Inspection system, method for setting inspection items using the inspection system, and inspection method.

Abstract

This invention provides an inspection system that can reduce the burden on workers, a method for setting inspection items using the inspection system, and an inspection method. [Solution] The inspection system 1 inspects the product 5 captured by the imaging device 4 based on the inspection items set in the controller 2. The inspection system 1 also includes a reference image creation unit 11 that creates a reference image based on two-dimensional conversion data converted from three-dimensional CAD data, and an inspection item setting unit 19 that sets inspection items using the reference image. The reference image creation unit 11 includes a CAD function unit 15 that allows the composition to be changed by moving a virtual product 50 composed of three-dimensional CAD data, and a data conversion unit 10 that converts the composition of the three-dimensional CAD data into two-dimensional conversion data in a state that matches the composition in which the imaging device 4 captures the product 5.

Description

Technical Field

[0001] The present invention relates to an inspection system, an inspection item setting method using the inspection system, and an inspection method.

Background Art

[0002] As a conventional inspection device, an appearance of an inspection object is photographed with an actual camera (also referred to as a real camera), and it is determined whether a hole or the like is formed in a required part so as to satisfy a standard, from data of a real image obtained by photographing. For example, there is known an inspection device that acquires imaging data of a plurality of real images while changing a posture of a product or a workpiece as an inspection object (see Patent Document 1). In such a device, inspection imaging data in which the inspection object appears in the most suitable posture for inspection can be selected from the plurality of imaging data.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In a conventional inspection device, a reference product is photographed in advance with an actual camera provided at a production site, and inspection items such as a part (hereinafter also referred to as an inspection part) for performing determination using the photographed image and determination items are set. In order to set an allowable range such as a position of a boundary line that satisfies a standard as a normal product, a plurality of images are photographed while finely moving the position of the product in units of 1 to several millimeters to select an optimal reference image. However, it is difficult to intentionally photograph the product with a fixed dimensional shift such as 1 mm, and multiple retakes are required.

[0005] Furthermore, images captured by actual cameras vary depending on the equipment layout and lighting at the production site. Additionally, the images are affected by external factors such as background elements and other parts of the product, making it difficult to pinpoint the exact location of the desired edge. Setting complex judgment criteria in a production environment while recognizing the position of inspection areas and boundary lines that meet standards down to the millimeter using images captured by a real camera is not easy. Furthermore, such production sites are sometimes located throughout the country. In this case, workers need to travel to each location where the inspection equipment is installed in order to perform the setup work. Therefore, further improvements are needed to reduce the burden on workers while maintaining inspection accuracy.

[0006] The present invention aims to provide an inspection system that can reduce the burden on workers, a method for setting inspection items using the inspection system, and an inspection method. [Means for solving the problem]

[0007] The inspection system of the present invention is an inspection system that inspects products captured by an imaging device based on inspection items set in the inspection device. The inspection system comprises a reference image creation unit that creates a reference image based on two-dimensional conversion data converted from three-dimensional CAD data, and an inspection item setting unit that sets inspection items using the reference image. The reference image creation unit comprises a CAD function unit that allows the composition to be changed by moving a virtual product composed of three-dimensional CAD data, and a data conversion unit that converts the composition of the three-dimensional CAD data into two-dimensional conversion data in a state that matches the composition in which the imaging device captures the product. [Effects of the Invention]

[0008] The present invention provides an inspection system that can reduce the burden on workers, a method for setting inspection items using the inspection system, and an inspection method. [Brief explanation of the drawing]

[0009] [Figure 1]This figure shows the overall configuration of the inspection system in an embodiment of the present invention. [Figure 2] This is a plan view showing an example of an image actually captured by the imaging device on a product. [Figure 3] This is a plan view showing how the simulation unit of the inspection item setting device sets inspection items based on an image obtained by the data conversion unit of the inspection item setting device from three-dimensional CAD data to two-dimensional data. [Figure 4] This is a plan view showing an example of an image captured by an imaging device in a location with unfavorable shooting conditions, such as a production site. [Figure 5] This is a plan view showing how the simulation unit sets the detection area for the inspection items on an image that has been converted into two-dimensional data. [Figure 6] This is a flowchart illustrating the sequence for creating a reference image using the inspection item setting device of the embodiment. [Figure 7] This is a flowchart for simulating the inspection of a product using the inspection device of the embodiment. [Modes for carrying out the invention]

[0010] Hereinafter, an inspection system 1 according to an embodiment of the present invention will be described with reference to the drawings as appropriate.

[0011] As shown in Figure 1, the inspection system 1 of Embodiment 1 mainly comprises a production area 101 where a controller 2, which serves as an inspection device, is provided, and a setting area 102 for setting the inspection items to be used for the controller 2. Furthermore, the inspection system 1 of this embodiment is connected via a communication line 103 such as the Internet between a production area 101, such as a factory, and a designated area 102, such as a company building located in a region separate from the factory.

[0012] Inspection system 1 uses controller 2 to inspect whether products 5 produced in a production area 101, such as a factory, are properly formed. Inspection system 1 requires that the inspection items set in controller 2 be configured quickly and accurately. Therefore, in the setting area 102 which is separated from the production area 101, an inspection item setting device 14 is arranged, and the inspection items set in the controller 2 are set based on the basic image. In the embodiment, the inspection items transmitted from the setting area 102 to the production area 101 via the communication line 103 are configured to be set in the controller 2.

[0013] First, the configuration of the production area 101 where the product 5 is produced will be described. As shown in FIG. 1, in the production area 101, a controller 2, an imaging device 4 provided at the production site for producing the product 5, a robot hand device 6, and an inspection data storage device 41 as a storage for readably and writeably storing the imaging data of the imaging device 4 are arranged. These imaging device 4 and robot hand device 6 are respectively connected to the controller 2. Then, the imaging device 4 images the product 5 produced at the production site and transmits the captured imaging data to the controller 2. The imaging device 4 of the embodiment has a real camera actually arranged at the production site. The real camera is arranged in a direction perpendicular to the floor surface, and the imaging direction is fixed so that it can image from directly above the product 5.

