Inspection and sorting system

An inspection and sorting system sorts conveyed articles. The system is provided with a conveyance device, an X-ray inspection device, and a sorting device. The conveyance device conveys inspection articles. The X-ray inspection device inspects the conveyed inspection articles. The sorting device has an air sorting mechanism that sorts the conveyed inspection articles in a sorting operation. The sorting device has a sorting information receiving component, a reference signal receiving component, and a sorting mechanism control component. The sorting information receiving component receives sorting information relating to the sorting of the inspection articles based on an inspection result of the X-ray inspection device. The reference signal receiving component receives a fixed-interval reference signal relating to the conveyance by the conveyance device. The sorting mechanism control component controls the air sorting mechanism to execute the sorting operation based on the sorting information at a timing adjusted by the reference signal.

CROSS-REFERENCE TO RELATED APPLICATIONS

This U.S. National stage application of PCT/JP2015/072181 claims priority under 35 U.S.C. § 119(a) to Japanese Patent Application No. 2014-163088, filed in Japan on Aug. 8, 2014, the entire contents of which are hereby incorporated herein by reference.

TECHNICAL FIELD

The present invention relates to an inspection and sorting system that inspects articles and sorts the conveyed articles based on the inspection results.

BACKGROUND ART

Conventionally, inspection and sorting systems that inspect articles and sort the conveyed articles based on the inspection results have been known. For example, patent document 1 (Japanese Laid Open Publication No. 2002-362729) discloses an inspection and sorting system which, based on the results of a metal contamination inspection and a weighing inspection, blows air onto articles conveyed on a transport conveyor to thereby sort the articles.

Currently, from the standpoint of improving efficiency, it is desired that inspection and sorting systems sort conveyed articles at a high processing speed and with good precision.

SUMMARY OF INVENTION

Technical Problem

However, inspection and sorting systems have a following problem in the case that articles conveyed from an inspection device is sorted at a high processing speed based on the inspection results sent to a sorting device,

The sorting device receives the inspection results from the inspection device and sorts the articles, but there are cases where, owing to the specifications or the like of the control system of the inspection device, the timing when the sorting device receives the inspection results from the inspection device varies. In such cases, when the sorting device activates a sorting mechanism based on the timing when it received the inspection results, the timing when the sorting mechanism should be activated may be out of sync with the timing when the sorting mechanism actually operates. As a result, situations may occur where articles that should be sorted are not sorted or articles that should not be sorted are sorted and the precision of the sorting is lowered.

This kind of problem can be prevented by sufficiently lengthening the time of the sorting operation of the sorting device and keeping large intervals between the conveyed articles. However, if the system is configured in this way, the number of articles to be processed per unit time is reduced.

It is an object of the present invention to provide an inspection and sorting system that can sort conveyed articles, based on the inspection results, at a high processing speed and with good precision.

Solution to Problem

An inspection and sorting system pertaining to a first aspect of the present invention is provided with a conveying means, an inspection device, and a sorting device. The conveying means is configured to convey articles. The inspection device is configured to inspect the articles conveyed by the conveying means. The sorting device has a sorting mechanism being configured to execute a sorting operation in which the articles conveyed by the conveying means are sorted. The sorting device has a first receiving component, a second receiving component, and a sorting mechanism control component. The first receiving component is configured to receive sorting information relating to the sorting of the articles based on an inspection result of the inspection device. The second receiving component is configured to receive a fixed-interval reference signal relating to the conveyance by the conveying means. The sorting mechanism control component is configured to control the sorting mechanism to execute the sorting operation based on the sorting information at a timing adjusted by the reference signal.

In the inspection and sorting system pertaining to the first aspect, the sorting mechanism executes the sorting operation based on the fixed-interval reference signal relating to the conveyance by the conveying means for adjusting the timing of the execution of the sorting operation as well as the sorting information relating to the sorting. For that reason, the sorting operation can be executed at an appropriate timing regardless of variations in the reception timing of the sorting information. As a result, the articles conveyed from the inspection device can be sorted, based on the inspection results, at a high processing speed and with good precision.

An inspection and sorting system pertaining to a second aspect of the present invention is the inspection and sorting system pertaining to the first aspect, wherein the reference signal is a signal transmitted to the second receiving component each time the conveying means conveys a first distance.

In the inspection and sorting system pertaining to the second aspect, the second receiving component receives the reference signal each time the conveying means conveys a fixed distance. The articles conveyed from the inspection device can be therefore sorted, at a high processing speed and with good precision based on a timing adjusted by the reference signal and the inspection results.

An inspection and sorting system pertaining to a third aspect of the present invention is the inspection and sorting system pertaining to the second aspect, wherein the inspection device is an X-ray inspection device having a line sensor. The line sensor is configured to image, in every single imaging, a predetermined width along a conveyance direction of the conveyance means. The first distance is an integral multiple of the predetermined width.

