Sorting device and article inspection system

Abstract

To provide a distribution device and an article inspection system that can increase the reliability of a counter display showing the result of a distribution operation and an article inspection and the reliability of statistic management information of the operation result.SOLUTION: A distribution device includes: a conveyance unit 10; a distribution mechanism unit 30; a display operation unit 21; and a control unit 20b that stops both the mechanism units 10 and 30 when a stop command signal is input. The distribution device further includes: conveyance detection means 15; and a time memory unit 22M that stores a first delay time T3 until a detected article W reaches a distribution position, a second delay time T4 for a distribution operation by the distribution mechanism unit 30, and a cycle time Tcl set to the time when distribution is completed. The control unit 20b controls each unit based on stored information in the time memory unit 22M, when a stop command signal is input, the conveyance operation is stopped on the condition that the cycle time for all articles W that have been detected as having been brought in has elapsed, while the display output of the display operation unit 21 is updated on the condition that the cycle time has elapsed.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a sorting device and an article inspection system, and more particularly to a sorting device that sorts articles during transport and an article inspection system equipped with the same. [Background technology]

[0002] A sorting device that sorts articles conveyed along a predetermined conveying path in multiple directions in response to a sorting / sorting command signal input has been known for some time. Also, an article inspection system has been known in which articles conveyed along a predetermined conveying path are sequentially inspected by an article inspection device for weight, size, and other quality-related inspection items, and an inspected article is selectively removed from the conveying path by a sorting / sorting device disposed downstream of the article inspection device in accordance with the inspection results, or the inspected article is sorted to one of multiple downstream conveying paths corresponding to the inspection results.

[0003] In such a sorting device and item inspection system, the display unit of the item inspection device can display the inspection results of the item being inspected immediately after the inspection by screen display, etc., and can display the inspection results of multiple inspected items during a specified operating time in the form of a total number of good items and defective items, etc.

[0004] Conventional item inspection systems of this type include, for example, an inspection unit having multiple inspection means that inspect items for multiple inspection items and output a pass / fail judgment for each inspection item; a judgment unit that judges the inspection results based on the multiple pass / fail judgments for each item, and matches at least inspection results that indicate defective items with the sorting direction, determines a predetermined sorting direction corresponding to the inspection results based on pre-set sorting direction information, and outputs a sorting signal for sorting the items; and a display unit that displays the accumulated number of times for each sorting direction determined by the judgment unit alongside the sorting direction (see, for example, Patent Document 1).

[0005] Also known is a sorting device that includes, for example, a sorting mechanism that sorts items brought into a sorting conveying section by selecting one of the sorting directions corresponding to the inspection results and transporting them out of the sorting conveying section, and a sorting drive control unit that controls the operation of the sorting mechanism in accordance with a command signal from a higher-level weighing conveyor and stops the operation of the sorting mechanism when a stop command is input requesting that operation be stopped, in which the sorting mechanism is configured to return to a standby position when stopped so that items can be transported in a specific sorting direction out of multiple sorting directions while operation is stopped, and the sorting drive control unit performs sorting direction retention control that, when a stop command is input, retains one of the selected sorting directions for items that have not yet been transported in the sorting conveying section for a predetermined period of time so that the untransported items are transported out of the sorting conveying section (see, for example, Patent Document 2). [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Laid-Open No. 2011-206710 [Patent Document 2] Japanese Patent Application Laid-Open No. 2018-150130 Summary of the Invention [Problem to be solved by the invention]

[0007] However, in conventional sorting devices and item inspection systems such as those described above, if the system operation is suddenly forced to stop for some reason, there is a possibility that the system will be put into a shutdown state in which uninspected / unsorted items, so-called gray work, remain on the conveying route even though they have been detected by a sensor as entering a designated conveying section of the conveying route where sorting and inspection are performed and have become items subject to sorting and inspection, but have not yet been inspected or sorted based on the inspection results.

[0008] As a result, the number of items counted as items to be inspected by the item inspection device did not match the number of items sorted by a sorting device such as a downstream sorting machine, and there were concerns that the reliability of the counter display, which shows the number of items submitted for item inspection, the number of good items passed, the number of defective items generated, etc., would be reduced.

[0009] Furthermore, if immediately after the sorting device or item inspection system is suddenly forced to stop, an item being transported on a front-stage conveyor adjacent to the upstream end of a designated transport section free-runs (which may include the inertial rotation of the transport drive motor or slippage of items on the conveyor) until it stops moving completely, and then enters the item inspection section or the sorting section due to the sorting operation and stops, in addition to the gray work mentioned above, there is a possibility that undetected items that have not yet been detected by the sensor as having entered the designated transport section may remain on the transport path after the system stops, which also raises concerns about a decrease in the reliability of the statistical management information of the item inspection results.

[0010] In other words, in conventional sorting devices and item inspection systems, if they were suddenly forced to stop during operation, there was a possibility that the reliability of the counter display showing the results of item inspection and sorting operations, as well as the reliability of the statistical management information of such results, would be reduced.

[0011] The present invention has been made to solve the above-mentioned conventional problems, and aims to provide a sorting device and an item inspection system that can improve the reliability of counter displays showing the results of sorting operations and item inspections, and the reliability of statistical management information on operation results. [Means for solving the problem]

[0012] In order to achieve the above object, the sorting device of the present invention comprises: (1) a conveying unit that conveys an article so that it passes through a predetermined conveying section on a conveying path in sequence; a sorting mechanism unit that operates in one of a plurality of pre-set sorting directions corresponding to a received sorting command signal, and moves each article being conveyed in the one of the sorting directions at a predetermined sorting position; a display unit that displays and outputs the results of the sorting operation of each article; and a control unit that controls the display output of the display unit and the operation of the sorting mechanism unit based on the sorting command signal, and stops the operation of the sorting mechanism unit and the conveying unit in accordance with the stop command signal when a stop command signal requesting operation to be stopped is input, the sorting device comprising: an in-feed detection means that detects the in-feed of the article into the predetermined conveying section; a first delay time from when the in-feed of the article detected by the in-feed detection means is detected to when the article passes through the predetermined conveying section and reaches the sorting position; and a time memory unit that stores a second delay time required for the sorting mechanism to move an item in one of the sorting directions corresponding to the sorting command signal for the item, and a cycle time that is set to be equal to or longer than the time from the detection of the entry of each item to the completion of sorting when the second delay time has elapsed.The control unit controls the display output of the display unit and the operation of the sorting mechanism and the conveying unit based on the stored information in the time memory unit, and when the stop command signal is input, stops the operation of the conveying unit for all items whose entry has been detected by the entry detection means at the time of input, on the condition that all corresponding cycle times have elapsed since the detection of the entry of each item, while updating the display output of the sorting operation result for the item on the display unit, on the condition that the corresponding cycle time has elapsed since the detection of the entry of each item among all items whose entry has been detected.

[0013] With this configuration, when a stop command signal is input to the control unit of the sorting device of the present invention, the conveying unit continues to operate for all items that have been detected by the inbound detection means at the time of input until the corresponding cycle time has elapsed since the detection of each item. During this time, the display output of the sorting operation results is updated sequentially, provided that the corresponding cycle time has elapsed since the detection of each item that was detected at the time of input of the stop command signal. Therefore, even if operation is suddenly stopped for some reason, items that have already been detected entering the item inspection section on the conveying route and are subject to sorting, but have not yet been sorted—so-called gray work—will not remain on the conveying route. This improves the reliability of the counter display of the sorting operation results and the statistical management information of the sorting operation results.

[0014] In a preferred embodiment of the present invention, (2) the control unit can be configured to, when the stop command signal is input, stop the preceding conveyor adjacent to the upstream side of the predetermined conveying section, on the condition that the carry-in detection means has detected the completion of carry-in of the last detected item into the predetermined conveying section, for which the start of carry-in into the predetermined conveying section has been detected by the carry-in detection means at the time of input of the stop command signal. In this case, the last detected item, for which the start of carry-in into the predetermined conveying section has already been detected (leading edge detection) at the time the stop command signal is input to the control unit, can be reliably treated as an item to be processed for item inspection, and the number of items input into the predetermined conveying section to be subjected to item inspection can be clarified.

[0015] In a preferred embodiment of the present invention, (3) the control unit may be configured to inspect an item whose entry is detected by the entry detection means from the time the entry is detected until the item passes through the predetermined conveying section, obtain a sorting command signal corresponding to the inspection result, store result information of the sorting operation corresponding to the sorting command signal for the item in the time memory unit, and when the corresponding cycle time has elapsed since the entry of the item, read out the result information of the sorting operation corresponding to the sorting command signal for the item from the time memory unit, and update the display output of the sorting operation result for the item on the display unit. In this case, when the corresponding cycle time has elapsed since the entry of each item into the predetermined conveying section, the result information of the sorting operation corresponding to the sorting command signal for the item is read out from the time memory unit, and the display output of the sorting operation result on the display unit is reliably updated in a timely manner.

[0016] In a preferred embodiment of the present invention, (4) an operation confirmation sensor is provided for detecting completion of movement of each item in a specific sorting direction among the plurality of sorting directions corresponding to the sorting command signal, and the control unit determines that the cycle time corresponding to the item has elapsed on condition that the operation confirmation sensor detects that the movement of the item in the specific sorting direction corresponding to the sorting command signal has been completed from the time of detection of the introduction of the item detected by the introduction detection means in the specific sorting direction corresponding to the sorting command signal. In this way, the operation confirmation sensor can reliably detect in a timely manner the completion of the sorting operation corresponding to the sorting command signal for each item that had already been sorted at the time the stop command signal was input to the control unit.

[0017] In a preferred embodiment of the present invention, (5) when the stop command signal is input, if a subsequent item enters the predetermined conveying section from the upstream side before the corresponding cycle times have elapsed for all items whose entry has been detected by the entry detection means at the time of input, the control unit can output a notification that the subsequent item that was undetected at the time the stop command signal was input is an unprocessed item that requires manual removal from the conveying path. In this case, it is possible to accurately notify a manager or worker that the subsequent item that was undetected at the time the stop command signal was input to the control unit is an unprocessed item that requires manual removal from the conveying path, thereby enabling accurate processing of the unprocessed item.

[0018] In order to achieve the above-mentioned object, the item inspection system of the present invention is characterized by comprising a sorting device having any of the configurations (1) to (5) above, and an item inspection unit that inspects items within the specified conveying section and outputs a sorting command signal corresponding to the inspection results of the items.

[0019] With this configuration, in the object inspection system of the present invention, when a stop command signal is input to the control unit, the conveying unit continues to operate for all items that have been detected by the detection means at the time of input until the corresponding cycle time has elapsed since the detection of each item. During this time, the display output of the item inspection results and the corresponding sorting operation results are updated sequentially, provided that the corresponding cycle time has elapsed since the detection of each item that was detected at the time of input of the stop command signal. Therefore, even if the system operation is suddenly stopped for some reason, uninspected / unsorted items that have already been detected entering the item inspection section of the conveying route and are designated as items for inspection but have not yet been inspected or sorted according to the inspection results (so-called gray work) will not remain on the conveying route. This results in an object inspection system that can improve the reliability of the counter display of item inspection results and the statistical management information of item inspection results.