[0014] In addition, the robot hand device 6 can move the product based on the control data sent from the controller 2 and change the composition of the product 5 imaged by the imaging device 4. That is, the robot hand device 6 of the embodiment grips, moves, or rotates the product 5 to move it.

[0015] Thereby, even if the product 5 moved by the robot hand device 6 is imaged from directly above by the imaging device 4 with the imaging direction fixed downward, it is imaged in a desired composition, and imaging data at a position and angle where the product 5 is easy to inspect can be obtained.

[0016] The controller 2 has an inspection unit (also referred to as the actual machine controller) 3. In the inspection unit 3 of the embodiment, data of inspection items stored in an external storage such as a USB memory or an SD card, or in a notebook computer or the like is transferred, and when these notebook computers or the like are connected to the controller 2, various data is transferred. Note that the controller 2 and the inspection item setting unit 19 may be connected via a wired connection such as a cable or via the communication line 103 shown in FIG. 1. Then, transmission and reception are performed via the wired connection or, if necessary, via the communication line 103, and data of inspection items is transferred from the inspection item setting unit 19 to the controller 2.

[0017] Furthermore, an inspection data storage device 41 is provided in the production area 101 of the embodiment. The inspection data storage device 41 stores the imaging data of the imaging device 4. Also, the inspection data storage device 41 may store and accumulate the inspection items actually used in the inspection and the inspection data obtained by the inspection.

[0018] In the conventional inspection, an operator creates data of inspection items from an image of the product 5 captured by an actual camera at the manufacturing site, and determines whether the product 5 is manufactured with an error within the allowable range using a controller. In contrast, the controller 2 of the embodiment of the present invention is configured to perform an inspection to determine whether the product 5 is manufactured with an error within the allowable range using the data of inspection items transferred from the setting area 102 to the production area 101.

[0019] Next, the configuration of the setting area 102 for setting inspection items will be described. As shown in FIG. 1, the setting area 102 of the embodiment is provided with an inspection item setting device 14 having a display screen 18 made of a liquid crystal panel or the like, and a CAD device 30 for creating three-dimensional CAD data of the product 5. Also, the setting area 102 is provided with a storage device 40 that can read and write various data such as three-dimensional CAD data, and the CAD device 30 and the storage device 40 are each connected to the inspection item setting device 14.

[0020] Of these, the CAD device 30 is a "Computer Aided Design" drawing support device used when creating design drawings for product 5. In this embodiment, a three-dimensional CAD device capable of creating three-dimensional CAD data is used as the CAD device 30.

[0021] Furthermore, the storage device 40 is composed of a hard disk drive or other storage devices. The storage device 40 can store three-dimensional CAD data created by the CAD device 30. In addition, the storage device 40 may be configured to store reference image data or set inspection items in a read-write manner as needed.

[0022] The inspection item setting device 14 is capable of sending and receiving various data with the connected CAD device 30 or storage device 40. In this embodiment, the inspection item setting device 14 is connected to the controller 2 in the production area 101 via a communication line 103, and is capable of transmitting the set inspection items to the inspection unit 3. However, the communication line 103 is not required. In this case, the inspection items that have been verified are saved on a laptop computer or external storage and transported, and these are transferred by connecting them to the controller 2 via a wired connection.

[0023] Furthermore, the inspection item setting device 14 is equipped with a file format change unit 9, a reference image creation unit 11, and an inspection item setting unit 19. Of these, the file format change unit 9 changes the storage format of the three-dimensional CAD data created by the CAD device 30 to a three-dimensional data format that can be processed by the reference image creation unit 11. The file format change unit 9 may be provided independently of the inspection item setting device 14.

[0024] Furthermore, the reference image creation unit 11 is configured to create a reference image from the two-dimensional conversion data. The reference image creation unit 11 includes a CPU, RAM, ROM, HDD / SSD, etc. (not shown). The reference image creation unit 11 is configured to perform calculations by having a program extracted from the RAM, ROM, HDD / SSD work in cooperation with three-dimensional CAD data created by the CAD device 30. The reference image created by the reference image creation unit 11 may be configured to be displayed on the display screen 18.

[0025] Furthermore, the inspection item setting device 14 is equipped with a data conversion unit 10 that converts the composition of the three-dimensional CAD data into two-dimensional conversion data in a state that matches the composition in which the imaging device 4 images the product 5, and a CAD function unit 15. Of these, the data conversion unit 10 has a virtual camera 12a. The virtual camera 12a can convert the composition into two-dimensional data that matches the composition captured by the actual imaging device 4 by performing a process of virtually capturing three-dimensional CAD data. Furthermore, the CAD function unit 15 is configured to allow adjustments to the composition and shape of the three-dimensional CAD data before the data conversion unit 10 converts the three-dimensional CAD data into two-dimensional conversion data. In addition, the CAD function unit 15 may have an adjustment function to partially modify the two-dimensional conversion data. For example, in a conventional production site controller 2, as shown in Figure 2, the actual camera installed in the imaging device 4 captures the part of the product 5 that is to be inspected, and imaging data that serves as a reference image is created. However, within the detection area 7 of the image data, parts of other components 5b or the background located on the back side of the hole 5a to be detected may be captured. Therefore, when a reference image is created from the image data of an actual photograph of the product 5, noise that is not necessary for inspection, such as other components 5b or the background, is added.

[0026] In contrast, the inspection item setting device 14 of this embodiment can easily erase data of part 5b located further back in the 3D CAD data before converting it into 2D conversion data using 3D CAD data, which is digital data. Furthermore, other data that could cause noise, such as background, does not exist in the 3D CAD data.