In the inspection and sorting system pertaining to the third aspect, the reference signal is transmitted each time the conveyance distance of the conveying means becomes equal to the integral multiple of the predetermined width for which the line sensor of the X-ray inspection device images. It is therefore easy to execute the sorting operation at an appropriate timing matching the inspection results of the X-ray inspection.

An inspection and sorting system pertaining to a fourth aspect of the present invention is the inspection and sorting system pertaining to any of the first aspect to the third aspect, wherein the inspection device is configured to inspect the non-defective/defective or rank of the articles.

Here, the articles can be sorted by the sorting device based on the non-defective/defective or rank of the articles.

An inspection and sorting system pertaining to a fifth aspect of the present invention is the inspection and sorting system pertaining to any of the first aspect to the fourth aspect, is further provided with a conveyance checking sensor and a judging component. The conveyance checking sensor is configured to detect the articles on the downstream side of the sorting mechanism in the conveyance direction of the conveying means. The judging component is configured to judge, based on the detection results of the conveyance checking sensor, success or failure of the sorting by the sorting mechanism. The judging component is configured to judge the success or failure of the sorting by the sorting mechanism based on the sorting information and in accordance with whether or not the conveyance checking sensor detects the articles at a check timing adjusted by the reference signal.

In the inspection and sorting system pertaining to the fifth aspect, the sensor which detects the articles conveyed on the downstream side of the sorting mechanism is installed and the success or failure of the sorting is judged based on the sorting information and in accordance with whether or not an article is detected at the check timing adjusted by the reference signal. That is to say, here, the presence or absence of an article is judged at an accurate check timing adjusted by the reference signal in the same way as the timing of the operation of the sorting mechanism, and the success or failure of the sorting is thereby judged. For that reason, the success or failure of the sorting can be judged at a high processing speed and accurately.

An inspection and sorting system pertaining to a sixth aspect of the present invention is the inspection and sorting system pertaining to any of the first aspect to the fifth aspect, wherein the timing is configured to determine based on a fixed delay time determined by a characteristic of the sorting mechanism.

Here, the timing of the sorting operation is determined based on the fixed delay time determined by the characteristic of the sorting mechanism. Therefore, even in a case where the conveyance speed of the conveying means is changed, the sorting operation can be executed at an appropriate timing.

Advantageous Effects of Invention

In the inspection and sorting system pertaining to the present invention, the sorting mechanism executes the sorting operation based on the fixed-interval reference signal relating to the conveyance by the conveying means for adjusting the timing of the execution of the sorting operation as well as the sorting information relating to the sorting. For that reason, the sorting operation can be executed at an appropriate timing regardless of variations in the reception timing of the sorting information. As a result, the articles conveyed from the inspection device can be sorted, based on the inspection results, at a high processing speed and with good precision.

DESCRIPTION OF EMBODIMENTS

Embodiments of an inspection and sorting system pertaining to the present invention will be described below with reference to the drawings. It should be noted that the following embodiments are merely specific examples and can be appropriately changed without departing from the scope of the present invention.

First Embodiment

An inspection and sorting system100pertaining to a first embodiment of the present invention will be described.

(1) Overall Configuration

The inspection and sorting system100pertaining to the first embodiment is a system that inspects inspection articles P (also referred to as articles or articles to be inspected), such as food articles, being conveyed and sorts the inspection articles P based on the inspection results. Specifically, the inspection and sorting system100sorts the inspection articles P so that non-defective articles not contaminated with foreign matter is conveyed to a downstream process (e.g., a boxing process) and defective articles contaminated with foreign matter is removed from the line based on the results of a foreign matter inspection of the inspection articles P.

The inspection and sorting system100is mainly provided with a conveyance device10, an X-ray inspection device20, and a sorting device30(seeFIG. 1).

The conveyance device10receives the inspection articles P conveyed thereto by an upstream conveyor unit60and conveys the received inspection articles P. The arrow A inFIG. 1indicates the conveyance direction of the conveyance device10. The X-ray inspection device20performs a foreign matter inspection of the inspection articles P conveyed by the conveyance device10. The sorting device30executes a sorting operation that sorts the inspection articles P conveyed by the conveyance device10, based on the inspection results of the X-ray inspection device20.

(2) Detailed Configuration

The conveyance device10, the X-ray inspection device20, and the sorting device30of the inspection and sorting system100will be described below in detail.

The conveyance device10(also referred to as a conveying device) is an example of conveying means that conveys the inspection articles P. The conveyance device10receives the inspection articles P conveyed thereto by the upstream conveyor unit60and conveys the inspection articles P in such a way that the inspection articles P pass through a later-described shield box21of the X-ray inspection device20. Furthermore, the conveyance device10conveys the inspection articles P that have passed through the shield box21to the sorting device30on the downstream side of the X-ray inspection device20. More specifically, the conveyance device10conveys the inspection articles P that have passed through the shield box21so that those inspection articles P pass through the neighborhood of an air sorting mechanism31of the sorting device30described later. Moreover, the conveyance device10conveys inspection articles P that are not sorted by the air sorting mechanism31of the sorting device30(inspection articles P being judged to be non-defective articles as a result of the inspection) further downstream.

