Workpiece processing apparatus and workpiece processing method

Abstract

To provide a technique capable of confirming discharge of a workpiece after processing.SOLUTION: A workpiece processing device comprises: a cabinet which has a projection chamber that processes a plurality of workpieces; a projection machine which projects a projection material to a plurality of workpieces input to the projection chamber; an image sensor which generates an image by imaging the projection chamber; and a control unit which outputs information about the presence / absence of the remains in the projection chamber on the basis of an initial image being the image generated by the image sensor and also the image of the projection chamber in such a state that the workpiece is not left, and an inspection image being the image generated by the image sensor and also the image of the projection chamber after discharge processing of discharging the plurality of workpieces from the projection chamber.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to a work processing apparatus and a work processing method.

Background Art

[0002] Patent Document 1 discloses a polishing facility that polishes a plurality of workpieces by blasting. The polishing facility includes a rotating drum that houses a plurality of workpieces and an abrasive grain projection device. The rotating drum stirs the plurality of workpieces. The abrasive grain projection device projects abrasive grains onto the plurality of workpieces during stirring to polish them. After the polishing is completed, the rotating drum tilts downward to discharge the polished plurality of workpieces.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The polishing facility described in Patent Document 1 has a function of discharging all of the plurality of workpieces because the entire rotating drum tilts. However, this polishing facility cannot confirm that all of the workpieces have been completely discharged. The present disclosure provides a technique for confirming the discharge of the processed workpieces.

Means for Solving the Problems

[0005] The workpiece processing device according to this disclosure comprises a cabinet, a projection machine, an image sensor, and a control unit. The cabinet has a projection chamber for processing multiple workpieces. The projection machine projects a projection material onto multiple workpieces placed in the projection chamber. The image sensor captures images of the projection chamber and generates images. The control unit outputs information regarding the presence or absence of remaining workpieces in the projection chamber based on an initial image, which is an image of the projection chamber with no workpieces remaining, generated by the image sensor, and an inspection image, which is an image of the projection chamber after the discharge process in which multiple workpieces are discharged from the projection chamber, generated by the image sensor.

[0006] According to this workpiece processing device, the projection chamber is imaged and an image is generated. Based on the initial image, which is an image of the projection chamber when no workpieces remain, and the inspection image, which is an image of the projection chamber after the discharge process, information regarding the presence or absence of remaining workpieces in the projection chamber is output. In this way, the workpiece processing device can output information regarding the presence or absence of remaining workpieces in the projection chamber based on the image of the projection chamber, allowing for confirmation of the discharge of workpieces after processing.

[0007] In one embodiment, the initial image may be an image of the projection chamber captured by an image sensor during the initial startup or maintenance of the workpiece processing device. In this case, the workpiece processing device can output information regarding the presence or absence of remaining items in the projection chamber based on the state of the projection chamber during the initial startup or maintenance of the workpiece processing device.

[0008] In one embodiment, the control unit may compare the initial image with the inspection image and output information regarding the presence or absence of remaining items in the projection chamber. In this case, the workpiece processing device can output information regarding the presence or absence of remaining items in the projection chamber based on the comparison result.

[0009] In one embodiment, the control unit may output information regarding the presence or absence of remaining items in the projection chamber based on the difference information between the initial image and the inspection image. In this case, the workpiece processing device can output information regarding the presence or absence of remaining items in the projection chamber based on the difference information.

[0010] In one embodiment, the control unit may associate and store in a storage device at least one of the operation information of the workpiece processing device and the processing information of multiple workpieces with the inspection image. In this case, the workpiece processing device can refer to at least one of the operation information of the workpiece processing device and the processing information of multiple workpieces from the inspection image, and the inspection image can be used as product quality management information.

[0011] A work processing method relating to other aspects of this disclosure includes the following steps. (1) A step of generating an initial image by imaging the projection room when no workpieces remain. (2) A step of projecting a projection material onto multiple workpieces in a projection chamber. (3) A step of discharging multiple workpieces onto which the projection material has been projected from the projection chamber. (4) After the discharge step, the step of imaging the projection chamber and generating an inspection image. (5) A step of outputting information regarding the presence or absence of remaining items in the projection room based on the initial image and the inspection image.