[0027] Therefore, the data conversion unit 10 can eliminate disturbances when converting three-dimensional CAD data to two-dimensional data. Therefore, the reference data created from the two-dimensional conversion data by the reference image creation unit 11 of the inspection item setting device 14 can be made clearer. This makes it easier to identify inspection areas in the reference data, such as the edges located around the opening of hole 5a and the boundary between product 5 and the background.

[0028] For example, in this embodiment, as shown in Figure 3, the reference image created by the reference image creation unit 11 from noise-free digital data does not contain other parts or the surrounding background in the inner portion 52 of the hole 51 of the virtual product 50. Therefore, the boundary line 56 required for inspection can be clearly identified. Furthermore, the reference image creation unit 11 can easily perform image processing on the inner portion 52 by applying color enhancement using a shading scheme. In this case, image processing is performed to darken the inner portion 52. As a result, the reference image can accurately emphasize the edge 55 of the inner periphery of the hole 51 or the boundary line 56 with the background, making it even easier to set the detection area 7 surrounding the position of the inspection area.

[0029] The reference image creation unit 11 of this embodiment includes a CAD function unit 15 that allows the composition to be changed by moving a virtual product 50 composed of three-dimensional CAD data. The CAD function unit 15 of this embodiment is equipped with a virtual robot hand 16. As shown in Figure 1, the virtual robot hand 16 is capable of grasping a virtual product 50 created from three-dimensional CAD data in a virtual space and moving it forward, backward, left, right, up, down, or rotating. As a result, the reference image creation unit 11 of the embodiment can convert the composition when the virtual product 50 is photographed by the virtual camera 12a into two-dimensional conversion data that matches the composition captured by the actual imaging device 4 by operating the virtual robot hand 16 of the CAD function unit 15.

[0030] Furthermore, the reference image creation unit 11 of the embodiment includes a field of view adjustment function unit 12. The field of view adjustment function unit 12 has a virtual camera 12a in the virtual space shown in Figure 1. The virtual camera 12a is positioned perpendicular to the virtual floor and is fixed with its shooting direction pointing downwards in order to capture images from directly above the virtual product 50. Furthermore, the virtual camera 12a in this embodiment is configured to allow adjustment of the imaging field of view. In other words, the field of view adjustment function unit 12 allows the size of the imaging field of view of the reference image to be adjusted to match the size of the imaging field of view of the actual image captured by the imaging device by setting parameters. As shown in Figure 1, the field of view adjustment function unit 12 of the embodiment can easily obtain a desired composition by adjusting the field of view α of the virtual camera 12a by setting parameters.

[0031] For example, the actual camera of the imaging device 4 connected to the controller 2 has an effective pixel count of (W5104 × H4092) in its imaging field of view. On the other hand, the virtual camera 12a has an effective pixel count of (W900 × H700) in its initial imaging field of view. Therefore, in order to match the imaging field of view of the actual camera of the imaging device 4, the field of view adjustment function unit 12 adjusts the field of view α of the virtual camera 12a in a direction that expands it by setting parameters. As a result, it is possible to create a reference image of the size of the imaging field of view of the actual image, with the number of effective pixels being the same as the number of effective pixels of the actual camera (W5104 × H4092), as if viewing the virtual product 50 with the virtual camera 12a.

[0032] In this embodiment, the virtual product 50 held by the virtual robot hand 16 is moved forward, backward, left, right, up, or down, or rotated while being photographed by operating the CAD function unit 15. As a result, the reference image creation unit 11 of the embodiment can easily adjust the field of view α of the virtual camera 12a, set the number of effective pixels, and adjust the composition for imaging the virtual product 50. In this case, the desired composition can also be obtained by setting the shooting direction of the virtual camera 12a downwards and fixing it in the same way as the imaging device 4 on the production site.

[0033] For example, the same parameters used to operate the robot hand device 6 in the production area 101 can be input into the CAD function unit 15 as parameters used to operate the virtual robot hand 16 in the setting area 102. This allows the setting area 102 to be far from the production area 101, making it easy to match the composition in which the virtual camera 12a captures the virtual product 50 with the composition in which the imaging device 4 captures the actual product 5.

[0034] Thus, in this embodiment, the data conversion unit 10 can easily create two-dimensional converted data with the same composition as the composition captured by the imaging device 4 when the product 5 is imaged, as if the virtual product 50 were being viewed from a desired angle and size by operating the virtual robot hand 16. Therefore, the inspection item setting device 14 can easily create a reference image of the desired size and number of effective pixels shown in Figure 3, with the same composition as the actual product 5 captured by the imaging device 4 shown in Figure 2, using the excellent operability of the virtual robot hand 16 and the virtual camera 12a.

[0035] The reference image of the virtual product 50 shown in Figure 3 is created from low-noise digital data converted from the three-dimensional CAD data of the CAD device 30. The operator can use the clearly displayed reference image, such as the display screen 18 of the inspection item setting device 14, to perform the inspection item setting work described later.

[0036] The reference image creation unit 11 of this embodiment has a tolerance value specification function unit 13. The tolerance value specification function unit 13 can move the position of the virtual product 50 in the three-dimensional CAD data and reflect it in the two-dimensional conversion data by specifying the upper and lower limits of the tolerance range of the inspection item. In this embodiment, the upper and lower limits of the tolerance range for the inspection item are specified using the dimensional values ​​of the three-dimensional CAD data. As a result, the reference image creation unit 11 grasps the virtual product 50, which is composed of multiple parts as a semi-finished or finished product, with the robot hand device 6 and moves the virtual product 50 up, down, left, right, forward, backward, or rotates it according to the specified upper and lower limits. This makes it possible to change the position of the hole 51 of the virtual product 50 being inspected by moving it up, down, left, right, front, or back, or by rotating it. For example, the position of the hole 51 in the three-dimensional CAD data shown in Figure 3 can be moved up, down, left, right, forward, backward, or rotated by operating the robot hand device 6. In this case, since the desired upper and lower limits can be specified numerically, the precise movement dimensions required for setting inspection items can be obtained.