The conveyance device10mainly has an endless conveyor belt11(seeFIG. 3), a drive roller (not shown in the drawings), and a conveyor motor12(seeFIG. 4). Since drive rollers for endless conveyor belts are convention mechanical devices, further description is omitted for the sake of brevity.

The drive roller (not shown in the drawings) is driven by the conveyor motor12. When the drive roller is driven, the conveyor belt11rotates so that the inspection articles P placed on the conveyor belt11are conveyed.

The conveyor motor12is an inverter-controllable motor. Since inverter-controllable motors are conventional electro-mechanical devices well known in the art, further description is omitted for the sake of brevity. The conveyor motor12is inverter-controlled by a command from a controller24of the X-ray inspection device20described later, so that the rotational speed of the drive roller is adjusted. As a result, the conveyance speed of the inspection articles P placed on the conveyor belt11is finely and precisely controlled for synchronized movement control with operation of the sorting device30, as described further below. An encoder13is attached to the conveyor motor12. The encoder13detects the conveyance distance and conveyance speed of the inspection articles P by the conveyance device10and sends them to the controller24of the X-ray inspection device20and a controller33of the sorting device30(seeFIG. 4).

It should be noted that the conveyance device10may have one conveyor belt11, one drive roller, and one conveyor motor12, or may have a plurality of conveyor belts11, and/or a plurality of drive rollers, and/or a plurality of conveyor motors12.

The X-ray inspection device20is an example of an inspection device that inspects the inspection articles P conveyed by the conveyance device10. The X-ray inspection device20irradiates X-ray to the inspection articles P continuously conveyed by the conveyance device10to perform an inspection as to whether or not the inspection articles P are contaminated with foreign matter based on the amount of X-ray that has transmitted through the inspection articles P.

The X-ray inspection device20mainly has the shield box21(seeFIG. 2), an X-ray emitter22(seeFIG. 3), a line sensor23(seeFIG. 3), a monitor25having a touch panel function (seeFIG. 2), and the controller24(seeFIG. 4).

Each configuration of the X-ray inspection device20will be described below. It should be noted that when describing positional relationships or the like in the description of the X-ray inspection device20below, the expressions such as “front (front face),” “rear (back face),” “left,” “right,” “upper,” and “lower” may be used, and unless otherwise specified these express “front (front face),” “rear (back face),” “left,” “right,” “upper,” and “lower” in accordance with the arrows inFIG. 2.

(2-2-1) Shield Box

The shield box21is a casing that accommodates the X-ray emitter22, the line sensor23, the controller24, and the like. Furthermore, the monitor25, a key insertion opening, a power switch, and the like are disposed in the upper front portion of the shield box21(seeFIG. 2). Openings21aare formed in the left and right side faces of the shield box21(seeFIG. 2).

The conveyor belt11of the conveyance device10is disposed inside the shield box21. Specifically, the conveyor belt11is disposed through the openings21aformed in both side faces of the shield box21. The opening21aon the upstream side in the conveyance direction of the conveyor belt11functions as an inlet through which the inspection articles P conveyed by the conveyor belt11are conveyed into the shield box21. The opening21aon the downstream side in the conveyance direction of the conveyor belt11functions as an outlet through which the inspection articles P conveyed by the conveyor belt11are conveyed out from the shield box21. It should be noted that the openings21aare closed off by shield curtains26in order to prevent leakage of X-ray to the outside of the shield box21(seeFIG. 2). The shield curtains26are made of rubber including lead, tungsten, or the like. The shield curtains26are pushed out of the way by the inspection articles P when the inspection articles P are conveyed in and out through the openings21a.

The X-ray emitter22is disposed above the conveyor belt11inside the shield box21(seeFIG. 3). The X-ray emitter22emits X-ray, in a fan-shaped emission range Y (see the section with the hatching inFIG. 3), toward the line sensor23disposed under the conveyance surface of the conveyor belt11. The emission range Y of the X-ray radiation of the X-ray emitter22extends orthogonally to the conveyance surface of the inspection articles P of the conveyor belt11. Furthermore, the emission range Y spreads in a fan shape in a direction intersecting the conveyance direction (see the arrow A inFIG. 3) of the conveyor belt11. In other words, the X-ray radiation emitted from the X-ray emitter22spreads in the width direction of the conveyor belt11.

(2-2-3) Line Sensor

The line sensor23is disposed below the conveyance surface of the conveyor belt11and detects the X-ray transmitted through the inspection articles P and/or the conveyor belt11. The line sensor23mainly has numerous X-ray detection elements23a. The X-ray detection elements23aare horizontally disposed in a straight line orthogonal to the conveyance direction (see the arrow A inFIG. 3) of the conveyor belt11or in other words along the width direction of the conveyor belt11(seeFIG. 3).

