Generation device, generation system, processing system, generation method, program, and storage medium

Abstract

To provide a generation device, a generation system, a processing system, a generation method, a program and a storage medium with which it is possible to generate a temperature profile in a conveyed object.SOLUTION: A generation device according to an embodiment acquires a plurality of images that is generated by a thermal camera and indicates the temperature distribution of a conveyed object. The generation device further sets a plurality of measurement areas to each of the images along the conveyance direction of the conveyed object. The generation device further generates time-series data that indicates a temperature change over time in each of the measurement areas. The generation device further generates, using some of the temperatures extracted from the respective time-series data, a temperature profile that indicates a temperature change over time in the conveyed object.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] Embodiments of the present invention relate to a generation device, a generation system, a processing system, a generation method, a program, and a storage medium.

Background Art

[0002] In production, heat treatment of a workpiece may be performed for melting, joining, thermal activation, etc. In this heat treatment, the workpiece may be conveyed during the process. There is a need for a technique capable of acquiring a temperature profile for such a conveyed object.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The problem to be solved by the present invention is to provide a generation device, a generation system, a processing system, a generation method, a program, and a storage medium capable of generating a temperature profile in a conveyed object.

Means for Solving the Problems

[0005] The generation device according to the embodiment acquires a plurality of images showing the temperature distribution of a conveyed object generated by a thermal camera. The generation device further sets a plurality of measurement areas in each of the images along the conveyance direction of the conveyed object. The generation device further generates time-series data indicating the change in temperature with respect to time in each of the measurement areas. The generation device further generates a temperature profile indicating the change in temperature with respect to time in the conveyed object using a part of the temperatures extracted from each of the time-series data.

Brief Description of the Drawings

[0006]

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Embodiments for Carrying Out the Invention

[0007] Hereinafter, each embodiment of the present invention will be described with reference to the drawings. In the present specification and each figure, the same reference numerals are given to the same elements as those already described, and detailed descriptions thereof are appropriately omitted.

[0008] FIG. 1 is a schematic diagram showing a generation system according to an embodiment. The generation system according to the embodiment is used to generate a temperature profile for a conveyed object being conveyed in a specific direction. As shown in FIG. 1, the generation system 10 includes a generation device 11, a thermal camera 12, a detector 13, a storage device 14, an input device 15, and an output device 16.

[0009] The thermal camera 12 detects the surface temperature of the conveyed object and its surroundings, and acquires an image (thermal image) showing the temperature distribution. The generation device 11 generates a temperature profile in the conveyed object using the image. The detector 13 detects the approach of the conveyed object. The storage device 14 appropriately stores the image acquired by the thermal camera 12, the data used in the processing of the generation device 11, the data obtained by the processing of the generation device 11, and the like. The input device 15 is used for a user to input data to the generation device 11. The output device 16 outputs the data to the user.

[0010] FIG. 2 is a flowchart showing a generation method according to an embodiment. The temperature profile generation method M1 shown in FIG. 2 includes steps S1 to S13. First, the detector 13 detects the approach of the conveyed object to a specific position (step S1). For example, the detector 13 detects the approach of the conveyed object to the detection range by the thermal camera 12. The detector 13 includes one or more selected from a proximity sensor, a distance measuring sensor, a transmission sensor, and a pressure sensor.

[0011] FIG. 3 is an example of a thermal image acquired by a thermal camera. In the example of FIG. 3, a workpiece 50 with a plurality of pipes 52 joined to a housing 51 appears as the conveyed object. The thermal camera 12 starts detecting temperature in response to the detection of the conveyed object by the detector 13 (step S2). For example, the thermal camera 12 includes a plurality of infrared sensors. As shown in FIG. 3, the thermal camera 12 generates an image IM showing the temperature detection result. The thermal camera 12 is fixed at a specific position and repeats temperature detection and image generation. In the continuously generated images, the conveyed object moves in the conveyance direction. The thermal camera 12 stores the generated images in the storage device 14. Alternatively, the thermal camera 12 may directly transmit the images to the image generation device 11.