[0037] The reference image creation unit 11 can move or rotate the virtual product 50 in three dimensions by simply changing the numerical data of its position or size, without having to perform individual unit conversion calculations. For example, if a dimensional error of up to 1 mm is allowed, the data at the upper limit position 53 will be reflected after being moved by the number of pixels (dots) corresponding to 1 mm from the edge position 55. Similarly, the data at the lower limit position 54 will be reflected after being moved by the number of pixels corresponding to the allowed 1 mm from the edge position 55.

[0038] For example, by intentionally shifting the hole position by 1 mm in 3D data and then capturing the resulting data with a virtual camera, the number of pixels can be adjusted. Therefore, the worker can determine how many pixels correspond to a 1 mm shift.

[0039] This makes it possible to reproduce positional dimensions that are difficult to achieve in a physical product in a virtual space. Therefore, compared to conventional methods that require repeated trial and error, such as shifting the position of the actual product 5 in the production area 101 and changing its relative position with respect to the imaging device 4, this method allows for the rapid and accurate creation of a reference image indicating the acceptable range.

[0040] Furthermore, the inspection item setting unit 19 does not require an actual image of the product 5. Therefore, the inspection item setting device 14 can be placed in a location where there is no reference product 5, such as a location far from the production site. Therefore, the task of setting inspection items, which was previously difficult without going to the production site, can now be easily performed by the worker using the inspection item setting device 14, even from a location far from the production site. As a result, the worker no longer needs to go to the production site to set inspection items, thus reducing their burden.

[0041] The inspection item setting unit 19 then sets inspection items using a reference image. In this embodiment, inspection items are set using a reference image to check whether or not they are within the tolerance range. In this embodiment, the inspection items include, for example, whether the position of holes, corners, and edges, the shape of holes, the center position and axial direction, or the number and position of installed screws meet the standards. The controller 2 then performs the inspection to determine, on a pixel-by-pixel basis, whether or not the inspection area of ​​the product 5, which has been manufactured with the set inspection items implemented, is formed within the desired tolerance range.

[0042] For example, in the image captured by the imaging device 4 shown in Figure 4, if the detected area is the side or bottom surface of the product 22, the illumination may be low and the image may be dark depending on the lighting in the production site and the arrangement of the production equipment, making it difficult to set inspection items using the actually captured image data as a reference image. Furthermore, with relatively small screw holes 64, it may be impossible to distinguish between the screw threads 26 formed inside the screw hole 64 and the edge located at the periphery of the opening when setting the detection area 17. Therefore, it is necessary to change the lighting and the position of the product 5 multiple times and retake the image.

[0043] In the reference image created using the inspection item setting device 14 of the embodiment, there is no background data such as other parts at the axial position 65 of the hole 63 of the virtual product 60 shown in Figure 5. Furthermore, the angle at which the virtual product 60 is displayed within the reference image is predetermined by setting parameters that move the virtual robot hand 16 and the virtual camera 12a. Therefore, it is possible to easily set the axial position 65 and axial direction of the hole 63 as inspection items using a reference image.

[0044] Furthermore, a detection area 7 can be set around each hole 63, and a detection area 17 can be set to surround the screw hole 64. Furthermore, the reference image is created based on three-dimensional CAD data, which is digital data. Therefore, the positions of edges 67 and 68 of the virtual product 60 can be identified without being affected by external disturbances such as lighting.

[0045] For example, in the image captured by the imaging device 4 shown in Figure 4, the edges 27 and 28 of the corner section, which are bent at approximately 90 degrees, are curved in an arc shape. Therefore, depending on the direction of the light, a line of light and dark may appear at a position offset from the top of the curved surface, which could be mistaken for the edges 27 and 28. The reference image in this embodiment is created by the data conversion unit 10 of the reference image creation unit 11 from two-dimensional conversion data obtained by converting the three-dimensional CAD data used to create the product 5. Therefore, the positions of the edges 67 and 68 shown in Figure 5 are accurate, and the operator can easily set detection areas 71 and 72 around them.

[0046] Furthermore, in the reference image creation unit 11 of this embodiment, the CAD function unit 15 adjusts the three-dimensional CAD data to achieve the desired composition, and the data conversion unit 10 converts it into two-dimensional conversion data. As a result, it is possible to create a reference image with the same position and orientation as the manufactured product 22 shown in Figure 4. In addition, a reference image with clearly visible edges can be obtained, and for example, it can be made sharp as shown in Figure 5.

[0047] Then, using the reference image, the inspection item setting unit 19 sets inspection items such as the position, size, and shape tolerance range for each detection area 7, 17, 71, and 72 that are set in the parts to be detected, such as the holes 63. The inspection items created by the inspection item setting unit 19 and the reference images created by the reference image creation unit 11 may be written to the storage device 40 along with their respective inspection items and saved to accumulate multiple reference images. This allows the inspection items and reference images to be read from the storage device 40 as needed, enabling verification through simulation, resetting of inspection items, and other similar operations.

[0048] Furthermore, the inspection item setting unit 19 of the inspection system 1 is mainly composed of a simulator device and includes a simulation unit 20 equipped with simulation software. The simulation unit 20 sets inspection items for reference image data of the reference image and performs verification using the simulation software. The simulation software verification confirms whether the inspection items can be performed correctly.

[0049] In this embodiment of the inspection system 1, before the controller 2 implements the set inspection items, it is possible to verify in advance at a simulation unit 20 located remotely whether the inspection items can be performed as desired. Therefore, if the accuracy of the inspection does not meet the required level, the inspection items can be immediately reset in the inspection item setting unit 19. Thus, the efficiency of the inspection work performed using the controller 2 can be improved. Verification by the simulation unit 20 of the embodiment confirmed that the detection accuracy of inspection items set using a reference image created based on three-dimensional CAD data, which is digital data, can be equivalent to or better than the detection accuracy of inspection items set using actual images.