[0012] This workpiece processing method achieves the same effect as the workpiece processing device described above. [Effects of the Invention]

[0013] According to this disclosure, a technology is provided that allows for confirmation of the discharge of a workpiece after processing. [Brief explanation of the drawing]

[0014] [Figure 1] This is a schematic diagram of a workpiece processing apparatus according to one embodiment. [Figure 2] This is a flowchart showing the operation of a workpiece processing apparatus according to one embodiment. [Modes for carrying out the invention]

[0015] Embodiments of the present invention will be described below with reference to the drawings. In each drawing, the same or corresponding parts are denoted by the same reference numerals.

[0016] (Configuration of the workpiece processing device) Figure 1 is a schematic diagram of a workpiece processing apparatus according to one embodiment. The workpiece processing apparatus 1 shown in Figure 1 is a device for blast processing multiple workpieces W. The multiple workpieces W are not particularly limited, but as an example, they are multiple metal products. In the following, a so-called apron-type blasting apparatus will be described as an example of a workpiece processing apparatus.

[0017] As shown in Figure 1, the workpiece processing apparatus 1 comprises a cabinet 2. The cabinet 2 has a projection chamber S for processing multiple workpieces W. An apron 3 is placed in the projection chamber S for stirring the workpieces W. The apron 3 includes a drive roller 3a, two driven rollers 3b and 3c, a pair of headliners 3d, and an apron belt 3e (stirring belt).

[0018] The drive roller 3a has a substantially cylindrical shape and is rotatably supported on both side walls of the cabinet 2 such that its axis extends along the width direction of the cabinet 2. This drive roller 3a is configured to be rotatable by a motor (not shown). The driven roller 3b is located below the drive roller 3a, and the driven roller 3c is located at approximately the same height as the driven roller 3b. The driven rollers 3b and 3c have a substantially cylindrical shape and are rotatably supported on both side walls of the cabinet 2 such that their axis extends parallel to the axis of the drive roller 3a. The pair of headliners 3d have a substantially disc shape with an outer diameter approximately equal in length to the distance between the drive roller 3a and the driven roller 3b. The pair of headliners 3d are each rotatably supported on the side walls of the cabinet 2.

[0019] The apron belt 3e is an endless belt. The apron belt 3e is wound around a driving roller 3a and a pair of driven rollers 3b, 3c. The outer peripheral part of a headliner 3d is abutted against both side edges of the apron belt 3e. A plurality of through holes are formed in the apron belt 3e to prevent the projection material from staying on the apron belt 3e. The apron belt 3e is configured to move on a substantially L-shaped endless track. During shot processing, a plurality of workpieces W are arranged on the apron belt 3e, the apron belt 3e is rotated in the forward rotation direction, and the workpieces are agitated on the apron belt 3e. When the apron belt 3e is rotated in the reverse rotation direction, the plurality of workpieces W are carried out from the cabinet 2.

[0020] A projector 4 is provided above the cabinet 2. The projector 4 projects a projection material onto a plurality of workpieces W introduced into a projection chamber S. The projector 4 is, for example, a centrifugal projection unit. By rotating an impeller, a projection material such as steel balls is projected toward a plurality of workpieces W in the projection chamber S, and the plurality of agitated workpieces W are subjected to blasting. The projection material projected into the projection chamber S by the projector 4 falls below the projection chamber S. The fallen projection material is conveyed by a screw conveyor 5 extending in the horizontal direction to a bucket elevator 6 arranged in parallel with the cabinet 2. The bucket elevator 6 conveys the projection material in the vertical direction. The conveyed projection material is supplied to a separator 7 provided above the cabinet 2. The separator 7 separates the projection material and impurities by air classification. The impurities are sucked by a dust collector 8. The projection material is supplied to the projector 4. Thus, the projection material is recycled.

[0021] The cabinet 2 is provided with an openable and closable door (not shown) for carrying out a plurality of workpieces W carried out from the apron 3. When the apron belt 3e rotates in the reverse rotation direction, the plurality of workpieces W are placed on a carry-out conveyor 9 through the above-described door. The carry-out conveyor 9 conveys the plurality of processed workpieces W to an area where a subsequent process is carried out.

[0022] The workpiece processing apparatus 1 is equipped with a bucket 10 and a bucket loader 11 for loading workpieces W into the projection chamber S. The bucket loader 11 is configured to be able to move up and down by a motor or the like, and transports multiple unprocessed workpieces W to the position of the openable lid 2a of the cabinet 2. In this way, the unprocessed workpieces W are loaded into the projection chamber S by the bucket loader 11.