Each X-ray detection element23adetects the X-ray transmitted through the inspection articles P and/or the conveyor belt11and outputs an X-ray transmission signal based on the detected X-ray transmission amount (X-ray intensity). The X-ray transmission signals are sent to the controller24and used for creating X-ray images of the inspection articles P. The controller24performs a foreign matter contamination inspection of the inspection articles P based on the X-ray images created on the basis of the X-ray transmission signals or in other words created on the basis of the X-ray transmission amounts.

Furthermore, the line sensor23also functions as a sensor for detecting the timing when the inspection article P passes through the fan-shaped X-ray emission range Y (seeFIG. 3). Specifically, when the inspection article P conveyed by the conveyor belt11reaches the position above the line sensor23(the emission range Y), the line sensor23outputs an X-ray transmission signal (a first signal) representing a voltage equal to or less than a predetermined threshold value. On the other hand, in a case where the inspection article P is not passing through the emission range Y, the line sensor23outputs an X-ray transmission signal (a second signal) representing a voltage exceeding the predetermined threshold value. The first signal and the second signal are input to the controller24to thereby detect the presence or absence of the inspection article P in the emission range Y. It should be noted that the predetermined threshold value is a value set arbitrarily in order to determine the presence or absence of the inspection article P.

The monitor25is a liquid crystal display. The monitor25displays the X-ray images of the inspection articles P, the inspection results of the inspection articles P, and the like. The monitor25also has a touch panel function and receives the input of inspection parameters and so forth by an operator.

The controller24is a computer that controls each part of the X-ray inspection device20. The controller24mainly has a central processing unit (CPU) that performs calculation and control, a read-only memory (ROM), a random access memory (RAM), a hard disk, and the like that serve as storage components storing information. The controller24preferably includes a microcomputer with an inspection device and article sorting control program that controls the various components of the inspection and sorting system100as discussed herein. The controller24can also include other conventional components such as an input interface circuit and an output interface circuit. The memory circuit stores processing results and control programs such as ones for conveyance, sorting and X-ray operations that are run by a processor circuit of the system. The controller24is operatively coupled to the inspection and sorting system100in a conventional manner. The internal RAM of the controller24stores statuses of operational flags and various control data. The controller24is capable of and configured to selectively control any of the components of the control system. It will be apparent to those skilled in the art from this disclosure that the precise structure and algorithms for the controller24can be any combination of hardware and software that carries out the functions of the present invention.

The controller24has a sorting information sending component24aand a reference signal sending component24bthat send information/signals to the controller33of the sorting device30described later (seeFIG. 4). Furthermore, the controller24has a storage component24cand a control component24d(seeFIG. 4). The control component24dmainly has a CPU and executes a program stored in the storage component24cto thereby generate the X-ray images and determine, based on the generated X-ray images, whether or not the inspection articles P are contaminated with foreign matter. Furthermore, the control component24dcontrols the operation of each part of the X-ray inspection device20, such as the X-ray emitter22and the line sensor23. The various inspection parameters used in the foreign matter inspection, the results of the foreign matter inspection of the inspection articles P, and later-described unit sorting information d generated by the control component24dare stored in the storage component24c.

The controller24is electrically connected to the X-ray emitter22, the line sensor23, and the monitor25. Furthermore, the controller24is also electrically connected to the conveyor motor12and the encoder13of the conveyance device10(seeFIG. 4). The controller24acquires data relating to the rotation speed of the conveyor motor12from the encoder13and grasps, based on the acquired data, the conveyance distance and conveyance speed of the inspection articles P.

Furthermore, the controller24is connected to the controller33of the sorting device30by a communication line90such as the Internet in order to send later-described sorting information D to the sorting device30. Moreover, the controller24is connected to the controller33of the sorting device30by a dedicated signal line91in order to send a later-described reference signal S to the sorting device30.

The controller24detects the timings when the inspection articles P pass over the line sensor23based on the X-ray transmission signals sent from the line sensor23. When the inspection articles P pass through the fan-shaped X-ray emission range Y, the controller24acquires, for each fixed moving distance of the inspection articles P (each imaging width u), the X-ray transmission signals corresponding to that moving distance (equivalent to one line) from the line sensor23. In a case where the moving speed of the inspection articles P (the conveyance speed of the conveyance device10) is fixed, the controller24acquires from the line sensor23the X-ray transmission signals at every fixed time interval. Additionally, the controller24, particularly the control component24d, creates the X-ray images of the inspection articles P based on the X-ray transmission signals acquired from the line sensor23.

The control component24dimage-processes the X-ray images and judges, by plural judgment methods, the non-defective/defective of the inspection articles P (whether or not the inspection articles P are contaminated with foreign matter). Examples of the judgment methods include the trace detection method, the binarization detection method, and the mask binarization detection method. For example, the trace detection method is a method in which a threshold value is set beforehand along the approximate thickness of the inspection articles P and the inspection article P is judged being contaminated with foreign matter in a case where a region that appears darker than the threshold value exists in an X-ray image. For example, the binarization detection method is a method in which the inspection article P is judged being contaminated with foreign matter in a case where a region that appears darker than a threshold value set beforehand exists in an X-ray image of the inspection article P.

