Inspection Support System

Abstract

To provide an inspection support system which enables efficient inspection to be performed by both an automatic inspection device and an inspector.SOLUTION: An inspection support system 1 for notifying an inspector of inspection items, comprises: a server 11 for holding automatic inspection items and manual inspection items; an automatic inspection device 12 for acquiring the automatic inspection items from the server 11 and outputting the determination of good or bad as an inspection result; and a display device 13 for displaying both the manual inspection items and re-inspection items determined as bad and manually re-inspected among the automatic inspection items.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to an inspection support system that notifies an inspector of inspection items. [Background technology]

[0002] Manufactured products, such as vehicles, are inspected to check for defects. For example, in vehicle inspections, an inspection line is set up, and multiple inspection processes are carried out in sequence by multiple inspectors. Each inspector is assigned a specific inspection item to be carried out.

[0003] For example, inspectors keep track of inspection items using the following method. First, the inspection items for each vehicle to be inspected are obtained from the server and printed on paper. Next, the paper with the inspection items printed on it is attached to the vehicle on the inspection line. Then, as the inspection line progresses, each inspector sequentially inspects the inspection items listed on the paper.

[0004] Furthermore, Patent Document 1 discloses the following technology for notifying inspectors of inspection items: An inspection management system including a data storage means such as an information terminal and a communication terminal, and the inspection management system is equipped with an inspection item data conversion means for converting data of an inspection item list for a product to be inspected into data of inspection items by process. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Patent Publication No. 2021-076891 Summary of the Invention [Problem to be solved by the invention]

[0006] On the other hand, some inspection items may be performed using automatic inspection equipment installed on the inspection line. In this case, the inspection items that should be subsequently performed by inspectors may differ depending on the inspection results of the automatic inspection equipment.

[0007] However, when an inspection process using an automatic inspection device is introduced, inspectors are unable to efficiently grasp the inspection items that reflect the inspection results of the automatic inspection device. In other words, when inspections are performed by both the automatic inspection device and inspectors, it is necessary to manage additions and changes to the inspection items performed by the inspectors, and there is a need to improve the efficiency of this process.

[0008] Therefore, an object of the present disclosure is to provide an inspection support system that enables efficient inspections to be carried out by both automatic inspection equipment and inspectors. [Means for solving the problem]

[0009] The inspection support system according to the present disclosure is an inspection support system that notifies an inspector of inspection items, and includes a server that stores automatic inspection items and manual inspection items, an automatic inspection device that acquires the automatic inspection items from the server and outputs a judgment of pass or fail as the inspection result, and a display device that displays both the manual inspection items and re-inspection items among the automatic inspection items that are judged to be fail and are to be manually re-inspected.

[0010] Here, the display device may be a plurality of portable terminals carried by the plurality of inspectors, and the manual inspection items displayed on the target portable terminal carried by the target inspector may be those assigned to the target inspector, and the re-inspection items displayed on the target portable terminal may be similar to the manual inspection items assigned to the target inspector.

[0011] Furthermore, if the automatic inspection device judges a product to be defective but a re-inspection judges it to be good, the inspection result judged to be defective by the automatic inspection device may be able to be corrected to a good judgment on the screen of the display device.

[0012] The automatic inspection device may also perform inspection using image recognition based on deep learning. [Effects of the Invention]

[0013] According to the present disclosure, it is possible to provide an inspection support system that enables efficient inspections to be carried out by both automatic inspection equipment and inspectors. [Brief explanation of the drawings]

[0014] [Figure 1] 1 is a block diagram showing a configuration of an examination support system according to a first embodiment. [Figure 2] FIG. 3 is a diagram showing an example of a display on the test result display terminal of the test support system according to the first embodiment. [Figure 3] FIG. 2 is a diagram showing an example of a display on a mobile terminal of the examination support system according to the first embodiment. [Figure 4] 4 is a flowchart illustrating an example of processing by the examination support system according to the first embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0015] Embodiment 1 <Configuration of the examination support system> Hereinafter, a first embodiment will be described with reference to the drawings. FIG. 1 is a block diagram showing the configuration of an inspection support system 1. The inspection support system 1 is a system that notifies inspectors of inspection items on an inspection line, reflecting the status of the previous process. The inspection support system 1 is used, for example, in a visual inspection process on a vehicle production line. As shown in FIG. 1, the inspection support system 1 includes a server 11, an automatic inspection device 12, a display device 13, and an inspection result display terminal 21. In this embodiment, the display device 13 is a plurality of mobile terminals 22.