[0012] The image generation device 11 acquires a plurality of images generated by the thermal camera 12. The image generation device 11 calculates the conveyance direction of the conveyed object from the plurality of images (step S3). For example, the image generation device 11 extracts feature points from each image. The image generation device 11 associates the feature points extracted between the images. The movement direction between the associated feature points corresponds to the conveyance direction. Alternatively, the conveyance direction may be input by the user.

[0013] Furthermore, the image generation device 11 may calculate the movement amount of the conveyed object from a plurality of images that are temporally continuous. The image generation device 11 calculates the distance between the extracted feature points as the movement amount of the conveyed object during the temperature detection interval. The calculated movement amount is used for setting the measurement area described later.

[0014] FIG. 4 is an image showing an example of setting the measurement line. The generating device 11 selects one of the images. The generating device 11 sets measurement lines for the selected image (step S4). As shown in FIG. 4, a plurality of measurement lines L1 to L3 are set in the orthogonal direction D2 orthogonal to the conveyance direction D1. Each of the measurement lines L1 to L3 is set along the conveyance direction D1. The number of measurement lines, the interval between the measurement lines, and the length of each measurement line are preset by the user. The number and length of the measurement lines may be automatically set by the generating device 11 based on the detection range of the thermal camera 12, the size of the conveyed object, etc.

[0015] FIGS. 5(a) to 5(c) are graphs showing an example of the temperature distribution in the measurement lines. The generating device 11 acquires the temperature distribution in each measurement line (step S5). FIGS. 5(a) to 5(c) respectively show the temperature distributions in the measurement lines L1 to L3. In FIGS. 5(a) to 5(c), the horizontal axis represents the position P on the measurement line, and the vertical axis represents the temperature T. The generating device 11 selects one measurement line from the plurality of measurement lines in which a temperature distribution satisfying a preset condition is obtained (step S6).

[0016] The conditions are set according to the relationship between the temperature of the point to be monitored and the temperature around it. For example, when the temperature of the point to be monitored is higher than its surroundings, as conditions, the appearance of a temperature exceeding the threshold, the appearance of a positive temperature peak, or the appearance of a positive temperature gradient of the threshold or more is set. When the temperature of the point to be monitored is lower than its surroundings, as conditions, the appearance of a temperature below the threshold, the appearance of a negative temperature peak, or the appearance of a negative temperature gradient of the threshold or more is set.

[0017] In this example, the repeated appearance of a positive peak is set as the condition. The generating device 11 selects the measurement line L3 from the measurement lines L1 to L3 in which the positive peak p repeatedly appears in the temperature distribution.

[0018] The conditions may further include a comparison between temperature distributions. For example, when the temperature at the point to be monitored is higher than its surroundings, among the plurality of temperature distributions in which a temperature exceeding the threshold or a positive temperature peak appears, select the temperature distribution with the largest maximum temperature in each temperature distribution. When the temperature at the point to be monitored is lower than its surroundings, among the plurality of temperature distributions in which a temperature below the threshold or a negative temperature peak appears, select the temperature distribution with the smallest minimum temperature in each temperature distribution.

[0019] FIG. 6 is an image illustrating an example of setting the measurement area. As shown in FIG. 6, the generation device 11 sets a plurality of measurement areas A1 to A8 along the selected measurement line (step S7). The plurality of measurement areas A1 to A8 are set apart from each other. Preferably, each measurement area includes a plurality of pixels in each of the transport direction D1 and the orthogonal direction D2. Thereby, it is possible to prevent the point for which it is desired to generate a temperature profile from being outside the measurement area. The number of measurement areas, the size of the measurement areas, and the intervals between the measurement areas may be preset by the user or automatically set by the generation device 11.