Moreover, the control component24dgenerates, based on the results of the foreign matter inspection, unit sorting information d relating to the sorting of the inspection articles P for a segment with a predetermined width L along the conveyance direction of the conveyance device10. The unit sorting information d is information representing the positions of inspection articles P contaminated with foreign matter on the conveyance surface of the conveyor belt11that has passed over the line sensor23in a period from the rise to the fall of a later-described reference signal S outputted by the reference signal sending component24bor in a period from the fall to the rise of the reference signal S. As described later, the reference signal S is a signal that is switched on or off each time the conveyance distance of the conveyance device10becomes equal to the width L (a distance equivalent to N lines of single imaging width u of the line sensor23).

This will be specifically described usingFIG. 5. For example, it is supposed that inspection articles P are placed like inFIG. 5(b)on the conveyor belt11that has passed over the line sensor23in a period from the fall to the rise of the reference signal S. Additionally, it is also supposed that the control component24dhas judged that the inspection articles P to which diagonal lines are added inFIG. 5(b)are contaminated with foreign matter.

In this case, the control component24ddivides the width L into N sections (divides the width L by every single imaging width u of the line sensor23) and determines whether or not there exists, in each of the sections into which the width L is divided, the inspection article P judged as being contaminated with foreign matter. Then, the control component24duses the determination results to generate unit sorting information d where each of the sections into which the width L has been divided is expressed as one bit (seeFIG. 5(a)). In the unit sorting information d, a bit expressed as “1” represents that an inspection article P contaminated with foreign matter exists in the position corresponding to that bit. On the other hand, a bit expressed as “0” represents that an inspection article P contaminated with foreign matter does not exist in the position corresponding to that bit.

The generated unit sorting information d is stored in the storage component24cof the controller24. Furthermore, when the unit sorting information d is generated, the sorting information sending component24asends, via the communication line90, sorting information D to the controller33of the sorting device30described later. The sorting information D is information, relating to the sorting of the inspection articles P, in which the unit sorting information d that has just been generated and plural (in the present embodiment, four) sets of unit sorting information d of segments on the downstream side of the generated unit sorting information d as viewed from the conveyance direction of the conveyance device10are connected together. That is to say, the sorting information D is information representing the positions of inspection articles P contaminated with foreign matter in an interval spanning a distance of five times the width L.

In the present embodiment, the sorting information D is information for an interval spanning a distance of five times the width L because a distance of five times the width L is substantially equal to the distance, as seen in a plan view, from the line sensor23to a nozzle32of the air sorting mechanism31of the sorting device30described later. However, in actuality the distance from the line sensor23to the nozzle32is given by (width L×5+delay adjustment width α). The reason why the distance from the line sensor23to the nozzle32is not a distance of five times the width L but deviates therefrom by the delay adjustment width α will be described later.

It should be noted that the distance from the line sensor23to the nozzle32of the air sorting mechanism31is an exemplification and is not limited to this. For example, the distance from the line sensor23to the nozzle32of the air sorting mechanism31may also be (M (where M is an arbitrary integer) times the width L+delay adjustment width α). In this case, the sorting information D may be information of an interval spanning a distance of M times the width L.

(2-2-5-1) Reference Signal Sending Component

The reference signal sending component24boutputs a fixed-interval reference signal S relating to the conveyance by the conveyance device10. The transmission of the reference signal S by the reference signal sending component24bis a process performed independently of the process of the foreign matter inspection.

The reference signal sending component24bswitches on/off of the reference signal S, based on the data that the controller24acquires from the encoder13, each time the conveyance distance of the conveyance device10becomes equal to the predetermined width L (a distance equivalent N lines of single imaging widths u of the line sensor23). That is to say, when the conveyance device10starts driving and conveys the conveyor belt11a distance equal to the width L, the reference signal sending component24bsends the reference signal S from that point in time until the conveyance device10further conveys the conveyor belt11a distance equal to the width L. Thereafter, the reference signal sending component24bstops sending the reference signal S and stands by until the conveyance device10further conveys the conveyor belt11a distance equal to the width L, and when the conveyance device10finishes conveying the conveyor belt11a distance equal to the width L, the reference signal sending component24bagain starts sending the reference signal S. The reference signal sending component24brepeatedly performs these operations. That is to say, the reference signal S is a signal which, each time the conveyance device10conveys the conveyor belt11a distance of two times the width L, is transmitted while the conveyance device10conveys the conveyor belt11a distance equal to the width L. In other words, the reference signal S is a signal that is switched on or off each time the conveyance distance of the conveyance device10becomes equal to the width L.

The reference signal S is, as described above, a signal transmitted independently of the process of the foreign matter inspection. The reference signal sending component24btherefore transmits the reference signal S without any lag (without the reference signal S being advanced or delayed) relative to the conveyance distance of the conveyor belt11.