[0016] The server 11 stores information about the inspection items to be performed on the inspection line. For example, the server 11 stores inspection items for each vehicle to be inspected. The server 11 stores the inspection items, which are automatic inspection items performed by the automatic inspection device 12 and manual inspection items performed by inspectors. An example of a manual inspection is a visual inspection. The server 11 is configured to be able to communicate with the automatic inspection device 12 and the display device 13, and outputs information about the inspection items to each device.

[0017] The automatic inspection device 12 is installed in part of the inspection line and is a device that automatically performs some of the inspections. The inspection items to be performed by the automatic inspection device 12 are stored as automatic inspection items in the server 11. The automatic inspection device 12 stores conditions for determining whether the inspection object is in a good state or a bad state for each of the automatic inspection items stored in the server 11. The automatic inspection device 12 is configured to be able to communicate with the server 11 and acquires the automatic inspection items from the server 11. The automatic inspection device 12 automatically performs an inspection based on the acquired automatic inspection items. The automatic inspection device 12 automatically inspects the inspection object and outputs a pass judgment if it is determined to be in a good state, or a fail judgment if it is determined to be in a bad state.

[0018] The automatic inspection device 12 is, for example, a device that performs image recognition using deep learning. The automatic inspection device 12 learns which inspection objects are in good condition and which are in bad condition based on a large amount of image data. Based on the results of the learning, the automatic inspection device 12 analyzes images of the inspection objects and outputs a pass / fail judgment if it determines that the part is in good condition as a product, or a fail judgment if it determines that the part is in bad condition. Note that, as will be described later, when an inspection result that was judged as bad is corrected to a pass judgment by an inspector, the automatic inspection device 12 may learn whether the inspection object is in good or bad condition in the inspection based on information about the corrected inspection result.

[0019] Furthermore, for example, the automatic inspection device 12 has a server function that outputs inspection results based on an external request. The automatic inspection device 12 is configured to be able to communicate with the display device 13. The automatic inspection device 12 transmits information about the inspection results to the display device 13 based on a request from the display device 13.

[0020] The display device 13 displays both manual inspection items and, among the automatic inspection items, re-inspection items that have been determined to be defective by the automatic inspection equipment 12 and are to be manually re-inspected. The display device 13 is configured to be able to communicate with, for example, the server 11 and the automatic inspection equipment 12. The display device 13 acquires manual inspection items from the server 11 and displays the acquired manual inspection items. The display device 13 also acquires automatic inspection results from the automatic inspection equipment 12 and displays at least re-inspection items that have been determined to be defective in the automatic inspection and are to be manually re-inspected by an inspector. The display device 13 has a function that allows the inspection results acquired from the automatic inspection equipment 12 to be corrected. The display device 13 is, for example, a plurality of portable terminals 22 carried by each inspector.

[0021] The inspection result display terminal 21 is a terminal that displays the results of inspections performed by the automatic inspection equipment 12. The inspection result display terminal 21 is installed, for example, in a location on the inspection line where it can be confirmed by an inspector. The inspection result display terminal 21 is configured to be able to communicate with the automatic inspection equipment 12, and acquires the pass / fail judgment results from the automatic inspection equipment 12. The inspection result display terminal 21 displays, for example, the pass / fail judgment results for all inspection items automatically inspected by the automatic inspection equipment 12.