[0023] Each element of the workpiece processing device 1 described above is controlled by the controller 12. The controller 12 is configured, for example, as a PLC (Programmable Logic Controller). The controller 12 may also be configured as a computer system including a processor such as a CPU (Central Processing Unit), memory such as RAM (Random Access Memory) and ROM (Read Only Memory), input / output devices such as a touch panel, mouse, keyboard, and display, and communication devices such as a network card. The controller 12 realizes its functions by operating each piece of hardware under the control of the processor based on a computer program stored in memory.

[0024] The workpiece processing apparatus 1 includes a camera 13 (an example of an image sensor) and a control device 14 to confirm that all of the multiple workpieces W have been removed from the projection chamber S. The camera 13 is an image sensor that captures images of the projection chamber S and generates an image. The camera 13 is supported by a frame 15 arranged in parallel with the cabinet 2 so that the projection chamber S fits within its field of view. For example, the camera 13 captures images of the projection chamber S at the moment the lid 2a of the cabinet 2 opens.

[0025] The control device 14 may be configured as a PLC or as a computer system, similar to the controller 12 described above. Functionally, the control device 14 comprises a control unit 141 and a storage device 142. The control unit 141 is configured to communicate with the camera 13. The control unit 141 is configured to control the imaging timing of the camera 13 and to change the imaging parameters of the camera 13. For example, the control unit 141 may change the camera parameters according to the product being imaged. This improves the accuracy of information regarding the presence or absence of remaining items in the projection room S, which will be described later.

[0026] The storage device 142 pre-stores an image (initial image) that serves as a criterion for determining whether or not a workpiece remains. The initial image is an image generated by the camera 13 of the projection room S in a state where no workpieces W remain. For example, the initial image is acquired when the workpiece processing device 1 is first started up or during maintenance, by the camera 13 capturing an image of the projection room S.

[0027] The control unit 141 acquires an image (inspection image) from the camera 13. The inspection image is an image generated by the camera 13 and is an image of the projection chamber S after the discharge process in which multiple workpieces W are discharged from the projection chamber S. Based on the initial image acquired by referring to the storage device 142 and the inspection image acquired from the camera 13, the control unit 141 outputs information regarding the presence or absence of remaining items in the projection chamber S. The information regarding the presence or absence of remaining items is information indicating whether or not multiple workpieces W remain in the projection chamber S. The information may be in the form of text, images, video, sound, vibration, etc., and is not particularly limited in form. Output of information includes not only a manner in which the data is made recognizable, but also a manner in which it is output to a storage medium and stored.

[0028] The control unit 141 may perform machine learning on multiple initial images and output information regarding the presence or absence of remaining items in the projection room S based on the learning results and the inspection images acquired from the camera 13. For example, if the control unit 141 determines, based on the learning results, that the inspection images are similar to the initial images, it may output information indicating that multiple workpieces W are not remaining in the projection room S.

[0029] The control unit 141 may compare the initial image and the inspection image and output information regarding the presence or absence of remaining items in the projection room. For example, the control unit 141 may compare the feature points of both images to calculate the degree of agreement and output information indicating whether or not multiple workpieces W remain in the projection room S based on the calculated degree of agreement. For example, if the degree of agreement is above a threshold, the control unit 141 outputs information indicating that multiple workpieces W do not remain in the projection room S.

[0030] The control unit 141 may output information regarding the presence or absence of remaining items in the projection chamber S based on the difference information between the initial image and the inspection image. For example, the control unit 141 may generate a difference image using the difference between the pixel values ​​of the initial image and the pixel values ​​of the inspection image as the pixel values, and output information indicating whether or not multiple workpieces W remain in the projection chamber S by determining whether or not an area with pixel values ​​above a predetermined threshold is a product. For example, if there is no area with pixel values ​​above a predetermined threshold, the control unit 141 outputs information indicating that multiple workpieces W do not remain in the projection chamber S.

[0031] As described above, the apron belt 3e is provided with multiple small holes and may also have connecting members. Therefore, the appearance of the apron belt 3e may change depending on the rotation position of the apron belt 3e. The control unit 141 may learn the appearance (brightness, color) of the apron belt 3e according to its rotation position based on multiple initial images. The control unit 141 may correct the inspection image according to the rotation position of the apron belt 3e, apply at least one of the judgment methods described above to the corrected inspection image, and determine whether or not multiple workpieces W remain in the projection chamber S.