[0020] In a preferred embodiment of the present invention, the sorting completion time can be set when a second delay time required for an item whose introduction is detected by the introduction detection means to move in one of the sorting directions corresponding to the sorting command signal or the inspection result signal for the item has elapsed, or when the longest delay time among the second delay times for each of the multiple sorting directions has elapsed from the time of introduction of the item whose introduction is detected by the introduction detection means. In this case, if the sorting completion time is set to the time when the longest delay time among the second delay times for each of the multiple sorting directions has elapsed, the sorting operation time can be made uniform regardless of the sorting direction, and control at the time of stopping can be facilitated. On the other hand, if the sorting completion time is set to the time when the second delay time corresponding to a specific sorting operation direction has elapsed, the sorting completion time can be set relatively early. [Effects of the Invention]

[0021] According to the present invention, it is possible to provide a sorting device and an article inspection system that can improve the reliability of the counter display of the sorting operation results and the reliability of the statistical management information of the sorting operation results. [Brief explanation of the drawings]

[0022] [Figure 1] 1 is a schematic configuration diagram of an article inspection system including a sorting device according to an embodiment of the present invention. [Figure 2] 10A and 10B are explanatory diagrams of the pushing operation of a pusher-type sorting mechanism in an article inspection system according to an embodiment of the present invention. [Figure 3] 1 is an explanatory diagram showing a display section of an article inspection system according to an embodiment of the present invention, which displays a foreign matter contamination image, a measurement value, a judgment result, a counter display, and an alarm status display when stopped. [Figure 4] 10 is a timing chart showing the operational procedure for stopping a cycle in processing mode 1 of an article inspection system according to an embodiment of the present invention. [Figure 5]This is a timing chart when processing mode 2, which updates the counter immediately after determining the inspection result as in the conventional case, is selected in a case where the operating procedure of an article inspection system according to one embodiment of the present invention can be switched to an immediate stop mode different from the cyclic stop operating procedure of processing mode 1 shown in Figure 4. [Figure 6] This is a timing chart when processing mode 3 is selected, which employs normal cycle processing by a timer but interrupts the cycle stop processing of counter update immediately after a stop command, when the operating procedure of an item inspection system according to one embodiment of the present invention can be switched to an immediate stop mode different from the cycle stop operating procedure of processing mode 1 shown in Figure 4. [Figure 7] 10 is a timing chart showing the procedure of timer delay processing (delay update) for updating a counter on a display unit in an article inspection system according to an embodiment of the present invention. [Figure 8] This is a timing chart when processing mode 2 is selected in which the counter is updated (immediately updated) immediately after the inspection result is determined, as in the conventional case, when the counter update procedure on the display unit in an item inspection system according to one embodiment of the present invention can be switched to an immediate stop mode different from the procedure shown in Figure 6. [Figure 9] 10 is a timing chart showing the procedure for timer delay processing for updating a counter on a display unit when the operation of the sorting mechanism unit in an item inspection system according to one embodiment of the present invention is confirmed by operation position confirmation sensors on the extension and contraction sides of the cylinder. [Figure 10] This is a timing chart showing the procedure for timer delay processing for updating the counter on the display unit when the operation of the sorting mechanism unit in an item inspection system according to one embodiment of the present invention is confirmed by the discharged item detection sensor on the sorting and discharge outlet side. [Figure 11] 10 is a flowchart showing the procedure of a counter update process in an article inspection system according to an embodiment of the present invention. [Figure 12] 12 is a flowchart showing the processing procedure following a connector A during the counter update processing shown in FIG. [Figure 13]10 is a flowchart showing the procedure of a cycle stop process in an article inspection system according to an embodiment of the present invention. [Figure 14] FIG. 10 is a schematic diagram of a dispensing device according to another embodiment of the present invention. [Figure 15] 10A is a perspective view of a carrier sorting type sorting mechanism in a sorting device according to another embodiment of the present invention, and FIG. 10B is an explanatory diagram of an example of a display screen of a control unit of the sorting device. DETAILED DESCRIPTION OF THE INVENTION

[0023] Hereinafter, embodiments of the present invention will be described with reference to the drawings.

[0024] (One embodiment) 1 to 13 show an article inspection system equipped with a sorting device according to one embodiment of the present invention.

[0025] First, the configuration will be described.

[0026] 1 to 3, an article inspection system 1 according to one embodiment of the present invention includes a conveyor-type transport unit 10 that forms a transport path Lp, an inspection unit 20 that inspects articles sequentially transported by the transport unit 10 along the transport path Lp as works W (objects to be inspected) using a predetermined inspection method, a sorting mechanism unit 30 that uses a predetermined sorting method, for example, a pusher-type sorter, and a plurality of reject item receiving tray conveyors 45A, 45B, 45C that are arranged downstream in specific sorting directions D1, D2, and D3 by the sorting mechanism unit 30. Note that, although a pusher-type sorter is shown as an example of the sorting mechanism unit 30 here, it may also be configured with other types of sorting mechanisms, such as a flipper-type, drop or up-out type, or carrier type.

[0027] The transport unit 10 has an inspection conveyor 12 with a length Lx and a sorting conveyor 13 with a length Lri that transport workpieces W as inspected articles (products to be inspected) fed from a conveyor 11 of a previous stage device (hereinafter also referred to as the previous stage conveyor 11) in a predetermined transport direction D0 shown in Fig. 1. In this embodiment, the transport unit 10 is configured to include the previous stage conveyor 11 upstream of the inspection conveyor 12 and a subsequent stage conveyor 14 located downstream of the sorting conveyor 13. The subsequent stage conveyor 14 is disposed immediately after the sorting conveyor 13 in the normal sorting direction D0 by the sorting mechanism unit 30.

[0028] The front conveyor 11, inspection conveyor 12, sorting conveyor 13, and rear conveyor 14 of the conveying unit 10 (hereinafter also referred to as conveyors 11-14 of the conveying unit 10) are assumed to have approximately the same conveying speed here, but different conveying speed settings or acceleration / deceleration may be used. Furthermore, although the details of the conveyors 11-14 of the conveying unit 10 are not shown, they are belt conveyors that, for example, have a loop-shaped conveying belt stretched over multiple conveying rollers, and sequentially convey the workpieces W to the right in FIG. 1 by the upper running section of the conveying belt above these conveying rollers, and are supported by a housing not shown.

[0029] The inspection unit 20 is an item inspection device that inspects the quality condition of the work W in the inspection zone Z1 on the inspection conveyor 12 immediately following the preceding conveyor 11 using a predetermined inspection method and inspection conditions corresponding to the type of work. In other words, the inspection unit 20 constitutes an inspection device that performs a predetermined method of item inspection on the work W being transported together with the inspection conveyor 12. Note that the predetermined method of item inspection is an inspection of whether the work W meets the quality or physical quantity required for a product, such as the presence or absence of contaminants, the presence or absence of missing parts, the pass / fail of the shape, size, storage condition, etc. of the contents, the density, thickness, volume or mass distribution, etc.

[0030] Between the upstream conveyor 11 and the inspection conveyor 12, a workpiece detection sensor 15 is provided to detect the transport of a workpiece W into the inspection section Z1. This workpiece detection sensor 15 is, for example, an optical type having an optical axis that is approximately perpendicular to the transport direction D0 of the transport section 10, and is switched on / off by being blocked or reflected by the workpiece W, and is capable of detecting the timing when the leading and trailing ends of each workpiece W pass through predetermined positions in the transport direction. Note that another object detection sensor may be additionally installed between the inspection conveyor 12 and the sorting conveyor 13, or the workpiece detection sensor 15 may be used as a means for detecting objects from camera images or X-ray images.

[0031] The inspection section 20 is composed of an inspection mechanism section 20a for a predetermined inspection method, and a control section 20b including a display operation section 21, an inspection processing section 22 (inspection control section), a statistical processing section 23, an external input / output control section 24, a sorting control section 25, a transport control section 27, and a memory 22M (a memory device including an internal memory Mcl). In this embodiment, a sorting control unit 26 is provided on the sorting mechanism section 30 side to control the fluid pressure control circuit 35 in response to a control signal from the sorting control section 25. However, it is also possible to configure the sorting control unit 26 integrally with the sorting control section 25.

[0032] The display operation unit 21 is configured to include a touch panel with operation input and display output functions, and is capable of setting the type of work W to be inspected, as well as performing various settings and instruction operations related to item inspection conditions.

[0033] This display operation unit 21 displays and outputs a display screen 60 as shown in Figure 3, and allows the user to perform necessary operation input by touching specific display areas such as various buttons and tab display areas on this display screen 60.

[0034] The display screen 60 has, for example, a main display screen area 61 that displays inspection images of each work W, a selection operation bar area 62 below the main display screen area 61 and which has a menu button 62a, a display mode switching button 62b, multiple display operation tabs 62c, 62d, 62e, a function operation tab 62f, a stop button 62g, a start button 62h, etc. arranged therein, an operation status display operation bar area 63 above the main display screen area 61 and which has a display operation button 63a for displaying the operation status of the inspection processing unit 22 and an equipment status display 63b for displaying operation-related information, etc., an inspection information display area 64 at the top right of the main display screen area 61 that displays information related to the inspection target and other inspection conditions, and a statistical information display area 65 below the inspection information display area 64 on the right side of the main display screen area 61 that displays the inspection results of all work W for which the specified item inspection for the inspection target variety has been completed and the corresponding sorting operation results in the form of a list or an image such as a histogram based on the inspection items, pass / fail judgment results, operation confirmation results, etc.

[0035] More specifically, on the display screen 60, for example, a menu screen can be opened by touching the menu button 62a, or an operation confirmation screen, a production management screen, or a setting / adjustment screen can be opened by touching one of the multiple display operation tabs 62c, 62d, and 62e, and a function selection screen can be opened by operating the function operation tab 62f. Furthermore, for example, with the setting / adjustment screen open, it is possible to set and display various timers that are product type settings and setting parameters for each product type, such as the sorting operation delay time T3, sorting operation time T4, cycle transport time Tcl, sorting operation confirmation time T6, sorting confirmation delay time T7, and sorted workpiece passage confirmation time T9.

[0036] The statistical information display area 65 of the display screen 60 is divided into a total number counter display section 65a, a defective product counter display section 65b for each defective type, and a counter display section 65c for other defective items, as shown in FIG. In this case, the total number counter display section 65a displays, for example, a counter display of the total number of inspected workpieces W (in the figure, "Total number_123"), a counter display of products judged OK (in the figure, "OK_100"), and a counter display of products judged NG (in the figure, "NG_23"), and the NG product counter display section 65b for each defect type displays an NG product counter display for each defect type, for example, in the form of "Foreign matter NG_20", "Lightweight NG_2", "Overweight NG_1", and the counter display section 65c for other defect items displays, for example, a defect counter display for operation confirmation of the cylinder extension / retraction operation (in the figure, "Operation confirmation defective_0") and a counter display for sorting confirmation defects due to confirmation of the passage of sorted products (in the figure, "Sorting confirmation defective_2").

[0037] The inspection mechanism 20a includes, for example, an X-ray generator that generates X-rays that can penetrate the workpieces W and irradiates them in a fan beam pattern that is substantially perpendicular to the conveying direction of the conveying unit 10 toward the workpieces W on the inspection conveyor 12, and an X-ray detector, such as an X-ray line sensor camera, located directly below the upper running section of the inspection conveyor 12. The X-ray detector detects the X-rays emitted by the X-ray generator and transmitted through the workpieces W for each predetermined transmission area corresponding to the aforementioned detection elements, converts the X-rays into an electrical signal corresponding to the amount of transmitted X-rays, and outputs an X-ray detection signal for each transmission area. The inspection mechanism 20a may, of course, be another type of article inspection device. For example, when used as a weight measuring device, a portion of the inspection conveyor 12 is used as a weighing platform, and the gravity and load on the weighing platform are measured using an electromagnetic balance scale or a load cell scale.

[0038] The inspection processing unit 22 controls the inspection in the inspection unit 20, for example, by controlling the output of the X-ray generator of the inspection mechanism unit 20a based on the item detection information from the work detection sensor 15, and by controlling the X-ray line detection cycle and inspection period of the X-ray detector according to the conveying speed of the work W, while storing the X-ray detection signals for each transmission area from the X-ray detector of the inspection mechanism unit 20a in the image memory area of ​​the internal memory Mcl of the memory 22M to generate inspection image data, and performing image processing and inspection judgment processing using a predetermined inspection program based on that inspection image data, and storing the judgment result as the inspection result (sorting operation result) in the inspection result memory area of ​​the internal memory Mcl in association with the item detection time of the work W.