[0050] Figure 6 is a flowchart illustrating the method for setting inspection items using the inspection system 1 of the embodiment, following the order of setting. This section describes the process of converting three-dimensional CAD data into two-dimensional data and creating a reference image using the inspection item setting device 14 located in the setting area 102 of the inspection system 1 shown in Figure 1.

[0051] First, when the process is started in step S1, in step S2, the file format conversion unit 9 shown in Figure 1 converts the data format of the three-dimensional CAD data created by the CAD device 30 into a three-dimensional data format for the reference image creation unit 11. At this stage, the data is merely converted into a three-dimensional data format that can be processed by the reference image creation unit 11, and is read into the reference image creation unit 11 in its three-dimensional data file format. As a result, the virtual robot hand 16 can freely move the virtual product 50, which is in the form of a three-dimensional data file, in the up, down, left, right, forward, backward, and rotational directions within the virtual space. The virtual camera 12a can then obtain a composition of the virtual product 50 viewed from a desired angle.

[0052] In step S3, the field of view adjustment unit 12 uses the virtual camera 12a to change the size of the imaging field of view based on the set parameters. This adjusts the size of the imaging field of view of the virtual camera 12a to match the size of the imaging field of view of the actual camera of the imaging device 4 located in the production area 101, for example, the number of effective pixels (W5104 × H4092).

[0053] In step S4, the virtual camera 12a captures the virtual product 50 in the virtual space. In this process, the data conversion unit 10 of the inspection system 1 converts the composition of the three-dimensional CAD data into two-dimensional conversion data that matches the composition in which the imaging device 4 images the product 5.

[0054] Then, the reference image creation unit 11 creates a reference image from the two-dimensional conversion data as a reference image creation step (see Figure 3). In the reference image creation step of the embodiment, the tolerance value specification function unit 13 of the reference image creation unit 11 specifies the upper and lower limits of the tolerance range of the hole 51, which is an inspection item, using the dimensional values ​​of the three-dimensional CAD data. Therefore, multiple reference images can be created from multiple two-dimensional transformation data of different edges located at the upper and lower limits of the acceptable error range.

[0055] In step S5, the created reference image may be temporarily saved to the storage device 40 in the setting area 102. The reference image is stored in the storage device 40 and can be read out as needed during the simulation of the simulation unit 20, which will be described later. Then, in step S6, the reference image creation unit 11 terminates the reference image creation process.

[0056] Figure 7 is a flowchart illustrating the sequence of operations performed in the inspection system 1 of the embodiment and the inspection of product 5 by the controller 2. In this embodiment, before setting inspection items on the controller 2 and making it ready for inspection, a simulation is performed by the simulation unit 20 located in the setting area 102 to verify whether the inspection can be performed normally with the pre-set inspection items.

[0057] First, in step S10, when the process starts, a simulation is performed by the inspection item setting unit 19 in the setting area 102. The inspection item setting unit 19 uses the simulation unit 20 to verify whether the inspection of product 5 according to the set inspection items can be performed at a level that meets certain standards, using a reference image created in advance by the reference image creation unit 11.

[0058] In step S11, the reference image created by the reference image creation unit 11, or the reference image temporarily stored in the storage device 40 of the setting area 102, is loaded into the simulation unit 20 of the inspection item setting unit 19. Furthermore, the inspection item setting unit 19 sets inspection items using a reference image. In this embodiment, an example of an inspection item set by the inspection item setting unit 19 is whether the hole 63, which is the object of inspection within the detection area 7 shown in Figure 5, is formed between the upper and lower limits of the allowable range. In step S12, the reference image read by the simulation unit 20 is verified using simulation software.

[0059] In the inspection system 1, the inspection item setting method using the inspection system 1, and the inspection method of the embodiment, high-resolution reference images can be used. Therefore, the results of the simulation unit 20 verifying the reference image created by the reference image creation unit 11 using simulation software were able to detect with the same or better accuracy than the results of verification using actual images.

[0060] In step S13, the inspection items that have passed verification are transferred from the reference image creation unit 11 in the setting area 102 to the controller in the production area 101 via a wire or other means. For example, the inspection items that have been verified are transmitted to the controller 2 in the production area 101 via a communication line 103 such as the internet. In this case, multiple verification items stored in the storage device 40 may be transmitted together for each inspection part or for each product 5. Alternatively, instead of transmitting via the communication line 103 shown in Figure 1, the verified test items may be saved on a laptop computer or external storage device and transported, then connected to the controller 2 via a wired connection for transfer.

[0061] In step S14, the inspection items are implemented in the inspection unit 3 of the controller 2 located on the production floor. At this time, the controller 2 may be used to adjust the inspection items to match the actual product 5 being inspected, thereby further improving the accuracy of the inspection.

[0062] In step S15, the actual camera of the imaging device 4 takes an image of the product 5. Then, in step S16, an inspection is performed to determine whether product 5 has been produced accurately based on the set inspection items. In this embodiment, the inspection unit 3 inspects the product 5 captured by the imaging device 4 based on the inspection items sent from the inspection item setting unit 19 in the setting area 102 to the controller 2 in the production area 101 via the communication line 103 shown in Figure 1. Specifically, the controller 2 compares the reference image with the image captured by the imaging device 4 and detects how many pixels are misaligned. The controller 2 then determines that the misalignment exceeds a predetermined tolerance if it exceeds a certain number of pixels, such as 1 to 5 pixels. Furthermore, since the inspection items sent to the controller 2 directly from the storage device 40 in the setting area 102 or from the reference image creation unit 11 are matched to the effective pixel count of the controller 2 (W5104 x H4092), accurate inspections can be easily performed.

[0063] Furthermore, in step S17, the image processing detection and judgment are ultimately performed by the controller 2 in the production area 101. That is, the comparison with the reference image and the judgment based on the set inspection items are all processed by the controller 2. The judgment result from the controller 2 is stored in the inspection data storage device 41, which is provided as data storage in the production area 101.