[0020] The size of the measurement area may be set based on the moving amount of the conveyed object described above. If the size of the measurement area is smaller than the moving amount, there is a possibility that the point for which it is desired to generate a temperature profile passes through the measurement area during the temperature detection interval by the thermal camera 12. For this reason, it is preferable that the length of the measurement area in the transport direction is set larger than the moving amount of the conveyed object.

[0021] For example, the generation device 11 extracts a portion that satisfies the set conditions regarding the measurement area from the temperature distribution in the selected measurement line. As the set conditions, it is set that the temperature exceeds or falls below a threshold value, is a positive or negative temperature peak, is a positive or negative temperature gradient equal to or greater than the threshold value, and so on. The generation device 11 sets the measurement area in the portion that satisfies the set conditions. In the examples of FIGS. 5(c) and 6, being a positive peak is the set condition, and measurement areas A1 to A8 are respectively set in the portions where the positive peak p appears.

[0022] The generation device 11 stores the positions of the respective measurement areas in the storage device 14. Thereafter, when acquiring the temperature profile for the same type of conveyed object, the data regarding the stored measurement areas is used.

[0023] FIG. 7 is a graph illustrating the temperature distribution in the measurement area. The generation device 11 acquires the temperature in the set measurement area in each image (step S8). The temperature is determined based on the temperatures of each point within the measurement area. The generation device 11 acquires a temperature distribution as shown in FIG. 7. In FIG. 7, the horizontal axis represents the temperature T, and the vertical axis represents the number of times C that each temperature is measured. The number of times C corresponds to the number of points (pixels) at which that temperature is measured. For example, the generation device 11 determines the temperature with the highest number of measurements as the temperature of that measurement area. The generation device 11 may also determine the average value, maximum value, minimum value, or median value of the temperature distribution as the temperature of the measurement area.

[0024] FIGS. 8(a) to 8(c) are graphs showing an example of time-series data of the temperature in the measurement area. The generation device 11 arranges the acquired temperatures in chronological order for each measurement area and generates time-series data of the temperature (step S9). FIGS. 8(a) to 8(c) show the time-series data of the temperature in each of some of the measurement areas A1 to A3 shown in FIG. 6. In FIGS. 8(a) to 8(c), the horizontal axis represents the time t, and the vertical axis represents the temperature T.

[0025] The generation device 11 extracts, as feature parts, parts that satisfy preset conditions in each time-series data (step S10). The generation device 11 assigns identifiers to each feature part (step S11). The identifier is determined according to the order of appearance of the feature parts in one time-series data. For this reason, the same identifier is assigned to feature parts with the same order of appearance among different time-series data.

[0026] As a specific example, in the time-series data, positive peaks are extracted as feature parts. As shown in FIG. 8(a), the generation device 11 extracts a plurality of feature parts F and assigns identifiers ID1 to ID8 to each feature part F respectively. Similarly for the time-series data shown in FIGS. 8(b) and 8(c), the generation device 11 assigns identifiers to each feature part F respectively.

[0027] FIG. 9 is a graph illustrating a temperature profile. The generation device 11 arranges the temperatures of the feature parts to which the same identifier is assigned in chronological order. As the temperature of the feature part, for example, the temperature at the peak apex is used. As shown in FIG. 9, a temperature profile is generated (step S12). In the figure, the horizontal axis represents time t and the vertical axis represents temperature T. The temperature profile shows the change in temperature with respect to time at a specific point of the conveyed object. The generation device 11 outputs the generated temperature profile (step S13). Also, the generation device 11 stores the temperature profile in the storage device 14. 9 In the figure, the horizontal axis represents time t and the vertical axis represents temperature T. The temperature profile shows the change in temperature with respect to time at a specific point of the conveyed object. The generation device 11 outputs the generated temperature profile (step S13). Also, the generation device 11 stores the temperature profile in the storage device 14.