The sorting device30is a device that sorts the inspection articles P based on the results of the foreign matter inspection by the X-ray inspection device20. Specifically, the sorting device30is a device that removes, from the conveyor belt11of the conveyance device10, inspection articles P judged as being contaminated with foreign matter as a result of the foreign matter inspection by the X-ray inspection device20.

The sorting device30mainly has the air sorting mechanism31and the controller33(seeFIG. 4).

(2-3-1) Air Sorting Mechanism

The air sorting mechanism31is an example of a sorting mechanism that executes a sorting operation that sorts the inspection articles P conveyed by the conveyance device10. The air sorting mechanism31sorts the inspection articles P conveyed by the conveyor belt11upon receiving a command from a sorting mechanism control component33dof the controller33.

The air sorting mechanism31mainly has the nozzle32(seeFIG. 1) and an electromagnetic valve (not shown in the drawings) that opens and closes an air pathway that supplies high-pressure air to the nozzle32. Since electromagnetic valves are convention electro-mechanical devices, further description is omitted for the sake of brevity.

The nozzle32is attached diagonally above the conveyance surface of the conveyor belt11of the conveyance device10. The nozzle32is attached so as to discharge the high-pressure air in a direction intersecting the conveyance direction of the conveyance device10, particularly a direction orthogonal to the conveyance direction, as viewed in a plan view. When the electromagnetic valve is opened by a command from the sorting mechanism control component33d, the high-pressure air comes out from the nozzle32onto the inspection article P on the conveyor belt11and the inspection article P is removed to the outside of the conveyor belt11(e.g., to the inside of a box placed under the conveyor belt11).

It should be noted that, from the time when the air sorting mechanism31receives the command to discharge the high-pressure air from the sorting mechanism control component33dto until the time when the air sorting mechanism31actually blows out the air, the operation of the air sorting mechanism31is delayed a fixed amount of time Td due to individual response characteristics and tolerances of the air sorting mechanism31(e.g., the response characteristics and tolerances of the electromagnetic valve).

The controller33is a computer that controls each part of the sorting device30. The controller has a CPU that performs calculation and control, a ROM, a RAM, a hard disk and the like that serve as storage components storing information.

The controller33has a sorting information receiving component33aand a reference signal receiving component33bthat receive information/signals from the controller24of the X-ray inspection device20(seeFIG. 4). Furthermore, the controller33has a storage component33cand a sorting mechanism control component33d(seeFIG. 4). The sorting mechanism control component33dmainly has a CPU and executes a program stored in the storage component33cto thereby cause the air sorting mechanism31to execute the sorting operation that sorts the inspection articles P. The storage component33cstores the program executed by the sorting mechanism control component33dand various types of information. The storage component33cincludes a sorting information storage region33ca, which stores the sorting information D sent from the X-ray inspection device20, and a sorting operation storage region33cb, which is used when the sorting mechanism control component33dcauses the air sorting mechanism31to execute the sorting operation. The information stored in the sorting operation storage region33cbis the aforementioned unit sorting information d.

The controller33is electrically connected to the air sorting mechanism31. Furthermore, the controller33is also electrically connected to the encoder13of the conveyance device10(seeFIG. 4). The controller33acquires data relating to the rotation speed of the conveyor motor12from the encoder13and grasps, based on the acquired data, the conveyance distance and conveyance speed of the inspection articles P.

Furthermore, the controller33is connected to the controller24of the X-ray inspection device20by the communication line90in order to receive the sorting information D (seeFIG. 4). Moreover, the controller33is connected to the controller24of the X-ray inspection device20by the signal line91in order to receive the reference signal S from the controller24of the X-ray inspection device20(seeFIG. 4).

(2-3-2-1) Sorting Information Receiving Component

The sorting information receiving component33ais an example of a first receiving component. The sorting information receiving component33areceives the sorting information D, which relates to the sorting of the inspection articles P based on the inspection results of the X-ray inspection device20and is sent by the sorting information sending component24aof the controller24of the X-ray inspection device20. The sorting information D sent by the sorting information sending component24ais, as described above, information where five sets of the unit sorting information d are connected together. As described above, because the unit sorting information d is N bits of information, the sorting information D sent by the sorting information sending component24ais (N×5) bits of information. When the sorting information receiving component33areceives the sorting information D, the sorting information D is stored in the sorting information storage region33ca.

It should be noted that the timing when the sorting information receiving component33areceives the sorting information D is not fixed each time. This is, for example, because variations arise in the execution time of the foreign matter inspection necessary for the generation of the unit sorting information d by the control component24dof the controller24.