[0032] The control unit 141 can also determine the wear of each component that defines the projection chamber S based on the initial image and the inspection image. The image changes when there are remaining parts in the projection chamber S and the image changes due to wear have different feature quantities. The control unit 141 determines the wear of each component that defines the projection chamber S based on the feature quantities of the change in pixel value. This makes it possible to monitor the wear of each component that defines the projection chamber S and to identify the replacement time early, thereby preventing equipment malfunctions that lead to product defects.

[0033] The control unit 141 may store images generated by the camera 13 in the storage device 142. The control unit 141 is configured to communicate with the controller 12 and can obtain operational information of the workpiece processing device 1 and processing information of multiple workpieces W from the controller 12. Operational information may include, for example, operating time, current value of the impeller or conveyor, rotational speed of the impeller, and transport speed of the conveyor. Processing information may include, for example, processing time of workpiece W, ambient temperature, and humidity. The control unit 141 stores at least one of the operational information and processing information in association with the inspection image in the storage device 142. This allows the workpiece processing device 1 to provide the user with a traceability function. In addition, the workpiece processing device 1 can provide reference data for processing similar products, as well as quality control.

[0034] (Work processing method) Figure 2 is a flowchart illustrating the operation of the workpiece processing device. The workpiece processing method shown in Figure 2 is executed by the workpiece processing device 1. It is assumed that the workpiece processing device 1 acquires an initial image before executing the workpiece processing method.

[0035] First, the workers, as part of the work preparation process (step S10), place multiple workpieces W into the bucket 10.

[0036] Next, the controller 12 of the workpiece processing device 1 opens the lid 2a of the cabinet 2 as part of the cabinet opening process (step S12).

[0037] Next, as part of the workpiece loading process (step S14), the controller 12 has the bucket loader 11 transport the bucket 10 and position the bucket 10 at the workpiece loading location. Then, the controller 12 tilts the bucket 10 onto the bucket loader 11 and loads multiple workpieces W into the projection chamber S.

[0038] Next, the controller 12 closes the lid 2a of the cabinet 2 as part of the cabinet closing process (step S16). This seals the projection chamber S of the cabinet 2.

[0039] Next, the controller 12 performs a blasting process (step S18) by projecting abrasive material onto multiple workpieces W. First, the controller 12 operates the apron 3 (forward rotation). This starts agitation of the multiple workpieces W. At the same time, the controller 12 drives the projector 4, screw conveyor 5, bucket elevator 6, and dust collector 8 to supply abrasive material to the projector 4. The projector 4 projects the abrasive material onto the multiple workpieces W that are being agitated. This ensures that the multiple workpieces W are blasted evenly. Furthermore, the screw conveyor 5, bucket elevator 6, and dust collector 8 collect and circulate the abrasive material.

[0040] Once the blasting process (step S18) is complete, the controller 12 performs a projectile discharge process (step S20), which involves stopping the supply of projectile material to the projector 4 and stopping the operation of the projector 4. The controller 12 then rotates the apron belt 3e forward for a predetermined time, causing the projectile material present on the apron belt 3e to be discharged (dropped) through the small holes in the apron belt 3e.

[0041] Next, as part of the workpiece discharge process (step S22), the controller 12 opens the lid 2a of the cabinet 2 and rotates the apron belt 3e in the reverse direction to discharge the multiple workpieces W to the discharge conveyor 9. The discharge conveyor 9 may then begin transporting the processed workpieces W to an area where subsequent processes will be carried out.

[0042] Next, the control unit 141 of the control device 14 performs an imaging process (step S24), instructing the camera 13 to image the projection room S.

[0043] Next, the control unit 141 of the control device 14 determines, as a determination process (step S26), that there are no remaining items in the projection chamber S. The control unit 141 determines that there are no remaining items based on the initial image and the inspection image. If it is determined that there are remaining items (step S26: NO), the control device 14 outputs a signal to the controller 12 to stop the subsequent blast processing as a stop process (step S28). As a result, the subsequent blast processing is stopped. If it is determined that there are no remaining items (step S26: YES), and when the stop process (step S28) is completed, the flowchart shown in Figure 2 ends.

[0044] The controller 12 repeatedly operates the series of processes shown in Figure 2 as one batch. When performing the next batch, the worker or other personnel may supply the blasting material that was lost during the blasting process (the missing amount) to the cabinet 2.