[0064] The inspection data storage device 41 of this embodiment is provided with folders separated according to the pass / fail judgment result. The inspection results are written to the corresponding folders of the inspection data storage device 41 and saved together with the captured images. Then, in step S18, the inspection process of product 5 by controller 2 is completed.

[0065] As shown in Figure 2, the actual image data of product 5, the object to be inspected, captured by the imaging device 4 contains noise and the surrounding background. Therefore, in the case of actual image data where the position and angle of the object to be inspected are actually changed while being photographed, it was difficult to set inspection items that meet the required standards through further fine-tuning at the production site.

[0066] In contrast, the inspection system 1 of the embodiment can easily create a high-resolution reference image using two-dimensional conversion data created from three-dimensional CAD data, which is digital data as shown in Figure 3, via the inspection item setting device 14 provided in the setting area 102. Therefore, by setting the position and size of the part to be inspected in millimeters using the inspection item setting unit 19 of the inspection item setting device 14, inspection items are set that can be converted to pixel units and perform high-definition inspections.

[0067] Furthermore, in the inspection system 1, the inspection item setting method using the inspection system 1, and the inspection method of the embodiment, the inspection items set by the inspection item setting device 14 are set based on a reference image created so that it has the same composition as the actual image when actually captured by the imaging device 4. Furthermore, in this embodiment, the field of view adjustment function unit 12 of the reference image creation unit 11 creates a reference image by setting the size of the imaging field of view of the virtual camera 12a to the same size as the imaging field of view used when the controller 2 performs the inspection.

[0068] Therefore, data for the inspection items required for each detectable part of each product 5 on the production site can be set in the setting area 102, which is located away from the production area 101. Then, by implementing the inspection items based on the set data to the controller 2 in the production area 101, inspection can be performed directly. Therefore, in production area 101, the placement and angle adjustment of the imaging device 4 become easy or unnecessary, and inspection can be performed using the controller 2 while it remains fixed, for example. As a result, the inspection of product 5 is simplified and can be performed quickly, reducing the burden on workers in production area 101. Thus, in the inspection system 1 of this embodiment, it is no longer necessary for an operator to go to the production site and repeatedly photograph the object to be inspected while making fine adjustments to its position and angle, thereby reducing the workload.

[0069] Furthermore, even if there are multiple production areas 101, the inspection items set by the inspection item setting device 14 are transmitted as data to each area via the communication line 103. This eliminates the need for workers to go to each production area 101 to perform setup work, thus providing practically beneficial effects.

[0070] As described above, the inspection system 1 of the present invention inspects the product 5 captured by the imaging device 4 based on the inspection items set in the controller 2. Furthermore, the inspection system 1 includes a reference image creation unit 11 that creates a reference image based on two-dimensional conversion data converted from three-dimensional CAD data, and an inspection item setting unit 19 that sets inspection items using the reference image. The reference image creation unit 11 includes a CAD function unit 15 that allows the composition to be changed by moving a virtual product composed of three-dimensional CAD data, and a data conversion unit 10 that converts the composition of the three-dimensional CAD data into two-dimensional conversion data in a state that matches the composition in which the imaging device images the product.

[0071] The inspection system 1 of the present invention, configured in this way, can reduce the burden on the worker. In other words, the inspection item setting unit 19 can set inspection items using the reference image created by the reference image creation unit 11, in the same way as the composition in which the imaging device photographed the product 5. Furthermore, the two-dimensional conversion data is obtained by converting three-dimensional CAD data, which is digital data free from external disturbances. Therefore, the reference images created using the two-dimensional conversion data are clear and noise-free. Consequently, it is possible to set inspection items that achieve detection accuracy equivalent to or better than that obtained with conventional imaging devices.

[0072] For example, by using two-dimensional conversion data, which is digital data, the reference image creation unit 11 can be moved in units of one pixel, the same as the effective number of pixels used for inspection. Therefore, compared to conventional methods that require repeated trial and error while moving the relative position between the actual product 5 and the imaging device 4, the tolerance range can be set accurately and effectively. Therefore, the reference image creation unit 11 can create reference images that allow for the setting of inspection items to be comparable to those obtained when using actual images, such as imaging data from the imaging device 4, as reference images. Furthermore, by using the reference images created by the reference image creation unit 11, inspection items can be easily set.

[0073] Furthermore, the inspection item setting unit 19 does not require an actual image of the product 5. Therefore, the inspection item setting unit 19 can be located away from the production site where the imaging device 4 is installed. As a result, the operator can easily perform the inspection item setting task, which was difficult to do at the production site, from a distance using the reference image created by the reference image creation unit 11. Consequently, the operator no longer needs to go to the production site where the controller 2 is installed, reducing their workload.

[0074] The reference image creation unit 11 has a field of view adjustment function unit 12 that allows the size of the imaging field of view of the reference image to be adjusted to match the size of the imaging field of view of the actual image captured by the imaging device 4 by setting parameters.

[0075] The reference image creation unit 11 can create a reference image of the size of the actual image's imaging field of view by setting parameters using the field of view adjustment function of the field of view adjustment function unit 12. More specifically, the field of view adjustment function of the field of view adjustment unit 12 allows for free adjustment of the imaging direction and size, including the width, height, and diagonal field of view of the imaging field. This enables the reference image creation unit 11 to easily obtain a reference image of the desired size. Therefore, if an inspection cannot be performed accurately, the parameters of the field of view adjustment function can be changed, and the inspection items can be immediately reset using the inspection item setting unit 19. Consequently, the trial-and-error work of repeatedly taking images with the imaging device 4, which was performed on the production floor, can be eliminated, and the workload can be reduced.