[0039] By executing an inspection control program stored in memory 22M, the inspection processing unit 22 can generate an inspection judgment signal, such as an OK signal or an NG signal, depending on, for example, whether the weight measurement value or mass of the work W is excessive or light outside the allowable range, or whether foreign matter is mixed in the work W, and store the signal in internal memory Mcl, or output the inspection judgment signal to the display operation unit 21, the statistical processing unit 23, and the sorting control unit 25.

[0040] The statistical processing unit 23 executes a predetermined display control program stored in the internal memory Mc1 to display inspection result information based on the inspection result information of each inspected work W, such as the inspection quantity and the number of NG occurrences for each inspection item, as a counter. For example, the statistical information display area 65 of the display screen 60 shown in FIG. 3 displays the inspection results for all inspected works W of a set variety as a list or an image such as a histogram based on the inspection items and pass / fail judgment results.

[0041] The external input / output control unit 24 cooperates with the inspection processing unit 22 and the transport control unit 27 to output drive commands for the front-stage conveyor 11 and the rear-stage conveyor 14 individually. The external input / output control unit 24 also cooperates with the inspection processing unit 22 and the sorting control unit 25 to output counter update data to an external management PC and to import request information and setting information (for example, the length Lx of the inspection conveyor 12, the length Lrj of the sorting conveyor 13, specific timer setting information, etc.) from the management PC. The sorting control unit 25 and the transport control unit 27 will be explained after explaining the configuration of the sorting mechanism unit 30.

[0042] The control unit 20b of the inspection unit 20 executes predetermined stop control, which will be described later, when it detects a stop command signal input such as an operation input of the stop button 62g to the display operation unit 21 or an external stop input, or when it receives a stop command signal from an external management PC via the external input / output control unit 24. In response to an emergency stop command such as an emergency stop button (not shown), it executes immediate stop control.

[0043] When a workpiece W, such as a defective product, is found that requires sorting and discharging in a specific sorting direction according to the inspection results of the inspection unit 20, the sorting mechanism unit 30 pushes the workpiece W from one of multiple, for example, three, conveying positions (starting positions of the arrows indicating sorting directions D1, D2, D3) within the sorting section Z2 formed on the sorting conveying conveyor 13 that corresponds to the inspection result, in the sorting direction D1, D2 or D3 (one side in the conveying path width direction, the lower side in Figure 1) toward the outside of the conveyor 12, thereby allowing the defective workpiece to be transferred to the corresponding discharged product receiving table conveyor 45A, 45B or 45C.

[0044] This sorting mechanism unit 30 constitutes a sorting device that sorts the work W being transported together with the sorting conveyor 13 of the transport unit 10 into one of multiple sorting directions D0, D1, D2, and D3 depending on the inspection results at the inspection unit 20.For example, when the inspection result at the inspection unit 20 is a pass / fail judgment (OK judgment), it selects the sorting direction D0 corresponding to the inspection result (OK in Figure 1), and when the inspection result at the inspection unit 20 is a fail / fail judgment (NG judgment), it selects one of the sorting directions D1, D2, or D3 corresponding to the inspection result (NG1, 2, or 3 in Figure 1), and executes the discharge operation in the selected specific sorting direction when the corresponding sorting operation command signal RJ1, RJ2, or RJ3 is output.

[0045] The sorting mechanism 30 also has a plurality of push-out members 31A, 31B, 31C that move independently to push out the workpieces W in the sorting section Z2 (predetermined conveying section) in the sorting direction D1, D2 or D3 (one side in the conveying path width direction, the downward side in Figure 1) at a specific conveying position depending on the inspection results, and a plurality of drive mechanisms 32A, 32B, 32C that selectively drive the push-out members 31A, 31B, 31C independently back and forth between positions P1 and P2 (see Figure 2) on both sides of the sorting conveyor 13.

[0046] The push-out member 31 is formed of a plate-like body, such as a stainless steel plate or other metal plate, having a flat or curved plate surface that extends in the conveying direction of the workpieces W and in the height direction on the conveyor 13. The push-out member 31 may be a friction plate whose coefficient of friction with respect to the workpieces W is equal to or greater than the coefficient of friction with respect to the conveying surface of the sorting conveyor 13.

[0047] The multiple drive mechanisms 32A, 32B, 32C are configured as actuators, for example, air cylinders which are fluid-operated cylinders, that selectively operate according to the inspection results of the workpiece W, and perform a push-out operation to move one of the push-out members 31A, 31B or 31C corresponding to the inspection results in the sorting direction D1, D2 or D3 to enter the sorting section Z2 on the sorting conveyor 13, and further perform a retraction operation to move it in the opposite direction to the sorting direction D1, D2 or D3 to retreat it from above the sorting conveyor 13.

[0048] The air cylinder constituting each of drive mechanisms 32A, 32B, and 32C is, for example, a double-acting type, and includes a piston 42 slidably housed in cylinder 41. This piston 42 divides the interior of cylinder 41 into a pair of pressure chambers, for example, a pair of pressure chambers 44A and 47A, a pair of pressure chambers 44B and 47B, or a pair of pressure chambers 44C and 47C (hereinafter referred to as a pair of pressure chambers 44A, 47A, etc.). Supply and discharge ports 45a and 48a are formed on the cylinder extension side and cylinder contraction side, respectively, so as to communicate with the cylinder 41 that forms the pair of pressure chambers 44A, 47A, etc. Furthermore, a piston rod 43 (rod) is fixed integrally to piston 42, and a corresponding pusher member 31A, 31B, or 31C is attached to a tip end 43a of piston rod 43 that protrudes outward from each cylinder 41. Each cylinder 41 is also equipped with a standby position sensor 54 (representing standby position sensors 54a, 54b, and 54c of drive mechanisms 32A, 32B, and 32C, respectively) that detects when the rear end face of piston 42 retreats to a predetermined retraction standby position and outputs an ON signal, and a sorting position sensor 55 (representing sorting position sensors 55a, 55b, and 55c of drive mechanisms 32A, 32B, and 32C, respectively) that detects when the front end face of piston 42 reaches a predetermined extrusion position and outputs an ON signal.

[0049] The sorting mechanism unit 30 further has a fluid pressure control circuit 35 that selectively extends or contracts one of the multiple drive mechanisms 32A, 32B, 32C in response to an OK signal or an NG signal, which is an inspection result signal (sorting command signal) from the inspection unit 20 for the workpiece W to be inspected, a sorting operation signal RJ (sorting command signal) that commands the execution of a sorting operation corresponding to the NG signal, and an ON signal from either one of the standby position sensor 54 and the sorting position sensor 55 of each drive mechanism 32A, 32B, or 32C or an OFF signal from either the other.

[0050] Here, the NG signal from the inspection unit 20 selectively includes three types of NG signals, for example, NG1 indicating the presence of foreign matter, NG2 indicating a light weight measurement value that does not reach the allowable weight value range, and NG3 indicating an excessive weight measurement value that exceeds the allowable weight value range, and the sorting operation signal RJ is set to, for example, one of the RJ1, RJ2, or RJ3 signals corresponding to the NG1, NG2, or NG3 signals.

[0051] The fluid pressure control circuit 35 has control valve units 33A, 33B, and 33C that control the multiple drive mechanisms 32A, 32B, and 32C, respectively, and a filter regulator 34 that can adjust the air (compressed air) from an external air source 50, including an air compressor, to a set pressure and supply it to the supply pressure ports of the control valve units 33A, 33B, and 33C, and although not shown in detail, the control valve units 33A, 33B, and 33C are each configured to include a directional control valve and an air supply / discharge control valve for the extension / retraction operation of the drive mechanisms 32A, 32B, and 32C, respectively.

[0052] The sorting mechanism 30 switches the transport path downstream from the sorting section Z2 among the transport paths of each work W after inspection by selectively pushing out the push-out members 31A, 31B or 31C, so that the inspected work W can be sorted in one of multiple sorting directions D0, D1, D2 and D3 according to the inspection results.

[0053] On the other hand, the sorting control unit 25 of the inspection unit 20 selectively, for example, alternatively extends or retracts the corresponding drive mechanism 32A, 32B or 32C at a specific sorting operation position of the sorting mechanism unit 30 corresponding to the time of item detection and the judgment result information (NG1, NG2, NG3, which differ depending on the type of defect) of each work W, based on the judgment result information (OK / NG) of each inspected work W stored in the internal memory Mc1, timing information specifying the time of item detection of the work W, and the output signals of the standby position sensor 54 and the sorting position sensor 55 of each drive mechanism 32A, 32B or 32C. Note that if there are multiple defects, the NG judgment result with the highest preset priority from NG1, NG2, or NG3 will be used.

[0054] In addition, when the judgment result information of the work W, OK / NG, matches the output signal of the waiting position sensor 54 and the sorting position sensor 55 of the drive mechanism 32A, 32B or 32C corresponding to the inspection result, the sorting control unit 25 reads the judgment result from the internal memory Mcl at the end of the cycle transport time Tcl required for the work W to pass through the inspection section Z1 and reach a specific sorting operation position of the sorting mechanism unit 30 corresponding to the item detection of each work W and the judgment result information (the starting position of one of the arrows D0, D1, D2 or D3 in Figure 1), and outputs the judgment result to the sorting control unit 25, and can output, for example, one of the sorting operation command signals RJ1, RJ2 or RJ3 corresponding to one of NG1, NG2 or NG3 to the sorting control unit 26 on the sorting mechanism unit 30 side.

[0055] Furthermore, the sorting control unit 25, in cooperation with the inspection processing unit 22, is capable of reading out from the internal memory Mc1 stored information on the judgment results that can be used for counter updating for the display operation unit 21 at the end of the cycle transport time Tcl, and outputting it to the display operation unit 21 as counter update data.

[0056] The sorting control unit 25 also has the function of controlling the output timing of OK / NG signals and sorting operation commands RJ to the sorting control unit 26 according to the timer values ​​of the sorting operation delay time T3 and the sorting operation time T4, and of feeding back to the inspection processing unit 22 via the sorting control unit 26 the detection position information of the standby position sensor 54 and the sorting position sensor 55, which are cylinder operation position confirmation sensors of each drive mechanism 32A, 32B, 32C, and the passage detection information of the sorted product passage confirmation sensors 16, 46A, 46B, 46C.

[0057] In addition, the inspection processing unit 22, the sorting control unit 25 and the conveying control unit 27 cooperate with the conveying control unit 28 on the sorting mechanism unit 30 side to control at least the inspection conveyor 12 and the sorting conveyor 13 based on the item detection signal (tip detection signal of the work W) from the work detection sensor 15, the inspection result information of each inspected work W stored in the internal memory Mcl, and the angle detection information of the rotary encoders 17a and 18a attached to the conveying drive motor 17 for the inspection conveyor 12 and the conveying drive motor 18 for the sorting conveyor 13.

[0058] The sorting control unit 26 is capable of confirming the cylinder operation based on the detection position information of the standby position sensor 54 and the sorting position sensor 55 of each drive mechanism 32A, 32B, 32C, and confirming whether the sorting operation result is OK / NG based on the passage detection information of the sorted product passage confirmation sensors 16, 46A, 46B, 46C, at respective timings according to timer values ​​such as the sorting operation confirmation time T6, the sorting confirmation delay time T7, and the sorting work passage confirmation time T9, and outputting the confirmation results to the sorting control unit 25 as feedback information to be stored in the internal memory Mcl.

