermined length from a first end where the movement of the belt conveyor ends to a second end where the movement of the belt conveyor starts in the unit block image; a range of a predetermined length from the second end toward the first end is defined as a second range; calculating a progress of the belt conveyor based on the number of times the position of the marker in the unit block image disappears from the first range and appears in the second range, the predetermined interval, and the position of the marker in the unit block image; 2. The progress measuring device according to claim 1.

5. converting the unit block image so that the number of the markers in the unit block image becomes one; 2. The progress measuring device according to claim 1.

6. The markers are the boundaries between the panels that make up the belt conveyor.

6. A progress measuring device according to claim 5.

7. converting the unit block image so that the panel in the unit block image is rectangular; 7. A progress measuring device according to claim 6.

8. A progress measurement method for measuring the progress of a belt conveyor based on a captured image of the belt conveyor, comprising: Acquire the captured image; Dividing an area of ​​the captured image for measuring the progress of the belt conveyor into a plurality of unit block images; Recognizing markers arranged at predetermined intervals on the belt conveyor from each of the plurality of unit block images; Detecting the position of the marker in each of the plurality of unit block images; Calculating the progress of the belt conveyor based on the detection result. How to measure progress.

9. a camera that captures an image of the belt conveyor and generates a captured image; a progress measuring device for measuring the progress of the belt conveyor based on the captured image, The progress measuring device Acquire the captured image from the camera; Dividing an area of ​​the captured image for measuring the progress of the belt conveyor into a plurality of unit block images; Recognizing markers arranged at predetermined intervals on the belt conveyor from each of the plurality of unit block images; Detecting the position of the marker in each of the plurality of unit block images; Calculating the progress of the belt conveyor based on the detection result. Progress measurement system.

10. A program for executing a progress measurement method for measuring the progress of a belt conveyor based on a captured image of the belt conveyor, The computing device Acquiring the captured image, Dividing an area of ​​the captured image for measuring the progress of the belt conveyor into a plurality of unit block images; Recognizing markers arranged at predetermined intervals on the belt conveyor from each of the plurality of unit block images; detecting the position of the marker in each of the plurality of unit block images; and calculating the progress of the belt conveyor based on the detection result. program.

Images