As described above, the sorting information D is information where the five sets of unit sorting information d that have been most recently generated are connected together. For example, it is supposed that at a certain point in time the sorting information receiving component33areceives sorting information D including sets of unit sorting information d1, d2, d3, d4, and d5. It should be noted that, here, the sets of unit sorting information are denoted in such a way that the smaller the integer added thereto is older (the further downstream in the conveyance direction) set of unit sorting information. In this case, the sorting information D that the sorting information receiving component33awill receive the next time is sorting information D including sets of unit sorting information d2, d3, d4, d5, and d6. That is to say, the sorting information D that the sorting information receiving component33areceives at a certain point in time includes information redundant with the sorting information D that the sorting information receiving component33ahas received before.

With this configuration, even if a communication error were to occur so that at a certain timing the sorting information storage region33careceives incomplete sorting information D (in which some unit sorting information d is missing), the missing information can be compensated with the sorting information D that the sorting information storage region33cahave received in the past or that the sorting information storage region33cawill receive from the next time on.

(2-3-2-2) Reference Signal Receiving Component

The reference signal receiving component33breceives the fixed-interval reference signal S relating to the conveyance by the conveyance device10. The reference signal S is, as described above, a signal which, each time the conveyance device10conveys the conveyor belt11a distance of two times the width L, is transmitted while the conveyance device10conveys the conveyor belt11a distance equal to the width L. It should be noted that in a case where the conveyance speed of the conveyance device10is fixed, the reference signal S is a signal sent from the reference signal sending component24beach fixed amount of time.

(2-3-2-3) Storage Component

(2-3-2-3-1) Sorting Information Storage Region

The sorting information D received by the sorting information receiving component33ais stored in the sorting information storage region33ca. The sorting information D is, as described above, (N×5) bits of information where five sets of the unit sorting information d are connected together. When the sorting information receiving component33areceives the sorting information D, the content stored in the sorting information storage region33cais rewritten to the received (most recent) sorting information D.

(2-3-2-3-2) Sorting Operation Storage Region

The set of unit sorting information d furthest downstream in the conveyance direction of the conveyance device10, or in other words the oldest N bits of information in terms of the time series, in the sorting information D stored in the sorting information storage region33cais written to the sorting operation storage region33cbby a sorting operation storage rewriting component33daof the sorting mechanism control component33ddescribed later and stored in the sorting operation storage region33cb. The content of the sorting operation storage region33cbis rewritten at a timing adjusted by the reference signal S received by the reference signal receiving component33b.

(2-3-2-4) Sorting Mechanism Control Component

The sorting mechanism control component33dcontrols the air sorting mechanism31to execute the sorting operation based on the sorting information D received by the sorting information receiving component33aat a timing adjusted by the reference signal S received by the reference signal receiving component33b.

The sorting mechanism control component33dmainly has, as sub-function components, a sorting operation storage rewriting component33daand a command generating component33db(seeFIG. 4).

(2-3-2-4-1) Sorting Operation Storage Rewriting Component

The sorting operation storage rewriting component33darewrites the content stored in the sorting operation storage region33cbbased on the sorting information D stored in the sorting information storage region33caat a timing adjusted by the reference signal S received by the reference signal receiving component33b. As described later, when the content of the sorting operation storage region33cbis rewritten, the command generating component33dbstarts, at that timing, the control of the air sorting mechanism31based on the rewritten content. Therefore, the timing of the rewriting of the content of the sorting operation storage region33cbdetermines the timing of the sorting operation of the air sorting mechanism31.

The timing when the sorting operation storage rewriting component33darewrites the information in the sorting information storage region33cawill be described in detail.

First, an operation delay of the air sorting mechanism31will be described. It is supposed that the air sorting mechanism31operates without delay when it receives a command to operate. In this case, the sorting mechanism control component33dcan send the command to discharge air to the air sorting mechanism31at the moment when the inspection article P to be sorted (contaminated with foreign matter) is conveyed in front of the nozzle32.

However, in actuality, as described above, the air discharge operation is delayed owing to the activation time of the electromagnetic valve that switches between supplying and stopping the supply of the high-pressure air or the like. For that reason, the sorting mechanism control component33dneeds to send the command to discharge air to the air sorting mechanism31before the inspection article P to be sorted is conveyed in front of the nozzle32. Therefore, the sorting device30is given, for controlling the air sorting mechanism31, sorting information D prepared such that in a case where it is supposed that the air sorting mechanism31could operate without delay when it receives a command to operate, air would be discharged from the nozzle32when the inspection article P to be sorted passes a point located before the actual position of the nozzle32by the delay adjustment width α when controlling the air sorting mechanism31based on the sorting information D.

It should be noted that the delay adjustment width α is determined in such a way that, in a case where the conveyance speed of the conveyance device10is set to a maximum conveyance speed Vmax, by sending the air discharge command to the air sorting mechanism31when the inspection article P to be sorted is being conveyed at the point located before the position of the nozzle32by the delay adjustment width α in the conveyance direction, air will be discharged to the inspection article P to be sorted when that inspection article P passes in front of the nozzle32.