[0076] The reference image creation unit 11 has a tolerance value specification function unit 13 that moves the virtual product 50 of the three-dimensional CAD data by specifying the upper and lower limits of the tolerance range of the inspection item and reflects this in the two-dimensional conversion data.

[0077] The reference image creation unit 11 can easily change the reference image by moving the corresponding position of the virtual product 50 by specifying the upper and lower limits of the tolerance range using the tolerance value specification function unit 13. For example, the specified upper and lower limits may be units of measurement for the dimensions of the product on the three-dimensional CAD data, such as millimeters, and can be immediately converted to units of one pixel, which is the effective number of pixels in the digital data, and thus used directly as the units for the inspection items. Therefore, inspection items can be set using a reference image of a virtual product 50 that has been moved to a position corresponding to the upper and lower limits of the acceptable range for a normal product 5, thereby enabling accurate inspection of product 5.

[0078] Furthermore, as shown in Figure 3, for example, by specifying numerical values, the edge 55, which is the inspection area of ​​the virtual product 50, can be moved multiple times in different up, down, left, right, or front and back directions by specifying upper and lower limits, thereby creating a continuous ring-shaped connection of the outermost or innermost contact points, and thus creating the portion of the edge 55 that has moved to the upper limit position 53 and lower limit position 54 that the hole 51 allows. In this case, the reference image creation unit 11 of the embodiment can easily move the position of the edge 55 using the virtual robot hand 16 of the CAD function unit 15. Therefore, the inspection item setting device 14 of the embodiment can further improve the work efficiency of creating reference images.

[0079] Furthermore, for example, by specifying numerical values, the shape of the product at the edge 55 portion may be deformed to create an upper limit position 53 and a lower limit position 54, thereby creating a reference image corresponding to the upper and lower limits of the tolerance range for the inspection item.

[0080] Based on the inspection items set in this way, the controller 2 inspects the product 5 captured by the imaging device 4 by implementing the inspection items. At this time, pass / fail determination can be easily made on a pixel-by-pixel basis by reflecting upper and lower limits, such as boundary lines, on the digital data and determining whether or not the product straddles either limit. Therefore, the accuracy of defective product inspection can be easily improved.

[0081] Furthermore, for example, if an inspection cannot be performed accurately, the shape of the product in the reference image can be altered by changing the numerical value specified in the tolerance value specification function unit 13 as needed. In this case, there is no need to perform cumbersome calculations to convert units, and the inspection items can be immediately and accurately reset. Moreover, it eliminates the need for trial and error work such as remaking the actual product 5 and re-imaging it with the imaging device 4, thereby improving work efficiency.

[0082] Furthermore, the CAD function unit 15 has a virtual robot hand 16 that can grasp and move a product of three-dimensional CAD data in a virtual space. The virtual robot hand 16 can freely move the virtual product 50 it grasps in the virtual space while maintaining its grip, thereby obtaining a reference image of the virtual product 50 viewed from a desired angle. This makes it even easier to obtain the same composition as the actual image of the product 5 captured by the imaging device 4.

[0083] Furthermore, the inspection item setting unit 19 has a simulation unit 20 that uses simulation software to verify whether the set inspection items can be used to properly inspect the product 5. This allows the simulation software in the simulation unit 20 to verify whether the inspection items can perform the desired inspections before implementing the inspection items in the controller 2. Therefore, if the inspection accuracy does not meet the required level, the inspection items can be immediately reset by the inspection item setting unit 19, thereby improving the efficiency of the inspection work.

[0084] Furthermore, the inspection item setting method using the inspection system 1 includes a conversion step of converting three-dimensional CAD data into two-dimensional converted data according to the composition to be captured by the imaging device 4, a reference image creation step of creating a reference image from the two-dimensional converted data, and an inspection item setting step of setting inspection items using the reference image.

[0085] Depending on the inspection item setting method, a reference image is created from two-dimensional conversion data of the composition that matches the composition to be captured by the actual imaging device 4 using the inspection system 1. The 2D conversion data is derived from 3D CAD data that does not contain external disturbances, resulting in a clear reference image. Therefore, it is possible to set inspection items using reference images that are comparable to or even better than actual images, compared to using real images as reference images.

[0086] Furthermore, the inspection method using the inspection system 1 includes an inspection unit 3 that can send and receive inspection items between the controller 2 and the inspection item setting unit 19 via a communication line 103. The inspection system 1 includes a conversion step of converting the composition of three-dimensional CAD data into two-dimensional converted data to match the composition to be captured by the imaging device 4, and a reference image creation step of creating a reference image from the two-dimensional converted data. It also includes an inspection item setting step of setting inspection items using the reference image, and an inspection step in which the inspection unit 3 inspects the product 5 captured by the imaging device 4 based on the inspection items sent from the inspection item setting unit 19 to the controller 2 via the communication line 103 or the inspection items set by the controller 2.

[0087] Even when the controller 2 located at the production site is far from the inspection item setting unit 19, the inspection items set in the inspection item setting unit 19 can be sent to the inspection unit 3 via the communication line 103 to perform the inspection. Therefore, workers can reduce their workload by decreasing the number of times they have to go to the production site.

[0088] The present invention is not limited to the embodiments described above, and various modifications are possible. The embodiments described above are illustrative examples provided to facilitate understanding of the present invention, and are not necessarily limited to those comprising all the configurations described. Furthermore, it is possible to replace parts of the configuration of one embodiment with those of another embodiment, and it is also possible to add configurations from other embodiments to the configuration of one embodiment. In addition, it is possible to delete parts of the configuration of each embodiment, or to add or replace other configurations. Possible modifications to the above embodiments are as follows, for example.

[0089] In the embodiment described, the reference image creation unit 11 and the inspection item setting unit 19 are provided in a single inspection item setting device 14. However, the embodiment is not limited to this, and they may be configured as separate devices connected via a wired or communication line 103.