[0059] The control valve units 33A, 33B, 33C of the distribution mechanism 30 can control the direction and flow rate of air supply and exhaust to the air cylinders constituting the corresponding drive mechanisms 32A, 32B, 32C, and when a sorting command is input from the sorting control unit 26, compressed air can be supplied to any one pressure chamber of a pair of pressure chambers 44A, 47A, etc. through one supply / exhaust port 45a or 48a of the corresponding drive mechanism 32A, 32B, or 32C (hereinafter also simply referred to as drive mechanism 32) and exhausted from the other pressure chamber (for example, in the case of drive mechanism 32A, compressed air from the air source 50 side is supplied to the expansion-side pressure chamber 44A or the contraction-side pressure chamber 47A through one supply / exhaust port 45a or 48a, while compressed air is exhausted from the other pressure chamber through the other supply / exhaust port 48a or 45a). However, the pressure chamber 47C on the contraction side or the pressure chamber 44A on the extension side can be exhausted. When compressed air is supplied to any one of the pair of supply / discharge ports 45a, 48a, for example, the supply / discharge port 45a, and air is exhausted from the other supply / discharge port 48a, the piston rod 43 is moved to one side in the forward / backward movement direction so that the push-out member 31 enters the sorting section Z2 on the sorting conveyor 13 and pushes the workpiece W to be removed outward from the conveyor 12. Conversely, when compressed air is supplied to one supply / discharge port 48a of the drive mechanism 32 and air is exhausted from the other supply / discharge port 45a, the piston rod 43 is moved to the other side in the forward / backward movement direction (upward in FIG. 1) so that the push-out member 31 retreats to the outside of the sorting section Z2 on the conveyor 12.

[0060] Furthermore, by controlling the supply and discharge of air to and the direction of air discharge from each drive mechanism 32 using each control valve unit 33A, 33B, 33C, the drive mechanism 32 can perform a push-out operation to move the push-out member 31 in the push-out direction from the push-out start position P1 shown by the solid line in FIG. 3 to the push-out end position P2 shown by the virtual line in the same figure, and a retraction operation to return the push-out member 31 from the push-out end position P2 to the push-out start position P1, in accordance with the extension and contraction operation of the cylinder of the drive mechanism 32, which is approximately the width of the conveying path of the conveyor 12.

[0061] In addition, the discharged product receiving platform conveyors 45A, 45B, and 45C are positioned downstream of the sorting conveyor 13 and the sorting mechanism unit 30 in the sorting directions D1, D2, and D3, and are capable of receiving and removing the work W that has been sorted and discharged in the sorting directions D1, D2, or D3 by the sorting mechanism unit 30.

[0062] The control unit 20b of the inspection unit 20, the specific hardware configuration of which is not shown, is configured to include, together with the sorting control unit 26, for example, a CPU, ROM, RAM, input / output interface circuit, drive circuit, etc., and functions as a controller that executes predetermined transport control programs, inspection control programs, sorting control programs, etc. stored in the ROM or other memory devices.

[0063] The control unit 20b of the inspection unit 20 can perform a transport control function of controlling the transport speed Vrj (see FIG. 2) of the workpiece W by the conveyor 12 of the transport unit 10 and a sorting delay time corresponding to the workpiece transport interval, and an inspection control function of controlling the inspection in the inspection mechanism unit 20a of the inspection unit 20 by controlling the output of the above-mentioned X-ray generator and the X-ray line detection cycle and inspection period of the X-ray detector according to the transport speed of the workpiece W, while outputting object detection information from the workpiece detection sensor 15 and an inspection result signal in the inspection unit 20 to the sorting control unit 26. Furthermore, this control unit 20b can generate an inspection determination signal according to the inspection result (OK / NG) in the inspection unit 20, for example, when it determines whether or not the workpiece W being inspected contains foreign matter, and can generate a sorting operation signal RJ within a predetermined time from the time of the determination and output it to the sorting control unit 26.

[0064] Furthermore, the control section 20b of the inspection section 20, together with the sorting control unit 26, has a sorting control function for controlling the operation of the sorting mechanism section 30 based on the sorting operation signal RJ and the inspection judgment (OK / NG) from the sorting control section 25, and the item detection information from the work detection sensor 15. Note that, in the case where there are multiple defects, the judgment result here corresponds to the NG judgment signal with the highest preset priority out of NG1, NG2, and NG3.

[0065] In this case, the sorting control unit 26, which receives the sorting operation signal RJ and the NG judgment signal from the control unit 20b of the inspection unit 20, sets the sorting operation delay time T3, for example, from the time when the NG judgment signal rises to the time when the work W reaches the sorting and removal position within the sorting area Z2, for example, as shown in Figure 2, until the time when half of the conveying direction length L of the work W enters the front area of ​​the corresponding extrusion member 31 (in standby position P1) of the drive mechanism 32 and operation can begin, and is configured not to cause the sorting mechanism unit 30 to perform the sorting and discharge operation on the work W to be discharged during the sorting operation delay time T3.

[0066] In addition, the sorting control unit 26 is capable of outputting a sorting operation signal RJ, which serves as a sorting operation command in the removal direction to the directional control valve of the corresponding control valve unit 33A, 33B or 33C, for a sorting operation time T4 [ms], which is the normal discharge operation setting time, so that in the case of normal sorting operation, the work W to be sorted is sorted and discharged by a push-out operation of a stroke close to the conveying path width of the conveyor 12 at a push-out operation speed according to the type of work W, based on the time when the operation can be started when the sorting operation delay time T3 has elapsed.

[0067] Furthermore, in the case of normal sorting operation, when sorting operation time T4 has elapsed from the time when operation can be started (for example, the end times of times T4(1), T4(2), and T4(3) in FIG. 4), the sorting control unit 26 stops outputting the sorting operation signal RJ to the corresponding push-out position P2, while starting output of a standby operation signal at the retracted position P1, so that the push-out member 31 can be retracted and held outside the sorting zone Z2 on the conveyor 12 at a predetermined retraction operation speed. Note that the air cylinder of each drive mechanism 32 may be constantly spring-biased toward the retracted standby position, and the push-out operation may be performed by air supplied when the sorting operation signal RJ is output. In this case, the sorting control unit 26 may output the sorting operation signal RJ only during the sorting operation time T4.

[0068] The sorting control unit 26 extends and retracts a specific drive mechanism 32 corresponding to the item detection timing and defect type of at least the work W whose inspection result has been judged NG in accordance with the sorting operation signal RJ, thereby moving the extrusion member 31 from the extrusion start position P1 shown by the solid line in Figure 2 to the extrusion end position P2 shown by the virtual line in the same figure, and then completing the reciprocating movement back to the extrusion start position P1 again within a specified operating time that is less than the transport time for the transport interval of the work W.

[0069] Here, the normal sorting operation time T4 is set to a time greater (longer) than the shortest operation time Ta [ms] when extending the heaviest allowable workpiece W from the extrusion start position P1 in a contracted state at the standby position of the cylinder-configured drive mechanism 32 to the extrusion completion position P2, and is set according to the discharge flow rate throttling state of the speed control valves in the control valve units 33A, 33B, and 33C so that the workpiece W will have a stable discharge posture and discharge completion position under a pre-test run by the user.

[0070] 2, pushing must begin once the center G, which is close to the center of gravity of the workpiece W to be discharged, has reached the area of ​​the conveying direction length Lg of the pusher member 31, and pushing must be completed before the center of the workpiece W passes through the conveying direction length area of ​​the pusher member 31. Therefore, the workpiece movement distance Lz during the pushing operation must be kept below the pusher plate length Lg (Lg≧Lz).

[0071] This workpiece movement distance Lz can be calculated as conveyor speed Vrj × extrusion operation setting time Tex × extrusion deceleration rate β, where the extrusion deceleration rate β can be large in the case of an extrusion member 31 made of a stainless steel plate or a resin plate, and can be small in the case of a high-grip type extrusion member 31 made of a high-friction material.

[0072] The sorting control unit 26 stores the extrusion deceleration rate β in advance in memory according to the shape and type of the pusher member 31, such as the magnitude of the friction coefficient, and the type of product being transported (such as cardboard, plastic case, tray, etc.) of the various workpieces W, and is able to specify the extrusion deceleration rate β according to the type of product set in the inspection unit 20 and the type of pusher member 31 used in the sorting mechanism unit 30, as well as determine whether the required discharge condition is met, in which the workpiece movement distance Lz during the push operation is less than or equal to the pusher plate length Lg (Lg≧Lz). Furthermore, when it is determined that the required discharge condition is not met, the sorting control unit 26 can also display a warning on the display operation unit 21 or a display prompting the display operation unit 21 to request a trial discharge operation, etc.

[0073] In addition, the sorting control unit 26 controls the conveying speed Vrj of the work W by the sorting conveyor 13 of the conveying section 10, the sorting operation delay time T3 corresponding to the conveying interval of the work W, and the like, and after setting the sorting operation time T4 to an appropriate value as described above, controls the operation of the sorting mechanism section 30 based on the sorting operation signal RJ and inspection judgment signal (OK / NG) from the sorting control section 25 and the timing information of item detection from the work detection sensor 15.

[0074] The item inspection system 1 of this embodiment thus comprises a conveying unit 10 that conveys the work W so that it passes sequentially through the inspection section Z1 and sorting section Z2, which are predetermined conveying sections in the conveying path Lp; an inspection mechanism unit 20a (item inspection unit) of the inspection unit 20 that inspects the work W in the predetermined conveying section using a predetermined inspection method and outputs the inspection result signal as an OK signal or an NG signal; a display screen 60 of the display operation unit 21 that displays and outputs the inspection results of each inspected work W based on the input inspection result signal; a sorting mechanism unit 30 that operates in one of a plurality of pre-set sorting directions corresponding to the inspection result signal and moves each inspected work W in that sorting direction at a sorting position downstream of the predetermined conveying section; and a control unit 20b that controls the display output of the display screen 60 and the operation of the sorting mechanism unit 30 based on the inspection result signal, and stops the operation of the sorting mechanism unit 30 and the conveying unit 10 in accordance with the stop command signal when a stop command signal requesting operation to be stopped is input.

[0075] In addition, the item inspection system 1 of this embodiment further includes a work detection sensor 15 (incoming detection means) that detects the entry of each work W into a specified conveying section, and a memory 22M as a time memory unit that stores a sorting operation delay time T3 as a first delay time from the time when the entry of the work W detected by the incoming detection means is detected until the center G of the work W passes through the specified conveying section and reaches the corresponding sorting position (one of the starting points of arrows D0, D1, D2, and D3 in Figure 1), a sorting operation time T4 as a second delay time required for the sorting mechanism unit 30 to move the work W that has reached the sorting position in one of the sorting directions D0, D1, D2, or D3 corresponding to the inspection result signal of the work W, and a cycle time Tcl that is set to be equal to or longer than the time from the time when the entry of each work W is detected until the sorting is completed when the sorting operation time T4 as the second delay time has elapsed. Note that the sorting operation delay time T3 as the first delay time in the sorting direction D0 and the sorting operation time T4 as the second delay time are apparent delay times for controlling the sorting direction of non-defective products, and do not actually perform sorting operations.

[0076] The control unit 20b and sorting control unit 26 in the item inspection system 1 control the display output of the display screen 60 of the display operation unit 21 and the operation of the sorting mechanism unit 30 and the conveying unit 10 based on the stored information in the memory 22M as a time memory unit, and when the above-mentioned stop command signal is input, it stops the conveyor transport, which is the operation of the conveying unit 10, for all undischarged work W that has been detected as being brought in by the work detection sensor 15 at the time of input, on the condition that all corresponding cycle times Tcl have elapsed since the detection of each work W, while updating the display output of the inspection results of that work W on the display screen 60 of the display operation unit 21, on the condition that the corresponding cycle time Tcl has elapsed since the detection of each work W, among all work W that has been detected as being brought in.

[0077] More specifically, when a stop command signal is input, the control unit 20b of the inspection unit 20 stops the upstream conveyor 11 adjacent to the inspection conveyor 12 corresponding to the specified transport section, provided that the work detection sensor 15 has detected (rear end detection) that the last work W (last detected item) has been completed being transported into the inspection section Z1 at the time of input, for which the work detection sensor 15 has already detected (leading end detection) that the last work W has started to be transported into the inspection section Z1.