[0022] FIG. 2 illustrates a specific example of a display by the inspection result display terminal 21. FIG. 2 is a diagram illustrating an example of a display by the inspection result display terminal 21. As illustrated in FIG. 2, the inspection result display terminal 21 lists automatic inspection items as an automatic inspection item display 101 on the display screen. If there are multiple automatic inspection items, multiple automatic inspection item displays 101 are displayed on the display screen as illustrated in FIG. 2. The automatic inspection item display 101 displays the names and abbreviations of the inspection items. The automatic inspection item display 101 displays the pass / fail judgment results by the automatic inspection device 12 so that an inspector can distinguish them. For example, the automatic inspection item display 101 displays items judged as pass and items judged as fail in the automatic inspection using different colors. As a specific example, the automatic inspection item display 101 displays the background of items judged as pass in green and the background of items judged as fail in yellow. By checking the automatic inspection item display 101, an inspector can understand the results of the automatic inspection by the automatic inspection device 12.

[0023] 2, the test result display terminal 21 may display an automatic test type display 102 indicating the test type together with the automatic test item display 101. The automatic test type display 102 displays the name and symbol of the test type, the test subject, etc. The automatic test type display 102 is displayed, for example, at the top of the display screen.

[0024] The mobile terminal 22 is a terminal that displays the inspection items to be performed by an inspector. The mobile terminal 22 is, for example, a smartphone or a tablet terminal. The mobile terminal 22 is configured to be able to communicate with the server 11 and the automatic inspection equipment 12. The mobile terminal 22 transmits and receives information to and from the server 11 and the automatic inspection equipment 12, for example, via short-range wireless communication. The mobile terminal 22 acquires manual inspection items from the server 11. The mobile terminal 22 also acquires automatic inspection items that have been determined to be defective by the automatic inspection equipment 12, from the automatic inspection equipment 12. Here, automatic inspection items that have been determined to be defective by the automatic inspection equipment 12 are re-inspection items that require manual re-inspection by an inspector. The mobile terminal 22 displays the manual inspection items and the re-inspection items.

[0025] The manual inspection items displayed on the mobile terminal 22 are assigned to the inspector who owns the mobile terminal 22, and the reinspection items displayed on the mobile terminal 22 are similar to the manual inspection items assigned to the inspector. That is, the mobile terminal 22 selectively acquires and displays inspection items to be performed by the inspector who owns the mobile terminal 22 from among the many inspection items stored in the server 11 and the automatic inspection equipment 12. The mobile terminal 22, for example, communicates with the server 11 to acquire manual inspection items assigned to the inspector who owns the mobile terminal 22. The mobile terminal 22 also communicates with the automatic inspection equipment 12 to determine the similarity of reinspection items determined to be defective by the automatic inspection equipment 12 to the acquired manual inspection items, and acquires the reinspection items determined to be similar. The mobile terminal 22 displays both the acquired manual inspection items and reinspection items. As a result, the mobile terminal 22 notifies the inspector who owns the mobile terminal 22 of the manual inspection items and reinspection items assigned to the inspector.

[0026] A specific example of a display by the mobile terminal 22 will be shown using FIG. 3. FIG. 3 is a diagram showing an example of a display by the mobile terminal 22. As shown in FIG. 3, the mobile terminal 22 lists manual inspection items and reinspection items on the display screen as a manual inspection item display 201. Here, if there are multiple manual inspection items and reinspection items, multiple manual inspection item displays are displayed on the display screen as shown in FIG. 3. The manual inspection item display 201 displays the names of the inspection items, abbreviations of the inspection items, etc. The manual inspection item display 201 displays, for example, manual inspection items and reinspection items so that an inspector can distinguish between them. The manual inspection item display 201 displays, for example, the background of the manual inspection items and the background of the reinspection items in different colors.