[0090] Furthermore, the inspection item setting device 14 of this embodiment is connected to a CAD device 30 and a storage device 40, respectively, enabling the transmission and reception of various types of data. However, the configuration of the inspection system 1 is not limited to this. For example, as long as various data can be sent and received between the inspection item setting unit 19 and the setting area 102, either the CAD device 30 or the storage device 40 may be located outside the setting area 102, for example, in a remote location. Even if the CAD device 30 or storage device 40 is not located in the same place as the inspection item setting unit 19 in the setting area 102, it is sufficient if they are connected to the inspection item setting device 14 via a storage device or communication line 103. This allows various data to be sent and received to set inspection items using reference images.

[0091] Furthermore, the inspection item setting device 14 may be connected to the controllers 2 of multiple production areas 101 via a communication line 103, and may be capable of transmitting the set inspection items to the inspection units 3 located in each area. In this case, the inspection system 1 transmits common inspection items set in the setting area 102 to the controllers 2 in multiple production areas 101. Then, the controller 2 in each production area 101 individually adjusts the transmitted inspection items. This allows each production site to perform inspections appropriate to the manufactured product 5. Therefore, the efficiency of setting inspection items is good for the entire inspection system 1.

[0092] In this embodiment, the field of view adjustment unit 12 uses a virtual camera 12a to match the imaging field of view of the actual camera of the imaging device 4, but it is not limited to this. For example, as long as the number of effective pixels can be the same as the number of effective pixels of the actual camera (W5104 × H4092), the field of view adjustment unit 12 may have any configuration, such as allowing the operator to set the number of effective pixels through input work.

[0093] Furthermore, in the CAD function unit 15 of this embodiment, the position of the virtual product 50 is moved up, down, left, right, or forward and backward using the virtual robot hand 16 to set the upper limit position 53 and the lower limit position 54, but this is not the only way to do so. For example, in the virtual product 50 of the three-dimensional CAD data, the radial dimensions of the edge 55 of the hole 51 shown in Figure 3 may be expanded or contracted to form the upper limit position 53 and the lower limit position 54. In this case, the inspection item setting device 14 of the embodiment allows the reference image to be changed using the CAD function unit 15 shown in Figure 1. Therefore, there is no need to change the three-dimensional CAD data again using the CAD device 30, resulting in good work efficiency.

[0094] Furthermore, while the three-dimensional CAD data and two-dimensional conversion data are displayed on one of the monitors of the inspection item setting device 14 as display screen 18, this is not the only option. For example, multiple liquid crystal display devices or a single monitor can be used as a multi-screen setup, and the number of display screens and the combinations of displayed content are not particularly limited.

[0095] In Figure 1 of the embodiment, the product 5 is imaged from directly above by the imaging device 4, but this is not the only option. For example, the imaging device 4 may image the product 5 from any direction, and the imaging direction may be configured to be changeable. For example, when photographing the product 5 from an oblique angle above or to the side using an imaging device 4 installed diagonally above or to the side of the product 5, the virtual camera 12a may also be configured to photograph the virtual product 50 from an oblique angle above or to the side to match the composition. In other words, the installation position, installation angle, and imaging direction of the imaging device 4 are not particularly limited; it is sufficient that the placement position, installation angle, and imaging direction of the virtual camera 12a are set to match the composition of the imaging device 4. [Explanation of Symbols]

[0096] 1. Inspection System 2. Controller (inspection device) 3. Inspection Department 4. Imaging device 5 products 10 Data conversion unit 11. Reference Image Creation Unit 12 Field of view adjustment function section 13. Tolerance value specification function unit 15 CAD Function Unit 19. Inspection Item Setting Unit

Claims

1. An inspection system that inspects products imaged by an imaging device based on inspection items set in the inspection device, A reference image creation unit that creates a reference image based on two-dimensional conversion data converted from three-dimensional CAD data, An inspection item setting unit that sets the inspection items using the aforementioned reference image, Equipped with, The aforementioned reference image creation unit includes a CAD function unit that allows the composition to be changed by moving the virtual product composed of the three-dimensional CAD data, An inspection system characterized by having a data conversion unit that converts the composition of the three-dimensional CAD data into two-dimensional conversion data in a state that matches the composition in which the imaging device images the product.

2. The inspection system according to claim 1, characterized in that the reference image creation unit has a field of view adjustment function that allows the size of the imaging field of view of the reference image to be adjusted to match the size of the imaging field of view of the actual image captured by the imaging device by setting parameters.

3. The inspection system according to claim 1, characterized in that the reference image creation unit has an tolerance value specification function unit that moves the three-dimensional CAD data and reflects it in two-dimensional conversion data by specifying an upper limit and a lower limit as the tolerance range of the inspection item.

4. The inspection system according to claim 1, characterized in that the CAD function unit has a virtual robot hand capable of grasping and moving the virtual product of the three-dimensional CAD data in a virtual space.

5. The inspection system according to claim 1, characterized in that the inspection item setting unit has a simulation unit that uses simulation software to verify whether the set inspection items can be used to inspect the product normally.

6. A conversion step that converts three-dimensional CAD data into two-dimensional data to match the composition captured by the imaging device, A reference image creation step, which involves creating a reference image from the aforementioned two-dimensional conversion data, A step of setting inspection items by setting inspection items using the aforementioned reference image, A method for setting inspection items using the inspection system according to claim 1, characterized by comprising the above.

7. The inspection device includes an inspection unit capable of sending and receiving the inspection items via a communication line with the inspection item setting unit. A conversion step that converts the composition of three-dimensional CAD data into two-dimensional conversion data to match the composition to be captured by the imaging device, A reference image creation step, which involves creating a reference image from the aforementioned two-dimensional conversion data, A step to set inspection items using a reference image, An inspection method using the inspection system according to claim 1, comprising: an inspection step in which the inspection unit inspects a product imaged by the imaging device based on the inspection items sent from the inspection item setting unit to the inspection device via the communication line, or the inspection items set by the inspection device.

Images