[0078] Furthermore, the control unit 20b of the inspection unit 20 acquires an inspection signal containing the inspection results of the workpiece W detected by the workpiece detection sensor 15 from the time of detection of the workpiece W being delivered until the workpiece W passes through the inspection zone Z1, stores the inspection result information contained in the inspection signal of the workpiece W in the internal memory 22M, which is a time storage unit, and provisionally displays and outputs an image of the foreign matter contamination, measurement values, and judgment results in the main screen display area 61 of the display screen 60 of the display operation unit 21 (FIG. 3-(a)). Furthermore, when the corresponding cycle time has elapsed since the time of detection of the delivery of the workpiece W, the control unit 20b reads out the inspection result information (OK / NG) corresponding to the inspection result signal of the workpiece W from the internal memory 22M, and officially displays the main screen display area 61 of the inspection results of the workpiece W on the display operation unit 21 (FIG. 3-(b)), and updates the display output of the statistical information display area 65. When the supply of workpieces W is continuous during the cycle time, the main screen display area 61 continuously outputs provisional displays of the foreign matter contamination image, measurement values, and judgment results, and when the supply of workpieces is separated by more than the cycle time, the foreign matter contamination image, measurement values, and judgment results of the workpiece are officially displayed.

[0079] In addition, when a stop command signal is input, and a subsequent work W (subsequent item) enters the inspection section Z1, which is a predetermined conveying section, from the upstream side before all corresponding cycle times Tcl have elapsed for all work W that have been detected as having been delivered by the work detection sensor 15 at the time of input, the control section 20b of the inspection section 20 outputs a notification on the display screen 60 of the display operation section 21 that the subsequent work W that was not detected at the time the stop command signal was input is an unprocessed item that requires manual removal from the conveying path Lp.

[0080] The article inspection system 1 of this embodiment further includes a standby position sensor 54 and a sorting position sensor 55 of each drive mechanism 32A, 32B, or 32C, and sorted article passage confirmation sensors 16, 46A, 46B, or 46C as operation confirmation sensors that detect the completion of movement in a specific sorting direction out of the multiple sorting directions D0, D1, D2, or D3 that corresponds to the inspection result signal of each work W. Here, the specific sorting direction that corresponds to the inspection result of each work W corresponds to one of the sorting directions D0, D1, D2, or D3 that corresponds to the inspection result of each inspection item.

[0081] Therefore, the control unit 20b of the inspection unit 20 can also determine that the cycle time Tcl corresponding to the work W has elapsed, provided that the work W, which has been detected as having been brought in by the work detection sensor 15 as a delivery detection means, has completed its movement in a specific sorting direction D0, D1, D2 or D3 corresponding to the inspection result signal from the time of detection of the delivery, detected by the standby position sensor 54 and sorting position sensor 55 of each drive mechanism 32A, 32B or 32C, which are operation confirmation sensors, or by the sorted product passage confirmation sensor 16, 46A, 46B or 46C.

[0082] In this embodiment, the sorting completion time is the time from the detection of the arrival of each workpiece W by the workpiece detection sensor 15 as the arrival detection means until the time when the sorting operation time T4, which is the second delay time required for the workpiece W to move in one of the sorting directions corresponding to the inspection result signal (OK signal or NG signal), has elapsed. However, this sorting completion time may also be set to the time when the longest delay time among the second delay times T4 corresponding to the multiple sorting directions D0, D1, D2, and D3 has elapsed from the detection of the arrival of each workpiece W by the workpiece detection sensor 15. Furthermore, the system may be configured to be switchable between processing modes 2 and 3, which have operating procedures as illustrated in FIGS. 5 and 6, respectively. In this case, the control unit 20b of the inspection unit 20 can be configured to switch to any of processing modes 1, 2, and 3 by operating a mode switching button or the like on the display screen 60 (details will be described later). The sorting operation time T4 as the second delay time in the sorting direction D0 is an apparent time for controlling the sorting direction of non-defective products, and is not used to actually perform sorting operation.

[0083] Next, the operation will be described.

[0084] (Operation procedure) In the item inspection system 1 of this embodiment configured as described above, the directional control valve of the corresponding control valve unit 33A, 33B or 33C is switched depending on the results of the item inspection of each work W in the inspection section 20, and any work W that has a poor inspection result is discharged onto the discharged item receiving tray conveyor 45A, 45B or 45C by one of the corresponding drive mechanisms 32A, 32B or 32C of the sorting mechanism section 30, and stored within a specified receiving tray area.

[0085] Furthermore, in the item inspection system 1 of this embodiment, when a stop command signal is input to the control unit 20b of the inspection unit 20, the operation of the conveying unit 10 will continue for all workpieces W that have been detected as being delivered by the workpiece detection sensor 15 at the time of input until the corresponding cycle time Tcl has elapsed from the time of detection of each workpiece W that has been detected as being delivered at the time of input of the stop command signal, and during this time, the display output contents of the item inspection results (corresponding to the results of the sorting operation) on the display screen 60 of the display operation unit 21 of the inspection unit 20 will be updated sequentially, provided that the corresponding cycle time Tcl has elapsed from the time of detection of delivery of each workpiece W that had been detected as being delivered at the time of input of the stop command signal.

[0086] (Processing mode 1) FIG. 4 is a timing chart of processing mode 1 illustrating the operation timing of each part of this embodiment in which such cycle stop processing is performed. In this diagram, workpiece numbers (1) to (7) are assigned in order preceding "workpiece," and the diagram illustrates a case in which stop commands are input at times ts1 and ts2 during the inspection of workpiece number (3). Note that processing modes 2 and 3 are additionally provided as auxiliary processing modes when processing mode 1 is not used, and processing mode 1 is the normal processing mode. Note that in the explanation of the processing modes, multiple NGs will be treated as NGs for the sake of simplicity.

[0087] In the figure, at the start of operation t0 when the article inspection system 1 starts operating, the counter display of the total number counter display unit of the inspection unit 20 (inspection device) shows the numbers of "total number," "OK," and "NG" displayed as 10, 8, and 2, respectively. In this state, at the start of operation t0, the front-stage conveyor 11 and rear-stage conveyor 14 start to be driven.

[0088] Next, when the workpiece W(1) is carried from the preceding conveyor 11 into the inspection section Z1 on the inspection conveyor 12 and is detected by the workpiece detection sensor 15, the timers for the sorting operation delay time T3(1) and cycle transport time Tcl(1) corresponding to the workpiece W(1) are started from the detection time t1, and the timers for the inspection judgment, the foreign matter contamination image, the measurement value, the provisional display output of the judgment result, and the display time for statistical information are started.

[0089] After the inspection and judgment of the workpiece W(1) is completed, the next workpiece W(2) is carried from the preceding conveyor 11 into the inspection section Z1 on the inspection conveyor 12. As with the first workpiece W(2), when this workpiece W(2) is detected by the workpiece detection sensor 15, the timers for the sorting operation delay time T3(2) and cycle transport time Tcl(2) corresponding to the workpiece W(2) are started from the detection time t2, and the timers for the inspection judgment, the foreign matter contamination image, the measurement value, the provisional display output of the judgment result, and the display time for statistical information are also started. In Figure 4, the inspection judgment result is an NG judgment.

[0090] After the inspection and judgment of the workpiece W(2) is completed, the next workpiece W(3) is carried from the preceding conveyor 11 into the inspection section Z1 on the inspection conveyor 12. When this workpiece W(3) is detected by the workpiece detection sensor 15, the timers for the sorting operation delay time T3(3) and cycle transport time Tcl(3) corresponding to the workpiece W(3) are started from the detection time t3, and the timers for the inspection judgment, the foreign matter contamination image, the measurement value, the provisional display output of the judgment result, and the display time for statistical information are started.

[0091] During this time, for example, when the sorting operation delay time T3(1) corresponding to the workpiece W(1) has elapsed from the detection time t1 of the workpiece W(1), the timer for the sorting operation time T4(1) is started.

[0092] When the timer for this sorting operation time T4(1) is started, and even when the timer for the sorting operation time T4(1) times out, the timer for the cycle transport time Tcl(1) corresponding to the work W(1) has not yet timed out, and the work W(1) has not yet reached the specific sorting operation position (starting position of arrow D0, D1, D2 or D3 in Figure 1) of the sorting mechanism unit 30 corresponding to its judgment result information (OK / NG1, NG2, NG3) due to the transport since the item detection time t1.

[0093] Next, when the timer for the cycle transport time Tcl(1) corresponding to the workpiece W(1) times out, the inspection result information corresponding to the workpiece W(1) is read from the internal memory Mcl, and the counter display on the total number counter display unit of the inspection unit 20 (inspection device) is updated. Here, for example, the displayed numbers of "total number," "OK," and "NG" on the counter display become the total number and the number of OK judgments increased by one each (11, 9, 2).

[0094] Next, when the sorting operation delay time T3(2) corresponding to the workpiece W(2) has elapsed from the detection time t2 of the workpiece W(2), the timer for the sorting operation time T4(2) is started in sequence.

[0095] In this state, the counter display of the total number counter display unit of the inspection unit 20 (inspection device) remains updated once.

[0096] Next, at time ts1 during inspection of the workpiece W(3), a stop command is input.

[0097] At this time, the workpiece detection sensor 15 is being shaded by the workpiece W(3). Therefore, the timing at which the drive of the preceding conveyor 11 is stopped is delayed until the workpiece W(3) being carried in is completely carried into the inspection section Z1 on the inspection conveyor 12, and the drive of the preceding conveyor 11 is stopped after the workpiece W(3) is completely carried in. During this time, a sorting operation time T4(2) elapses after the sorting operation delay time T3(2) corresponding to the workpiece W(2).

[0098] Next, when the timer for the cycle transport time Tcl(2) corresponding to the workpiece W(2) times out, the counter display of the total number counter display unit of the inspection unit 20 (inspection device) is updated, and the displayed numbers of "total number," "OK," and "NG" on the counter display become the total number and the number of NG judgments increased by one each (12, 9, 3).

[0099] Next, when the sorting operation delay time T3(3) corresponding to each work W(3) has elapsed from the detection time t3 of the work W(3), the timer for the sorting operation time T4(3) is started, and when the timer for the cycle transport time Tcl(3) corresponding to the work W(3) times out, the counter display of the total number counter display unit of the inspection unit 20 (inspection device) is updated, and the displayed numbers of "total number," "OK," and "NG" on the counter display become the total number and the number of OK judgments increased by one each (13, 10, 3).

[0100] Then, at the time ts1 when the stop command is input, the timer for the cycle transport time Tcl(3) for the last workpiece W(3) of all the works W(1), W(2), and W(3) that have been detected as having been brought in times out, and after the counter display on the total number counter display unit of the inspection unit 20 (inspection device) is updated, the operation of the inspection conveyor 12 and the sorting conveyor 13 and the drive output of the subsequent conveyor 14 are stopped.

[0101] Next, when an operation command to restart is input, all conveyors 11 to 14 of transfer section 10 are driven at the input time tr.

[0102] Next, the next work W(4) is carried from the preceding conveyor 11 into the inspection section Z1 on the inspection conveyor 12, and when this work W(4) is detected by the work detection sensor 15, the timers for the sorting operation delay time T3(4) and cycle transport time Tcl(4) corresponding to the work W(4) are started from the detection time t4, and the timers for the inspection judgment, the foreign matter contamination image, the measurement value, the provisional display output of the judgment result, and the display time for statistical information are started.

[0103] Furthermore, once the inspection and judgment of the preceding workpiece W(4) is completed, the next workpiece W(5) is carried into the inspection section Z1 from the preceding conveyor 11, and when this workpiece W(5) is detected by the workpiece detection sensor 15, the timers for the sorting operation delay time T3(5) and cycle transport time Tcl(5) corresponding to the workpiece W(5) are started from the detection time t5, and the timers for the inspection judgment and display time are also started. In Figure 4, the inspection judgment result for the workpiece W(5) is NG judgment.

[0104] Thereafter, similar detection of the arrival of workpieces W(6) and W(7) is performed, and from the respective detection times t6 and t7, the timers for the corresponding sorting operation delay times T3(6) and T3(7) and cycle transport times Tcl(6) and Tcl(7) are started, respectively, and the timers for the respective inspection judgments, foreign matter contamination images, measurement values, provisional display output of judgment results, and display time for statistical information are started.