[0027] Furthermore, when an inspection result determined as defective by the automatic inspection equipment 12 is determined as pass after reinspection, the display device 13 allows the inspection result determined as fail by the automatic inspection equipment 12 to be corrected to a pass judgment on the screen. For example, the mobile terminal 22 has a function that allows an inspector to correct the inspection result obtained from the automatic inspection equipment 12. That is, the mobile terminal 22 is equipped with an input means for accepting input by the inspector. For example, the mobile terminal 22 is configured to be able to rewrite the failure judgment obtained from the automatic inspection equipment 12 to a pass judgment in accordance with input by the inspector. Such correction of the inspection result is performed, for example, when an inspector reinspects an inspection item determined as fail by the automatic inspection equipment 12 and the reinspection results in a pass judgment.

[0028] <Example of processing by the examination support system> An example of processing by the inspection support system 1 on the inspection line will be described with reference to Fig. 4. Fig. 4 is a flowchart showing an example of processing by the inspection support system 1.

[0029] First, when the inspection line enters the inspection process by the automatic inspection equipment 12, the automatic inspection equipment 12 acquires automatic inspection items from the server 11 (step S301). Then, the automatic inspection equipment 12 performs an automatic inspection on the inspection target based on the acquired automatic inspection items (step S302). Then, the inspection result display terminal 21 acquires the results of the automatic inspection from the automatic inspection equipment 12 and displays the results of the automatic inspection on the display screen (step S303).

[0030] Next, the mobile terminal 22 acquires manual inspection items from the server 11 (step S304). Next, the mobile terminal 22 communicates with the automatic inspection equipment 12 and acquires, from among the automatic inspection items, reinspection items that have been determined to be defective by the automatic inspection and require manual reinspection (step S305). Here, the mobile terminal 22 determines the similarity between the manual inspection items acquired in step S304 and the automatic inspection items held by the automatic inspection equipment 12, and acquires the reinspection items that have been determined to be similar to the manual inspection items.

[0031] Next, the mobile terminal 22 displays both the acquired manual inspection items and re-inspection items (step S306), and the inspection support system 1 ends the processing. Note that the processing by the mobile terminal 22 shown in steps S304 to S306 is processing executed by each of the multiple mobile terminals 22. The inspector then performs a manual inspection based on the manual inspection items and re-inspection items displayed on the mobile terminal 22. Here, if the inspector determines that a re-inspection item that was determined to be defective by the automatic inspection device 12 is a pass, for example, the inspector may correct the results of the automatic inspection using the input means of the mobile terminal 22.

[0032] In the above example, the automatic inspection results are displayed on the inspection result display terminal 21 (step S303) and then the mobile terminal 22 acquires the manual inspection items from the server 11 (step S304), but this is not limiting, and the automatic inspection results may be displayed on the inspection result display terminal 21 (step S303) after the mobile terminal 22 acquires the manual inspection items from the server 11 (step S304). Also, the display of the automatic inspection results on the inspection result display terminal 21 (step S303) and the acquisition of the manual inspection items from the server 11 by the mobile terminal 22 (step S304) may be performed simultaneously.

[0033] Each component in the above-described embodiments may be configured by hardware or software, or both, and may be configured by a single piece of hardware or software, or may be configured by multiple pieces of hardware or software. The function (processing) of each device may be realized by a computer having a CPU (Central Processing Unit), memory, etc. For example, a program for performing a method (e.g., a control method) in the embodiment may be stored in a storage device, and each function may be realized by executing the program stored in the storage device with the CPU.

[0034] These programs can be stored and supplied to a computer using various types of non-transitory computer-readable media. Non-transitory computer-readable media include various types of tangible storage media. Examples of non-transitory computer-readable media include magnetic recording media (e.g., flexible disks, magnetic tapes, hard disk drives), magneto-optical recording media (e.g., magneto-optical disks), CD-ROMs (Read Only Memory), CD-Rs, CD-R / Ws, and semiconductor memories (e.g., mask ROMs, PROMs (Programmable ROMs), EPROMs (Erasable PROMs), flash ROMs, and RAMs (Random Access Memory)). The programs may also be supplied to a computer by various types of transitory computer-readable media. Examples of transitory computer-readable media include electrical signals, optical signals, and electromagnetic waves. The transitory computer-readable media can supply the programs to a computer via wired communication paths such as electric wires and optical fibers, or via wireless communication paths.