[0028] FIG. 10 is a diagram illustrating the correspondence between the identifier and the thermal image. In the example described above, identifiers ID1 to ID8 are assigned to each time-series data obtained in a plurality of measurement areas A1 to A8 on the measurement line L3. The parts to which the identifiers are assigned correspond to the points where the temperature profile is to be obtained. When the parts to which identifiers ID1 to ID8 are assigned are shown on the thermal image, it is as shown in FIG. 10. In this example, identifiers ID1 to ID8 are assigned to each joint location between the housing 51 and each pipe 52. Thereby, the temperature profile at each joint location is generated.

[0029] Describe the advantages of the embodiment. In production, heat treatment can be performed for melting, joining, thermal activation, etc. of the workpiece. Regarding this heat treatment, the temperature profile during the heat treatment may affect the quality of the workpiece. Conventionally, for quality control, the temperature profile at a specific point has been acquired during the heat treatment. Also, the thermal camera 12 can measure the surface temperature of the workpiece non-contact and with high precision. Therefore, it is suitable for acquiring the temperature profile. For example, by setting a fixed measurement area for the image acquired by the thermal camera 12 and arranging the temperatures in the measurement area in chronological order, the temperature profile can be acquired.

[0030] On the other hand, when the workpiece moves relative to the thermal camera 12, it is difficult to obtain the temperature profile at a specific point of the workpiece. Even in such a case, for quality control, it is desirable to be able to acquire the temperature profile at a specific point.

[0031] Regarding this problem, the generation device 11 according to the embodiment sets a plurality of measurement areas along the conveyance direction of the conveyed object for the image acquired by the thermal camera 12. Then, the generation device 11 generates time-series data indicating the change in temperature with respect to time in each measurement area. The generation device 11 generates a temperature profile in the conveyed object using a part of the temperatures extracted from each time-series data. According to the embodiment, even when the workpiece is conveyed, the temperature profile in the conveyed object can be generated.

[0032] GenerateIn order to reduce the computational amount by the device 11, it is preferable to provide the detector 13, but the detector 13 may be omitted. In that case, step S1 is omitted. Regardless of whether or not the conveyed object is approaching the detection range by the thermal camera 12, the thermal camera 12 repeats image acquisition. Also in this case, time-series data is generated from the temperatures in each measurement area in each image. By extracting the temperatures of the feature parts included in the time-series data, a temperature profile is generated.

[0033] (Modification example) FIG. 11 is a flowchart showing a generation method according to a modification example of the embodiment. The generation device 11 may further determine the quality of the conveyed object using the generated temperature profile. In the generation method M2 shown in FIG. 11, similar to step S2 shown in FIG. 2, the temperature of the conveyed object is detected (step S21). By executing steps S3 to S11, the temperature of the feature part is extracted from the time-series data of the temperature (step S22). By executing steps S12 and S13, a temperature profile is generated (step S23).

[0034] When the temperature profile is generated, the generation device 11 refers to the default profile (step S24). The default profile is a temperature profile regarding the conveyed object prepared in advance by the user and is stored in the storage device 14. For example, the temperature profile at a specific point of the conveyed object obtained when the quality is good is stored as the default profile. The generation device 11 compares the generated temperature profile with the default profile and determines the quality of the conveyed object from which the temperature profile is obtained (step S25). The generation device 11 outputs the temperature profile and the determination result (step S26).

[0035] For example, the generation device 11 calculates the temperature difference in each measurement area between the generated temperature profile and the preset profile. A threshold value is preset for the sum, mean square error, or average of the calculated plurality of temperature differences. The quality of the conveyed object is determined by comparing the sum, mean square error, or average of the plurality of temperature differences with the threshold value.

[0036] The generation device 11 may compare the image data indicating the generated temperature profile with the image data indicating the preset profile. For example, the generation device 11 calculates the distance between the two image data. A threshold value is preset for the distance. Based on the comparison result between the distance and the threshold value, the quality of the conveyed object is determined.

[0037] In each of the above-described methods, a plurality of threshold values may be set. The generation device 11 ranks the quality of the conveyed object according to the comparison results with the plurality of threshold values.