[0105] Then, when the timers for the cycle transport times Tcl(4), Tcl(5), and Tcl(6) corresponding to the respective workpieces W(4), W(5), and W(6) expire, the counter display of the total number counter display unit of the inspection unit 20 (inspection device) is updated according to the inspection judgment result at each time point.

[0106] Next, at time ts2 during inspection of the workpiece W (7), a stop command is input.

[0107] At this time, the workpiece detection sensor 15 is not shielded from light after the workpiece W (7) has been carried in, so the front-stage conveyor 11 is stopped immediately after the stop command is input.

[0108] Next, the sorting operation delay time T3(7) corresponding to the workpiece W(7) elapses, but at this time, since the transport of the subsequent workpiece W(8) into the inspection section Z1 is detected after the stop command input time ts2 due to free running at the stage of stopping the preceding conveyor 11, a process is executed to issue an alarm requesting the removal of the product from the inspection section Z1.

[0109] Here, when the subsequent work W(8) enters the inspection section Z1 after the stop command input time ts2, an alarm is issued to remove the product from the inspection section Z1. However, for the last work W(7), which had been detected before the stop command was issued, the sorting operation unit 30 can perform the sorting and discharge operation before the timer Tcl(7) times out, and when the timer Tcl(7) ends, the counter display of the total number counter display unit of the inspection unit 20 (inspection device) is updated according to the inspection judgment result.

[0110] (Processing modes 2 and 3) Next, a processing mode 2 whose operation procedure is exemplified in FIG. 5 and a processing mode 3 whose operation procedure is exemplified in FIG. 6 will be briefly described with reference to each drawing.

[0111] Processing mode 2, the operating procedure of which is illustrated in Figure 5, is similar to the conventional mode in that immediately after the inspection result is judged, the foreign matter contamination image, measurement value, and official display output of the judgment result, and the counter display in the statistical information display area 65 are updated, and immediately after the stop command input times ts1 and ts2, all timers for the inspection judgment, sorting operation delay time T3, and sorting operation time T4 are stopped, and cyclic processing using the cyclic transport time Tcl is not executed.

[0112] Processing mode 3, the operating procedure of which is exemplified in FIG. 6, executes cycle processing using cycle transport time Tcl and updates the counter display in the statistical information display area 65 when cycle transport time Tcl has elapsed. However, it differs from processing mode 1 in that all timers for inspection and judgment, sorting operation delay time T3, sorting operation time T4, and cycle transport time Tcl are stopped immediately after stop command input times ts1 and ts2.

[0113] (Comparison with and without timer delay processing) Next, the difference in operation depending on whether or not timer delay processing is performed when updating the counter display will be described with reference to FIGS.

[0114] 7 is a timing chart illustrating the timer delay process for updating the inspection result display counter on the display screen 60 in processing mode 1. The times t1, t2, and t5 are defined as the times when the entry of each workpiece W(1), W(2), and W(5) into the inspection section Z1 is detected. The operation of the timers for inspection judgment and display, and the timers for sorting operation delay time T3, sorting operation time T4, and cycle transport time Tcl is controlled, and inspection result information (OK / NG) is stored in internal memory Mc1 in association with these timer values ​​when the inspection judgment of each workpiece W is finalized, and a foreign matter contamination image, measurement values, and judgment results are provisionally displayed and output in the main screen display area 61 of the display screen 60 of the display operation unit 21. The operation of updating the inspection result display counter on the display screen 60 of the display operation unit 21 when the cycle transport time Tcl corresponding to that workpiece W has elapsed is shown.

[0115] Figure 8 is a timing chart explaining the timer delay processing for updating the inspection result display counter on the display screen 60 in processing mode 2. The times when the entry of each work W(1), W(2), W(5) into the inspection section Z1 is detected are set as t1, t2, and t5, and the operation of the timers for inspection judgment and display, sorting operation delay time T3, and sorting operation time T4 is controlled. However, regardless of these timer values, when the inspection judgment of each work W is confirmed, the foreign matter contamination image, measurement values, official display output of the judgment result, and the inspection result display counter in the main screen display area 61 of the display screen 60 of the display operation unit 21 are updated based on the inspection result information (OK / NG).

[0116] (Step-by-step operation check) Next, we will explain the step-by-step confirmation procedure for the sorting operation, which involves confirming the sorting operation by the drive mechanism 32 of the sorting mechanism unit 30 and confirming the passage of the work W sorted by the sorting through a specified downstream passage (hereinafter, this passage confirmation will be referred to as sorting confirmation).

[0117] 9 is a timing chart illustrating the first operation confirmation method in processing mode 1. In this case, the times when the entry of each workpiece W(1), W(2), and W(5) into the inspection section Z1 is detected are designated as t1, t2, and t5, and the operation of the timers for inspection judgment and display, and the sorting operation delay time T3, sorting operation time T4, and cycle transport time Tcl are controlled, and inspection result information (OK / NG) is stored in the internal memory Mcl in association with these timer values ​​when the inspection judgment of each workpiece W is finalized. Then, the presence or absence of a sorting abnormality is determined based on an OK detection, which is a detection (ON) signal from either the standby position sensor 54 or the sorting position sensor 55 of each drive mechanism 32A, 32B or 32C, which detects the operating position when the inspection result of each work W is OK, or / and an NG detection, which is a detection (ON) signal from either the sorting position sensor 55, which detects the operating position when the inspection result of each work W is NG, and after that determination, when the cycle transport time Tcl has timed out, the inspection result display counter on the display screen 60 of the display operation unit 21 is updated.

[0118] 10 is a timing chart illustrating a second operation confirmation method in processing mode 1. In this case, the detection times of the entry of each workpiece W(1), W(2), and W(5) into the inspection section Z1 are designated as t1, t2, and t5, and the operation of the timers for inspection judgment and display, the sorting operation delay time T3, the sorting operation time T4, the cycle transport time Tcl, the sorting confirmation delay time T7 from the sorting operation delay time T3 or the entry detection time until the sorted product passage confirmation sensor 16, 46A, 46B, or 46C downstream after each sorting operation, and the sorting confirmation time T9 corresponding to the passage time of each workpiece W are controlled, and inspection result information (OK / NG) is stored in the internal memory Mcl in association with these timer values ​​when the inspection judgment of each workpiece W is finalized. Then, the operation of each drive mechanism 32A, 32B or 32C is checked to determine whether there is a sorting abnormality depending on whether there is a workpiece passage detection signal at the sorting product passage confirmation sensor 16, 46A, 46B, 46C, and after that determination, when the cycle transport time Tcl has timed out, the inspection result display counter on the display screen 60 of the display operation unit 21 is updated.

[0119] Of course, for the processes in FIGS. 9 and 10, a combined operation check method can also be used.

[0120] (Counter update process control flow) Next, the process of updating the counter display of the item inspection results in the item inspection system 1 of this embodiment will be described with reference to the flowcharts shown in Figures 11 to 13. Note that the update process here starts from a stopped state (hereinafter simply referred to as a stopped state) in which the item inspection system 1 is powered on but operation has not started, and is set to one of a plurality of modes. Furthermore, when a stop command is input during operation, the counter update process is executed as needed along with the stop process.

[0121] First, a first counter update processing program for executing delayed update of the counter display in different modes will be described with reference to FIGS.

[0122] In this processing program, first, when an administrator or operator performs an operation (operation operation) to request the system, which is currently stopped, to start operation, for example, by pressing the start button 62h on the display screen 60, this processing is started and the system transitions to an operating state (step S21).

[0123] Next, it is determined whether the counter update mode is set to processing mode 1 or 3 for delayed update, or processing mode 2 for immediate update (step S22).

[0124] At this time, if the processing mode is set to delayed update 1 or 3 (if delayed update in step S22), it is then determined whether the work detection sensor 15 is shaded, i.e., whether the work W has been brought into the inspection section Z1 (step S23). When the work W starts to be brought in (if shaded in step S23), then, when the tip of the work W is detected, the timers for the sorting operation delay time T3 and the cycle transport time Tcl start counting (step S24).

[0125] Next, the result of the item inspection is judged in the inspection unit 20 (inspection device), and an OK signal or an NG signal is generated as the judgment result (step S25). The judgment result of OK or NG is displayed in the main display screen area 61 of the display screen 60 (step S26), and the judgment result information is stored in the internal memory Mcl (step S27).

[0126] Next, when the sorting operation delay time T3 associated with the work number expires, the inspection result information for that work number is read out from the internal memory Mcl, and the sorting operation is performed by the sorting mechanism unit 30 as the timer for the sorting operation time T4 associated with that work number counts down (step S28).

[0127] In addition, after the timer for the sorting operation delay time T3 has expired, a timer for the operation monitoring time T6 is started, and the ON / OFF output of the standby position sensor 54 and sorting position sensor 55 of each drive mechanism 32 is stored in the internal memory Mc1 as detection information of the OK / NG sensor for confirming the operation of the drive mechanism 32 of the sorting mechanism section 30 (sorting unit in Figure 11) during that monitoring time (step S29).

[0128] Next, by comparing the inspection judgment results stored in the internal memory Mc1 with the operating position (sorting operation direction) of each drive mechanism 32 based on the detection information of the OK / NG sensor for operation confirmation, it is determined whether the sorting operation direction of the drive mechanism 32 corresponding to the work W to be sorted is normal or not (step S30).

[0129] At this time, if the judgment result is a mismatch, i.e., if the operation check result is bad (if there is a mismatch in step S30), a judgment output of the operation check being bad and update information for updating the counter display indicating the abnormal state are generated and output (step S31), and then transportation is stopped to stop the system due to the occurrence of an abnormality, and the current processing is terminated.

[0130] On the other hand, if the judgment result of whether the direction of the sorting operation is normal or not matches, that is, if the operation confirmation result is normal (if there is a match in step S30), then the timer for the sorting confirmation delay time T7 is started after the sorting operation delay time T3 timer has expired (step S32), and the passage detection information (ON / OFF output) of the sorted item passage confirmation sensors 16, 46A, 46B, 46C is stored in the internal memory Mcl as the detection information of the OK / NG sensor for sorting confirmation by the sorting mechanism unit 30 (sorting unit in Figure 11) after the sorting confirmation delay time (step S33).

[0131] Next, by comparing the inspection judgment results stored in the internal memory Mc1 with the sorting operation direction based on the detection information of the OK / NG sensor for sorting confirmation, it is determined whether the passing direction of the sorted items after sorting is normal or not (step S34).

[0132] If the judgment result is inconsistent, i.e., if the passing direction of the sorted items after sorting is incorrect (if there is a mismatch in step S34), a judgment output indicating poor sorting confirmation and update information for updating the counter display indicating the abnormal state are generated and output (step S31), and then the system is stopped from transporting due to the occurrence of an abnormality, and the current processing is terminated.

[0133] On the other hand, if the sorting confirmation judgment result is a match, that is, if the passing direction of the sorted items after sorting is normal (if there is a match in step S34), then the inspection judgment result stored in the internal memory Mc1 is read out and the counter display of the inspection result (OK item, NG item, etc.) on the display screen 60 is updated (step S35), and then the current counter delay update process involving the sorting operation and operation / sorting confirmation is temporarily terminated, and the system returns to the state of waiting for the next work W to be brought in (step S23).

[0134] Here, or if it is determined that the result of the counter update mode determination made while waiting for the first work W to be delivered is set to processing mode 2, which is immediate update (if immediate update is selected in step S22), then, as shown in Figure 12, it is determined whether the work detection sensor 15 is shaded, i.e., whether the work W has been delivered into the inspection section Z1 (step S41), and when the delivery of the work W begins (if shaded in step S41), then the timer for the sorting operation delay time T3 starts counting when the tip of the work W is detected (step S42).