[0045] (Summary of the embodiments) According to the workpiece processing device 1, the projection chamber S is imaged and an image is generated. Based on the initial image, which is an image of the projection chamber S when no workpieces remain, and the inspection image, which is an image of the projection chamber S after the discharge process, information regarding the presence or absence of remaining workpieces in the projection chamber S is output. In this way, the workpiece processing device 1 can output information regarding the presence or absence of remaining workpieces in the projection chamber S based on the image of the projection chamber S, so it is possible to confirm the discharge of workpieces after processing. With conventional workpiece processing devices, when blast processing multiple workpieces W, there is a risk that some of the workpieces W may remain in the projection chamber S after the discharge process. If the next batch is executed with remaining workpieces present, not only will the number of products differ from the plan, but the remaining workpieces will be excessively blast processed, which may cause variations in product quality. When processing multiple products of the same specifications consecutively, it is difficult to determine afterward whether processed workpieces have been mixed in. In contrast, with the workpiece processing device 1, it is possible to confirm that no workpieces remain in the projection chamber S based on the initial image and the inspection image. Therefore, the workpiece processing device 1 can avoid a decrease in product quality.

[0046] Although exemplary embodiments have been described above, the invention is not limited to the exemplary embodiments described above, and various omissions, substitutions, and modifications may be made.

[0047] The workpiece processing apparatus 1 is not limited to a so-called apron-type blasting apparatus, but may also be a drum-type blasting apparatus. The workpiece processing apparatus 1 may also be an apparatus for peening multiple workpieces W.

[0048] The camera 13 is not limited to one. In other words, the workpiece processing device 1 may be equipped with multiple image sensors. By outputting information regarding the presence or absence of remaining items in the projection chamber based on the results of multiple image sensors, the workpiece processing device 1 can improve the accuracy of information regarding the presence or absence of remaining items in the projection chamber S compared to when a single image sensor is used.

[0049] If it is the first operation of the day, the workpiece processing device 1 may generate an inspection image with the camera 13 immediately before the workpiece preparation process (step S10) shown in Figure 2 to determine whether there are any remaining workpieces in the projection chamber S. This allows the workpiece processing device 1 to confirm that there are no remaining workpieces in the projection chamber S before loading the first workpiece of the day.

[0050] To enhance traceability, the workpiece processing apparatus 1 may photograph the projection chamber S immediately after the workpiece loading process (step S14) shown in Figure 2. This allows for retrospective confirmation of the state of multiple workpieces W immediately before processing. Alternatively, to enhance traceability, the workpiece processing apparatus 1 may photograph the projection chamber S immediately before the workpiece discharge process (step S22) shown in Figure 2. This allows for retrospective confirmation of the state of multiple workpieces W immediately after processing. [Explanation of Symbols]

[0051] 1...Work processing device, 2...Cabinet, 3...Apron, 4...Projector, 13...Camera (an example of an image sensor), 14...Control device, 141...Control unit, 142...Storage device, S...Projection room.

Claims

1. A cabinet having a projection chamber for processing multiple workpieces, A projection machine for projecting a projection material onto the plurality of workpieces placed in the projection chamber, An image sensor that captures the projection chamber and generates an image, A control unit outputs information regarding the presence or absence of remaining workpieces in the projection chamber in order to confirm the discharge of the multiple workpieces, based on the difference information between an initial image, which is an image of the projection chamber generated by the image sensor showing no remaining workpieces, and an inspection image, which is an image of the projection chamber after the discharge process in which the multiple workpieces are discharged from the projection chamber, or based on the degree of agreement of feature points between the initial image and the inspection image. A workpiece processing device equipped with the following features.

2. The workpiece processing apparatus according to claim 1, wherein the initial image is an image of the projection chamber captured by the image sensor when the workpiece processing apparatus is first started up or during maintenance.

3. The workpiece processing apparatus according to claim 1 or 2, wherein the control unit stores in a storage device, in association with at least one of the operation information of the workpiece processing apparatus and the processing information of the plurality of workpieces, the inspection image.

4. A workpiece processing method used in a workpiece processing apparatus comprising a cabinet having a projection chamber, a projection machine, an image sensor, and a control unit connected to the image sensor, The image sensor takes an image of the projection chamber when no workpiece remains and generates an initial image. The projection machine performs the steps of projecting a projection material onto multiple workpieces in the projection chamber, The image sensor, after the plurality of workpieces have been discharged from the projection chamber, takes an image of the projection chamber to generate an inspection image. The control unit outputs information regarding the presence or absence of remaining items in the projection chamber in order to confirm the discharge of the multiple workpieces, based on the difference information between the initial image and the inspection image, or based on the degree of agreement of feature points between the initial image and the inspection image. A workpiece processing method comprising:

Images