[0038] Alternatively, the generation device 11 may determine the quality of the conveyed object by inputting the generated temperature profile into a previously prepared model or classifier. The model includes, for example, a neural network. Supervised learning or unsupervised learning is performed on the model in advance. As the classifier, for example, a classifier learned by a random forest or a Bayesian classifier is used. The model and the classifier output a determination result of quality in response to the input of the temperature profile. When the model or the classifier is used, the reference to the preset profile by the generation device 11 is omitted.

[0039] FIG. 12 is an example of an output result by the generation device according to the embodiment. For example, the output device 16 is a monitor. As shown in FIG. 12, the generation device 11 causes the user interface (UI) 100 to be displayed. The generated temperature profile 101 and the determination result 102 are displayed on the UI 100. For the convenience of the user, an image 110 generated by the thermal camera 12, temperature distributions 111 to 113 in each measurement line, time-series data 121 to 123 in each measurement area, and a default profile 130 may be further displayed on the UI 100.

[0040] FIG. 13 is a schematic diagram showing a processing system according to an embodiment. As shown in FIG. 13, the processing system 1 according to the embodiment includes a generation system 10 and a processing device 20. The processing device 20 includes a heating unit 21 and a transport unit 22. In this example, the thermal camera 12 and the detector 13 are incorporated in the processing device 20.

[0041] The heating unit 21 heats the workpiece. As long as the workpiece can be heated, the specific configuration of the heating unit 21 is arbitrary. For example, the heating unit 21 includes a burner that heats the workpiece by flame, a lamp or a laser light source that heats the workpiece by light, or an electrode that heats the workpiece by current.

[0042] The transport unit 22 transports the workpiece to be heat-treated. For example, the transport unit 22 sequentially transports a plurality of workpieces at a constant speed in a specific direction. The transport unit 22 includes a belt conveyor, a roller conveyor, or the like. The heating unit 21 heats the workpiece being transported by the transport unit 22.

[0043] The detector 13 detects the approach of a conveyed object (workpiece) to the detection range by the thermal camera 12. The thermal camera 12 detects the temperature of the workpiece being transported by the transport unit 22.

[0044] According to the processing system 1, it is possible to generate a temperature profile of the workpiece that is heated while being transported by the processing device 20.

[0045] FIG. 14 is a schematic diagram showing the hardware configuration. The generation device 11 includes, for example, the configuration of the computer 90 shown in FIG. 14. The computer 90 includes a CPU 91, a ROM 92, a RAM 93, a storage device 94, an input interface 95, an output interface 96, and a communication interface 97.

[0046] The ROM 92 stores a program for controlling the operation of the computer 90. The ROM 92 stores programs necessary for causing the computer 90 to implement each of the above-described processes. The RAM 93 functions as a storage area in which the programs stored in the ROM 92 are expanded.

[0047] The CPU 91 includes a processing circuit. The CPU 91 executes a program stored in at least one of the ROM 92 or the storage device 94 using the RAM 93 as a work memory. During the execution of the program, the CPU 91 controls each component via the system bus 98 and executes various processes.

[0048] The storage device 94 stores data necessary for the execution of the program and data obtained by the execution of the program.

[0049] The input interface (I / F) 95 connects the computer 90 and the input device 95a. The input I / F 95 is, for example, a serial bus interface such as USB. The CPU 91 can read various data from the input device 95a via the input I / F 95.

[0050] The output interface (I / F) 96 connects the computer 90 and the output device 96a. The output I / F 96 is, for example, a video output interface such as Digital Visual Interface (DVI) or High-Definition Multimedia Interface (HDMI (registered trademark)). The CPU 91 can transmit data to the output device 96a via the output I / F 96 and cause the output device 96a to display an image.

[0051] The communication interface (I / F) 97 connects the computer 90 to a server 97a outside the computer 90. The communication I / F 97 is, for example, a network card such as a LAN card. The CPU 91 can read various data from the server 97a via the communication I / F 97.