[0135] Next, the result of the item inspection is judged in the inspection unit 20 (inspection device), and an OK signal or an NG signal is generated as the judgment result (step S43). The judgment result, OK or NG, is displayed in the main display screen area 61 of the display screen 60 (step S44), and the counter display in the statistical information display area 65 of the display screen 60 is updated. At the same time, the judgment result information for this time is stored in the internal memory Mcl (step S45).

[0136] Next, when the sorting operation delay time T3 associated with the work number expires, the inspection result information for that work number is read out from the internal memory Mcl, and the sorting operation is performed by the sorting mechanism unit 30 as the timer for the sorting operation time T4 associated with that work number counts down (step S46).

[0137] In addition, after the timer for the sorting operation delay time T3 has expired, a timer for the operation monitoring time T6 is started, and the ON / OFF output of the standby position sensor 54 and sorting position sensor 55 of each drive mechanism 32 is stored in the internal memory Mc1 as detection information of the OK / NG sensor for confirming the operation of the drive mechanism 32 of the sorting mechanism section 30 (sorting unit in Figure 12) during that monitoring time (step S47).

[0138] Next, by comparing the inspection judgment results stored in the internal memory Mc1 with the operating position (sorting operation direction) of each drive mechanism 32 based on the detection information of the OK / NG sensor for operation confirmation, it is determined whether the sorting operation direction of the drive mechanism 32 corresponding to the work W to be sorted is normal or not (step S48).

[0139] At this time, if the judgment result is a mismatch, i.e., if the operation check result is bad (if there is a mismatch in step S48), a judgment output of the operation check being bad and update information for updating the counter display indicating the abnormal state are generated and output (step S49), and then transportation is stopped so that the system is stopped due to the occurrence of an abnormality, and the current processing is terminated.

[0140] On the other hand, if the judgment result of whether the direction of the sorting operation is normal or not matches, that is, if the operation confirmation result is normal (if there is a match in step S48), then the timer for the sorting confirmation delay time T7 is started after the sorting operation delay time T3 timer has expired (step S50), and the passing detection information (ON / OFF output) of the sorted item passing confirmation sensors 16, 46A, 46B, 46C is stored in the internal memory Mc1 as the detection information of the OK / NG sensor for sorting confirmation by the sorting mechanism unit 30 after the sorting confirmation delay time (step S51).

[0141] Next, by comparing the inspection judgment results stored in the internal memory Mc1 with the sorting operation direction based on the detection information of the OK / NG sensor for sorting confirmation, it is determined whether the passing direction of the sorted items after sorting is normal or not (step S52).

[0142] If the judgment result is inconsistent, i.e., the passing direction of the sorted items after sorting is incorrect (if there is a mismatch in step S52), a judgment output indicating poor sorting confirmation and update information for updating the counter display indicating the abnormal state are generated and output (step S49), and then the system is stopped from transporting due to the occurrence of an abnormality, and the current processing is terminated.

[0143] On the other hand, if the sorting confirmation judgment result is a match, i.e., if the passing direction of the sorted items after sorting is normal (if there is a match in step S52), then the current processing involving the sorting operation and operation / sorting confirmation is temporarily terminated, and the system returns to the state of waiting for the next work W to be brought in (step S41).

[0144] By executing such a control program, during operation of the item inspection system 1 of this embodiment, the counter display update process in a processing mode that has been preset for counter display update is repeatedly executed each time each work W is transported into the inspection section Z1 on the conveying path Lp.

[0145] Figure 13 shows the steps of the cycle stop processing in processing mode 1 and mode 3, which is the processing performed when the item inspection system 1 of this embodiment transitions from an operating state to a stopped state in response to a stop operation accompanied by a stop command input.

[0146] First, when a manager or an operator performs a stop operation by, for example, pressing the stop button 62g on the display screen 60, or when a stop command is input from outside, this cycle stop process starts.

[0147] Then, it is determined whether the stop mode is set to processing mode 3 for immediate stop or processing mode 1 for cyclic stop (step S61).

[0148] At this time, if the stop mode is set to processing mode 3, which causes an immediate stop (if immediate stop is selected in step S61), the timers for the sorting operation delay time T3, sorting operation time T4, and cycle transport time Tcl used for operation control are cleared (step S62), and then the process returns to the stopped state, terminating this processing.

[0149] On the other hand, if the stop mode is set to processing mode 1 which causes a cycle stop (cycle stop in step S61), then at the time of inputting a stop command to stop the system operation, it is checked whether the work detection sensor 15 is shaded, i.e., whether there is a work W being transported into the inspection section Z1 (step S63).

[0150] At this time, if there is a workpiece W (for example, ts1 of workpiece W(3) in FIG. 4) in the middle of being carried in (if light is blocked in step S63), it is determined to be a workpiece whose carrying-in has been detected (step S64).

[0151] The front-stage conveyor 11 waits for the workpiece W to be completely carried in (the rear end is detected) and then stops (step S65). On the other hand, if there is no workpiece W being carried in (if it is blocked in step S61), the front-stage conveyor 11 is immediately stopped in response to a stop command input.

[0152] Whether or not there has been detection of overrun (tip detection) of the following work W after the preceding conveyor 11 is determined based on whether or not there has been a change in the light blocking state of the work detection sensor 15 (from non-light blocking to light blocking) (step S66), and if the determination result is that there has been detection of overrun (light blocking in step S66), the timers for sorting operation delay time T3, sorting operation time T4, and cycle transport time Tcl for operation control linked to the following work W (for example, work W(8) in FIG. 4) are not started (step S67), and an alarm state is entered requesting removal of the product (step S68). Note that if an alarm state requesting removal of the product occurs, an alarm is immediately issued (step S75), and the system can also be stopped.

[0153] On the other hand, if the result of determining (step S66) whether or not a subsequent work W has been detected as having been overrun after the stop command was input is that no detection of infeed has occurred (no light blocking in step S66), the timers for the sorting operation delay time T3, sorting operation time T4, and cycle transport time Tcl for operation control, which are linked to the last work W (for example, work W(7) in Figure 4) that had already been detected as having been infeed at the time the stop command was input, continue to operate (step S69). Then, after the sorting operation according to the inspection judgment results is performed by the sorting mechanism unit 30 using the timers for the sorting operation delay time T3 and sorting operation time T4 (step S70), when the sorting confirmation OK timer due to the passage of the work or the timer for the cycle transport time Tcl linked to the last work W times out, the counter display in the statistical information display area 65 of the display screen 60, etc., is updated according to the inspection results of the last work W (step S71).

[0154] Next, it is determined whether the timer for the cycle transport time Tcl associated with the last work W has timed out or not (step S72). If it has not yet finished (No in step S72), the process returns to the timer operation continuation state to wait for each timer to finish (step S69). If the timer for the cycle transport time Tcl has finished (Yes in step S72), the downstream conveyor 14 is then stopped in response to a stop command input (step S73), and then a check is made to see if there is an alarm state requiring product removal (step S74). If there is an alarm state (Yes in step S74), the alarm state requiring product removal is maintained (step S75). If the alarm state is no longer present due to the alarm cancellation operation after the product is removed (No in step S74), the process returns to the stopped state and ends this processing.

[0155] Next, the operation will be described.

[0156] In the item inspection system 1 of this embodiment, which has the configuration, operation and control procedures described above, even if the operation of the item inspection system 1 is suddenly forcibly stopped for some reason, uninspected / unsorted work W that has already been detected as entering the inspection section Z1 on the conveying path Lp and has become an item to be inspected, but has not yet undergone item inspection or sorting operations based on the inspection results, will not remain on the conveying path Lp as so-called gray work.

[0157] Therefore, the reliability of the counter display of the item inspection results and the statistical management information in the counter display area of ​​the item inspection results on the display screen 60, for example, the total number counter display section 65a in Figure 3, the NG item counter display section 65b for each defect type, and the other defect item display section 65c, can be improved.

[0158] Furthermore, in this embodiment, when a stop command signal is input, the control unit 20b of the inspection unit 20 stops the preceding conveyor 11 adjacent to the upstream side of the inspection conveyor 12 corresponding to the inspection zone Z1, on the condition that the work detection sensor 15 has detected the completion of carrying the last detected item into the inspection zone Z1 (rear end detection) for the last work W(3) or W(7) for which the start of carrying into the inspection zone Z1 has already been detected by the work detection sensor 15 at the time of input of the stop command signal (leading end detection). Therefore, the last work W(3) or W(7) for which the start of carrying into the inspection zone Z1 has already been detected at the time the stop command signal is input to the control unit 20b of the inspection unit 20 can be reliably treated as an item to be processed for item inspection, and the number of items to be input into the specified transport zone where item inspection is performed is clarified.

[0159] Furthermore, in this embodiment, the control unit 20b of the inspection unit 20 stores inspection result information (OK / NG) corresponding to the inspection result signal of the workpiece W in the internal memory Mc1 from the time when the workpiece W is detected by the workpiece detection sensor 15 until the workpiece W passes through the inspection section Z1, and provisionally displays and outputs an image of the foreign matter contamination, measurement values, and judgment results in the main screen display area 61 of the display screen 60 of the display operation unit 21. Then, when the corresponding cycle time Tcl has elapsed since the time when the workpiece W was detected being carried into the inspection section Z1, the control unit 20b reads the corresponding inspection result information from the internal memory Mc1 and updates the counter output for displaying the inspection results on the display screen 65 of the display operation unit 21. If the workpiece W is continuously supplied during the cycle time, the main screen display area 61 continuously provisionally displays and outputs an image of the foreign matter contamination, measurement values, and judgment results, and when the supply of the workpiece has been stopped for more than the cycle time, the control unit 20b formally displays and outputs an image of the foreign matter contamination, measurement values, and judgment results of the workpiece. Therefore, the display output of the item inspection results on the display screen 60 of the display operation unit 21 is updated in a timely manner based on the inspection result information of each workpiece W read out from the internal memory Mc1.

[0160] In addition, in this embodiment, the standby position sensor 54 and sorting position sensor 55 of each drive mechanism 32, and the sorted product passage confirmation sensors 16, 46A, 46B, and 46C are provided as operation confirmation sensors that detect completion of movement in a specific sorting direction D0, D1, D2, or D3 among the multiple sorting directions D0, D1, D2, and D3 corresponding to the inspection result signal of each work W. These are configured to determine that the cycle time Tcl corresponding to that work W has elapsed on the condition that operation confirmation has been made that completion of movement in the specific sorting direction D0, D1, D2, or D3 corresponding to the inspection result signal from the time the work W is detected as being brought in.This means that the completion of the sorting operation corresponding to the inspection result signal of each work W that had already been inspected at the time the stop command signal was input to the control unit 20b can be reliably detected in a timely manner by the operation confirmation sensors, the standby position sensor 54 and sorting position sensor 55 of each drive mechanism 32, and the sorted product passage confirmation sensors 16, 46A, 46B, and 46C.

[0161] Furthermore, in this embodiment, when a stop command signal is input, and a subsequent work (for example, work W(8) in FIG. 4) enters the inspection section Z1 from the upstream side before all of the corresponding cycle times Tcl have elapsed for all workpieces W that have already been detected (tip ends detected) by the workpiece detection sensor 15 at the time of input of the stop command signal, the control unit 20b of the inspection unit 20 outputs a notification that the subsequent item that was not detected as having been brought in at the time the stop command signal was input is an unprocessed item that requires manual removal from the conveying path Lp. Therefore, it is possible to accurately notify the manager or worker that the subsequent workpiece W that was not yet brought in at the time the stop command signal was input is an unprocessed item that requires manual removal from the conveying path Lp, making it possible to accurately process the unprocessed item.