[0035] According to the inspection support system 1 described above, on the inspection line, inspectors in charge of processes following inspection by the automatic inspection equipment 12 can grasp the inspection items that they themselves should perform, including items that require reinspection based on the results of inspection by the automatic inspection equipment 12. In other words, the inspection support system 1 can notify the inspectors of both the automatic inspection items that were inspected by the automatic inspection equipment 12, the reinspection items that were determined to be defective and require reinspection, and the manual inspection items. In other words, the inspection support system 1 can enable efficient inspections to be performed by both the automatic inspection equipment and the inspectors.

[0036] Furthermore, the inspection support system 1 notifies each inspector of both some of the manual inspection items assigned to that inspector and re-inspection items that are similar to the manual inspection items and that are determined to be defective by the automatic inspection device 12 and require re-inspection. This allows the inspection support system 1 to appropriately allocate the inspection items that each inspector should perform to each inspector.

[0037] As a specific example, suppose that on a vehicle inspection line, one inspector inspects the right side of the vehicle and another inspector inspects the left side of the vehicle, and the automatic inspection device 12 determines that an inspection item is defective on each side of the vehicle. In this case, the inspection support system 1 can assign and notify each inspector of the manual inspection items for the right or left side, and also appropriately assign and notify each inspector inspecting the right or left side based on the judgment that the items are similar to the manual inspection items.

[0038] Furthermore, the inspection support system 1 notifies each inspector of the inspection items assigned to that inspector using the mobile terminal 22 carried by each inspector. This allows the inspection support system 1 to efficiently allow each inspector to grasp the inspection items to be performed, and makes it possible to efficiently notify inspectors of the inspection items.

[0039] Furthermore, the inspection support system 1 allows an inspector to correct an inspection result determined as defective by the automatic inspection device 12 to a pass judgment on the display device 13. This allows the inspection support system 1 to quickly reflect the inspection results by the inspector. Furthermore, if the automatic inspection device 12 is a device that performs image recognition using deep learning, the automatic inspection device 12 can also learn whether the inspection object is pass or fail based on the information corrected by the inspector.

[0040] The present invention is not limited to the above-described embodiment, and can be modified as appropriate without departing from the spirit and scope of the invention. For example, although an example has been described in which the automatic inspection device 12 has a server function for storing the results of the automatic inspection and communicating with the inspection result display terminal 21 and the mobile terminal 22, the present invention is not limited to this. The path for transmitting the results of the automatic inspection by the automatic inspection device 12 to the inspection result display terminal 21 and the mobile terminal 22 can be set as appropriate. For example, the results of the automatic inspection by the automatic inspection device 12 may be stored in the server 11, and the inspection result display terminal 21 and the mobile terminal 22 may acquire the results of the automatic inspection by communicating with the server 11.

[0041] Furthermore, in the above embodiment, an example in which the display device 13 is a plurality of portable terminals 22 has been described, but this is not limiting. The display device 13 may be configured to display both manual inspection items and reinspection items, and the display method can be appropriately configured. For example, the display device 13 may be the inspection result display terminal 21. That is, the inspection result display terminal 21 may be configured to further acquire manual inspection items from the server 11 and display both manual inspection items and automated inspection items determined to be defective. Here, the inspection result display terminal 21 may have a function to narrow down the inspection items to be displayed to those assigned to a given inspector. That is, the inspection result display terminal 21 may display both some manual inspection items assigned to the inspector and reinspection items similar to those some manual inspection items. However, in order to efficiently notify each inspector of the inspection items that differ for each inspector, it is preferable to configure the portable terminal 22 carried by each inspector as the display device 13.