[0052] The storage device 94 includes one or more selected from a Hard Disk Drive (HDD) and a Solid State Drive (SSD). The input device 95a includes one or more selected from a mouse, a keyboard, a microphone (voice input), and a touch pad. The output device 96a includes one or more selected from a monitor, a projector, a speaker, and a printer. A device having both functions of the input device 95a and the output device 96a, such as a touch panel, may be used. The storage device 94, the input device 95a, and the output device 96a can be used as the storage device 14, the input device 15, and the output device 16, respectively.

[0053] The function of the generation device 11 may be realized by the cooperation of a plurality of computers. The processing of the various data described above may be recorded as a program that can be executed by a computer on a magnetic disk (such as a flexible disk and a hard disk), an optical disk (such as a CD-ROM, a CD-R, a CD-RW, a DVD-ROM, a DVD±R, a DVD±RW), a semiconductor memory, or other non-transitory computer-readable storage medium.

[0054] For example, the information recorded on the recording medium can be read by a computer (or an embedded system). In the recording medium, the recording format (storage format) is arbitrary. For example, the computer reads a program from the recording medium and causes the CPU to execute the instructions described in the program based on this program. In the computer, the acquisition (or reading) of the program may be performed through a network.

[0055] According to the generating apparatus, generating method, or processing system described above, it is possible to generate a temperature profile in a conveyed object. By using a program that causes a computer to execute the generating method, a similar effect can be obtained.

[0056] As described above, some embodiments of the present invention have been illustrated. However, these embodiments are presented by way of example and are not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, replacements, changes, etc. can be made without departing from the gist of the invention. These embodiments and their modifications are included in the scope and gist of the invention, and are included in the invention described in the claims and its equivalent scope. In addition, the above-described embodiments can be implemented in combination with each other.

Description of Reference Numerals

[0057] 10: Generating system, 11: Generating apparatus, 12: Thermal camera, 13: Detector, 14: Storage device, 15: Input device, 16: Output device, 21: Heating unit, 22: Conveying unit, 90: Computer, 50: Workpiece, 51: Housing, 52: Pipe, A1 to A8: Measurement areas, D1: Conveying direction, D2: Orthogonal direction, L1 to L3: Measurement lines, M1, M2: Generating methods

Claims

1. Obtain a plurality of images showing the temperature distribution of the conveyed object, generated by a thermal camera, Set a plurality of measurement areas in each of the images along the conveyance direction of the conveyed object, In each of the measurement areas, generate time-series data indicating the change in temperature over time, A generation device that generates a temperature profile indicating the change in temperature over time in the conveyed object, using a part of the temperatures extracted from each of the time-series data.

2. The generation device according to claim 1, wherein each of the time-series data is compared with a preset condition, and the part that satisfies the condition is extracted from each of the time-series data.

3. The generation device according to claim 1, wherein a positive peak is extracted as the part from each of the time-series data.

4. Set a plurality of measurement lines along the conveyance direction for the image, Select one of the measurement lines based on the temperature distribution in each of the measurement lines, The generation device according to any one of claims 1 to 3, wherein the plurality of measurement areas are set along the one measurement line.

5. The generation device according to any one of claims 1 to 4, wherein the generated temperature profile is compared with a profile prepared in advance to determine the quality of the conveyed object.

6. A generation system comprising the generation device according to any one of claims 1 to 5, The thermal camera, An output device that outputs the temperature profile.

7. A processing device that heats the conveyed object while conveying it, The generation device according to any one of claims 1 to 5. A processing system comprising.

8. Obtain a plurality of images showing the temperature distribution of the conveyed object, generated by a thermal camera, Set a plurality of measurement areas in each of the images along the conveyance direction of the conveyed object, In each of the measurement areas, generate time-series data indicating the change in temperature over time, A generation method that generates a temperature profile indicating the change in temperature over time in the conveyed object, using a part of the temperatures extracted from each of the time-series data.

9. A program for causing a computer to execute the generation method according to claim 8.

10. A storage medium storing the program according to claim 9. ​

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