[0162] Furthermore, in this embodiment, the sorting completion time for specifying the cycle time Tcl is set to the time when the sorting operation time T4 has elapsed as the second delay time required for the work W detected as having been carried in by the work detection sensor 15 to move in any of the sorting directions D0, D1, D2, or D3 corresponding to its inspection result signal, but it can also be set to the time when the longest delay time among the second delay times for each of the multiple sorting directions D0, D1, D2, and D3 (for example, the total delay time after detection of carry-in corresponding to sorting direction D3) has elapsed from the time when the work W detected as having been carried in by the work detection sensor 15 is carried in. In this way, the sorting operation time can be made uniform regardless of the sorting direction, and control at the time of stopping can be simplified. On the other hand, if the sorting completion time is set to the time when the second delay time corresponding to each sorting operation direction has elapsed, the sorting completion time can be set relatively early.

[0163] In this way, this embodiment can provide a sorting device and an article inspection system that can improve the reliability of the counter display of the article inspection results and the statistical management information.

[0164] In the embodiment described above, the sorting mechanism 30 is configured with push sorting type drive mechanisms 32 arranged in parallel, but as described above, other types of sorting devices, such as flipper type, drop or up-out type, or carrier type, may be used to sort the workpieces in multiple sorting directions. Furthermore, the present invention is not limited to application to article inspection systems, but can also be applied to a sorting device alone. Therefore, next, another embodiment in which the present invention is applied to a carrier type sorting device as an example of another type will be described.

[0165] (Other embodiments) 14 and 15 show an article inspection system equipped with a sorting device according to another embodiment of the present invention.

[0166] As shown in both figures, a sorting device 100 according to another embodiment of the present invention comprises a conveyor-type transport section 110 that forms a transport path Lp, a sorting mechanism section 130 that is configured using a predetermined sorting method, for example a known carrier-type sorting machine, and that sorts the work W (objects to be inspected) that are transported sequentially along the transport path Lp by the transport section 110, within a predetermined transport section Z2, and a subsequent conveyor 114 that forms multiple parallel sorted product transport paths L1, L2, and L3 that are arranged downstream of each of the specific sorting directions D1, D2, and D3 by the sorting mechanism section 130.

[0167] Although a detailed description of the carrier-type sorter that constitutes the sorting mechanism 130 will not be given here, as described, for example, in Patent Publication No. 131258 / 1979 and Patent Publication No. 39729 / 1983, it comprises a plurality of parallel bars that extend in a direction perpendicular to the item conveying direction and are supported and driven at both ends by endless chains, a plurality of item conveying plates that are slidably attached to the parallel bars, a plurality of guide rails that are arranged in the spatial area between the left and right endless chains and extend in each sorting direction in a shape that can engage with the protruding portions of the multiple item conveying plates, movable sorting gate members that are arranged at the upstream end of the multiple guide rails and engage the protruding portions of each item conveying plate with any one of the guide rails at a predetermined conveying start position (a predetermined position in the circumferential direction), and a drive mechanism that indexes the sorting gate member to a predetermined angular position in response to a sorting command input signal from the sorting control unit 116 (corresponding to the aforementioned item inspection result OK / NG and sorting operation command signal RJ).

[0168] The sorting device 100 also has a control unit 70 that controls the sorting mechanism unit 130, and this control unit 70 is composed of a display operation unit 71, a sorting determination unit 72 that determines the sorting direction corresponding to the sorting command signal and operates the aforementioned sorting gate member, a statistical processing unit 73, an external input / output control unit 74, a sorting / transport control unit 75, and a memory 72M that is layered on the aforementioned internal memory Mcl.

[0169] The configuration of the control unit 70 in this embodiment is similar to that in the case where a sorting judgment unit 72 is provided instead of the inspection processing unit 22 in the control unit 20b of one embodiment, and since in the above-mentioned embodiment the item inspection signal is a sorting command signal, the control by the control unit 70 of the sorting operation in response to the sorting command input signal to the sorting mechanism unit 130 can be executed in approximately the same manner as the control of the sorting mechanism unit 30 by the control unit 20b of one embodiment, and an instruction screen area 160 as shown in Figure 15(b) can be provided in a display screen such as the display screen 60 of one embodiment, and an update process for the counter display can be performed in approximately the same manner as in one embodiment.

[0170] However, in one embodiment, the first delay time T3 and cycle transport time Tcl corresponding to the transport direction position (sorting position) of the drive mechanism 32 may differ depending on the inspection results of the work W (e.g., defect type) and the corresponding sorting direction, whereas in this embodiment, it is possible to set a first delay time T3 to a predetermined transport start position and a constant cycle transport time Tcl until sorting is completed, thereby simplifying the control of cycle processing and counter update processing compared to the one embodiment.

[0171] In this embodiment, the same effects as in the first embodiment can be obtained.

[0172] In the above-described embodiments, the sorting operation direction of the sorting device is three, but it is of course possible to set it to any number of directions. Also, the inspection of the item in the inspection unit 20 is one type of inspection using a predetermined inspection method, but it goes without saying that multiple types of inspection are possible for the workpieces W in the same inspection section Z1.

[0173] As described above, the sorting device and item inspection system of the present invention can provide a sorting device and item inspection system that can increase the reliability of counter displays showing the results of sorting operations and item inspections, and the reliability of statistical management information on operation results, and is useful in general for sorting devices that sort items during transport and item inspection systems equipped with such devices. [Explanation of symbols]

[0174] 1. Product Inspection System 10, 110 Conveyor section 11, 111 Front conveyor 12 Inspection conveyor 13, 113 Sorting conveyor (sorting conveyor) 14, 114 Rear conveyor 15, 115 Work detection sensor (carry-in detection means) 16, 46A, 46B, 46C Item passage confirmation sensor 17, 18 Conveyor drive motor 17a, 18a rotary encoder 20 Inspection Department 20a Inspection Mechanism 20b control section 21, 71 Display operation section 22 Inspection processing section (inspection control section) 22M, 72M memory (time memory section) 23 Statistical Processing Unit 24, 74 External input / output control section 25 Sorting control unit (sorting control unit) 26, 116 Sorting control unit (sorting control unit) 27, 28 Transport control section 30, 130 Sorting mechanism (sorting mechanism) 31, 31A, 31B, 31C Extrusion members 32, 32A, 32B, 32C drive mechanism 33A, 33B, 33C Control valve unit 34 Filter regulator 35 Fluid pressure control circuit 41 cylinders 42 Piston 43 Piston rod 43a, 43b, 43c Tip 44A, 44B, 44C pressure chambers (extension side pressure chambers) 45A, 45B, 45C Discharged Product Receiving Conveyor 45a Intake / Exhaust Port (One Intake / Exhaust Port, One Intake / Exhaust Port) 47A, 47B, 47C pressure chambers (contraction side pressure chambers) 48a Intake / Exhaust Port (the other intake / exhaust port, the other intake / exhaust port) 50 Air source 54, 54a, 54b, 54c Standby position sensors (operation confirmation sensors) 55, 55a, 55b, 55c Sorting position sensor (operation confirmation sensor) 60, 160 display screen 61 Main display screen area 62 Selection operation bar area 62a Menu button 62c, 62d, 62e Display and operation tabs 62f Function operation tab 62g Stop button 62h Start button 63 Operation status display operation bar area 63a Display operation buttons 63b Device status display 64 Examination information display area 65 Statistical information display area 65a Total number counter display 65b NG product counter display 65c Counter display 65c Defective item display section 70 Control Unit 72 Sorting judgment section 73 Statistical Processing Unit 75 Sorting and transport control unit 100 sorting device 123 Sort Device Unit D0 Sorting direction (direction for sorting non-defective products) D1, D2, D3 sorting direction (defective product sorting direction) L1, L2, L3 Sorted product transport route Lg Push plate length Lp transport route Lz Workpiece movement distance Mcl internal memory (time memory section) NG1, NG2, NG3 Inspection result signal (sorting command signal, NG signal) OK / NG inspection result signal (sorting command signal, OK signal or NG signal) P1 Retraction standby position (extrusion start position) P2 Extrusion position (extrusion end position) RJ, RJ1, RJ2, RJ3 Distribution operation command signal (Distribution command signal) t0 When operation starts t1, t2, t3, t4, t5, t6, t7 Detection time (when detecting incoming goods, when detecting items) T3 Sorting operation delay time (first delay time) T4 Sorting operation time (second delay time) T6 Operation monitoring time T7 Sorting confirmation delay time T9 Time to confirm passing of sorted work (time to confirm sorting) ts1, ts2 Time (when stop command is input) Vrj Transfer speed (conveyor speed) Double work (items) Z1 Inspection section (prescribed transport section) Z2 Sorting section (prescribed transport section)

Claims

1. a conveying section (10, 110) for conveying an article (W) so that the article (W) passes through predetermined conveying sections (Z1, Z2) on a conveying path (Lp) in sequence; a sorting mechanism unit (30, 130) that operates in one of a plurality of pre-set sorting directions corresponding to the received sorting command signal, and moves each article being conveyed in one of the sorting directions at a predetermined sorting position; a display unit (21, 71) that displays and outputs the results of the sorting operation for each item; a control unit (20b, 26, 70, 116) that controls the display output of the display unit and the operation of the sorting mechanism unit based on the sorting command signal, and stops the operations of the sorting mechanism unit and the transport unit in accordance with the stop command signal when a stop command signal requesting stop of operation is input, a carry-in detection means (15, 115) for detecting the carry-in of the article into a predetermined conveying section (Z1, Z2); a time memory unit (22M, 72M) for storing a first delay time (T3) from the time when the inflow of an item detected by the inflow detection means is detected until the item passes through the predetermined conveying section and reaches the sorting position, a second delay time (T4) required for the sorting mechanism unit to move the item that has reached the sorting position in any sorting direction corresponding to the sorting command signal for the item, and a cycle time (Tcl) set to be equal to or longer than the time from the time when the inflow of each item is detected until sorting is completed when the second delay time has elapsed, The control unit controls the display output of the display unit and the operation of the sorting mechanism and the conveying unit based on the stored information of the time memory unit, and when the stop command signal is input, stops the operation of the conveying unit on the condition that all corresponding cycle times have elapsed since the time of detection of the entry for all items whose entry has been detected by the entry detection means at the time of the input, while updating the display output of the sorting operation result for each item on the display unit on the condition that the corresponding cycle time has elapsed since the time of detection of the entry for each item among all items whose entry has been detected.

2. The sorting device described in claim 1, characterized in that when the stop command signal is input, the control unit stops the upstream conveyor (11, 111) adjacent to the specified conveying section on the upstream side, for the last detected item whose start of delivery into the specified conveying section has been detected by the delivery detection means at the time of input, on the condition that the delivery detection means has detected that the last detected item has been delivered into the specified conveying section.

3. The sorting device according to claim 1 or 2, characterized in that the control unit acquires a sorting command signal for an item whose entry is detected by the entry detection means from the time the entry is detected until the item passes through the specified conveying section, stores result information of the sorting operation corresponding to the sorting command signal for the item in the time memory unit, and reads out result information of the sorting operation corresponding to the sorting command signal for the item from the time memory unit when the corresponding cycle time has elapsed from the time the entry of the item is detected, and updates the display output of the sorting operation result for the item on the display unit.

4. an operation confirmation sensor for detecting that movement of each article in a specific sorting direction corresponding to the sorting command signal has been completed for the specific sorting direction among the plurality of sorting directions; The sorting device described in claim 3, characterized in that the control unit determines that the cycle time corresponding to the item has elapsed when the operation confirmation sensor detects that the item's movement in the specific sorting direction corresponding to the sorting command signal has been completed from the time the item's entry was detected by the entry detection means.

5. The sorting device described in claim 1 or 2, characterized in that when the stop command signal is input, and a subsequent item enters the specified conveying section from the upstream side before all of the corresponding cycle times have elapsed for all items whose entry has been detected by the entry detection means at the time of input, the control unit outputs a notification that the subsequent item that was not detected at the time the stop command signal was input is an unprocessed item that requires manual removal from the conveying path.

6. The sorting device according to any one of claims 1 to 5, and an article inspection unit (20) that inspects articles within the predetermined conveying section and outputs a sorting command signal corresponding to the inspection results of the articles.

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