[0042] Furthermore, in the above example, the mobile terminal 22 selectively acquires inspection items from the server 11 and the automatic inspection equipment 12, but the present invention is not limited to this. For example, the mobile terminal 22 may acquire all inspection items from the server 11 and the automatic inspection equipment 12. The mobile terminal 22 may narrow down the information on all acquired inspection items and selectively display inspection items assigned to the inspector who carries the mobile terminal 22. Here, the selection of inspection items to be displayed on the mobile terminal 22 may be realized by the inspector operating the mobile terminal 22. In other words, as long as the configuration is such that the inspection items to be performed by the inspector can be extracted and notified to the inspector, the method of acquiring or displaying the inspection items can be set appropriately.

[0043] In the above example, the mobile terminal 22 communicates with the server 11 and the automatic inspection device 12 via short-range wireless communication to acquire inspection items, but this is not limiting. The mobile terminal 22, the server 11, and the automatic inspection device 12 may be configured to transmit and receive information to and from each other via a telecommunications line. Here, the server 11 is not limited to a physical server, and may be a cloud server.

[0044] Furthermore, although an example has been described in which the mobile terminal 22 is provided with an input means so that the results of the automatic inspection performed by the automatic inspection device 12 can be corrected, the configuration that allows the results of the automatic inspection to be corrected is not limited to this. As long as the results of the automatic inspection can be corrected by an inspector, the configuration can be set as appropriate. For example, instead of the mobile terminal 22, the input means may be provided in the inspection result display terminal 21. Alternatively, the input means may be provided in both the inspection result display terminal 21 and the mobile terminal 22. Alternatively, the automatic inspection device 12 may be provided with a function that allows the inspector to correct the results of the automatic inspection.

[0045] Furthermore, in the above-described first embodiment, an example has been described in which the inspection support system 1 is used in a visual inspection process in a vehicle production line, but the present invention is not limited to this. Furthermore, the automatic inspection device 12 in the inspection support system 1 is not limited to a device that performs image recognition using deep learning. The inspection support system 1 can be arbitrarily applied to an inspection line that includes a process of automatic inspection, even if it performs an inspection other than visual inspection. For example, the inspection support system 1 can also be applied to a case in which screw tightening torque management is performed using an automatic inspection device that detects screw tightening torque.

[0046] Specifically, in the inspection support system 1, the automatic inspection device is assumed to be a device that detects the torque of a screw tightening. For example, when an operator tightens a screw using this automatic inspection device, the automatic inspection device detects the torque. At this time, the automatic inspection device can detect whether the tightening torque is appropriate. If the tightening torque is appropriate, the automatic inspection device outputs a pass / fail judgment, and if it is not appropriate, a fail judgment. Then, at least when the automatic inspection device makes a fail judgment, the result of the automatic inspection is displayed on a display device to notify the inspector. This allows the inspector to determine whether or not the screw tightening torque needs to be reinspected in a later process based on the pass / fail judgment result by the automatic inspection device, along with the assigned manual inspection items. [Explanation of symbols]

[0047] 1. Inspection support system 11 Server 12 Automatic inspection equipment 13 Display device 21 Test result display terminal 22 Mobile devices 101 Automatic test item display 102 Automatic inspection type display 201 Manual inspection item display

Claims

1. An inspection support system that notifies an inspector of inspection items, a server that stores automatic inspection items and manual inspection items; an automatic inspection device that acquires the automatic inspection items from the server and outputs a pass / fail judgment as an inspection result; a display device that displays both the manual inspection items and re-inspection items that are determined to be defective and are to be manually re-inspected among the automatic inspection items; An inspection support system equipped with:

2. The display devices are a plurality of portable terminals carried by the plurality of inspectors, The manual inspection items displayed on the target mobile device carried by the target inspector are assigned to the target inspector, The re-inspection item displayed on the target mobile device is similar to the manual inspection item assigned to the target inspector. The inspection support system according to claim 1 .

3. If the automatic inspection device judges the product to be defective but the product is re-inspected and judges it to be good, The inspection result determined as defective by the automatic inspection device can be corrected to a pass judgment on the screen of the display device. The inspection support system according to claim 1 or 2.

4. The automatic inspection device performs inspection using image recognition based on deep learning. The inspection support system according to claim 1 or 2.

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