The delay time Td, determined by the characteristics of the air sorting mechanism31, from when the command to execute the sorting operation is received to when the sorting operation is actually executed is constant regardless of the conveyance speed of the conveyance device10. The sorting operation storage rewriting component33dadetermines, based on the fixed delay time Td determined by the characteristics of the air sorting mechanism31, the timing when it rewrites the information in the sorting information storage region33ca. It should be noted that the delay time Td is given by (delay adjustment width α/maximum conveyance speed Vmax).

For example, in a case where the conveyance speed of the conveyance device10acquired based on the data sent from the encoder13is the maximum conveyance speed Vmax, the sorting operation storage rewriting component33darewrites the information in the sorting information storage region33caat the timing when the reference signal S received by the reference signal receiving component33brises (when the reference signal switches from off to on) or when the reference signal S falls (when the reference signal switches from on to off).

For example, in a case where the conveyance speed of the conveyance device10acquired based on the data sent from the encoder13is a conveyance speed V (V<Vmax), the sorting operation storage rewriting component33darewrites the information in the sorting information storage region33caafter the elapse of {(delay adjustment width α/conveyance speed V)−delay time Td} from the point in time when the reference signal S received by the reference signal receiving component33brises or falls.

(2-3-2-4-2) Command Generating Component

The command generating component33dbgenerates a command to the air sorting mechanism31using the content stored in the sorting operation storage region33cband sends the command to the air sorting mechanism31. Specifically, at the timing when the content of the sorting operation storage region33cbis rewritten, the command generating component33dbgenerates a command for the air sorting mechanism31and sends the command to the air sorting mechanism31, so that the air sorting mechanism31executes the operation according to the time series information stored in the sorting operation storage region33cbin order starting from the beginning of the time series. This will be described specifically below.

As described above, the information written in the sorting operation storage region33cbis the unit sorting information d generated by the X-ray inspection device20, and is N bits of binary information. When the value of the bit is “1”, the command generating component33dbgenerates a command to discharge air and sends it to the air sorting mechanism31. When the value of the bit is “0”, the command generating component33dbgenerates a command prohibiting the discharge of air and sends it to the air sorting mechanism31. It should be noted that the time in which the air sorting mechanism31discharges air or prohibits the discharge of air based on each bit of information is the time in which the conveyance device10conveys the inspection article P by a distance given by (width L/N) or in other words by a single imaging width u of the line sensor23. That is to say, the time in which the air sorting mechanism31discharges air or prohibits the discharge of air based on each bit of information is a time obtained by dividing the distance given by (width L/N) by the conveyance speed V of the conveyance device10. It should be noted that the width L here is, as described above, a predetermined distance along the conveyance direction of the conveyance device10for which the control component24dof the X-ray inspection device20generates a unit sorting information d. N is the number of bits of the unit sorting information d.

This will be described by way of a specific example. For example, it is supposed that the information shown inFIG. 5(a)has been written in the sorting operation storage region33cb. It should be noted that, inFIG. 5(a), the further to the right the information is, the further downstream the information is in the conveyance direction. In this case, the value of the first bit from the rightmost is “0”, so the command generating component33dbgenerates a command prohibiting the discharge of air from the air sorting mechanism31for a time (width L/(N×conveyance speed V)) obtained by dividing the distance given by (width L/N) by the conveyance speed V of the conveyance device10. Next, the value of the second bit from the rightmost is “1”, so the command generating component33dbgenerates a command causing the air sorting mechanism31to execute air discharge for a time (width L/(N×conveyance speed V)). The command generating component33dbexecutes this process in succession until it finishes generating a command based on the value of the Nth bit from the rightmost or the information in the sorting operation storage region33cbis updated next.

(3) Process Executed by Sorting Device

The process executed by the sorting device30, and particularly the process of rewriting the sorting information storage region33caand the sorting operation storage region33cb, will be described usingFIG. 6.

First, as a premise, it is supposed that at a given time (point in time t0inFIG. 6) the sorting information D1including the sets of unit sorting information d1to d5is stored in the sorting information storage region33ca. It should be noted that the smaller the numbers added to the sets of unit sorting information d1to d5are, the further downstream the information is in the conveyance direction of the conveyance device10(in other words, the older the information is). Furthermore, it is supposed that at the point in time t0inFIG. 6the sorting mechanism control component33ddetects the rise of the reference signal S (expressed as Son inFIG. 6) received by the reference signal receiving component33b. It should be noted that, here, it is supposed that the conveyance speed of the conveyance device10is fixed at the conveyance speed V.

In this case, the sorting operation storage rewriting component33darewrites the content of the sorting operation storage region33cbfrom the unit sorting information d0that has been stored until then to the oldest set of unit sorting information d1in the sorting information D1at time t1after the elapse of {(delay adjustment width α/conveyance speed V)−delay time Td} (hereinafter, the value of {(delay adjustment width α/conveyance speed V)−delay time Td} will be expressed as Δt) from t0when the rise of the reference signal S is detected. When the content of the sorting operation storage region33cbis rewritten, the command generating component33dbstarts controlling the air sorting mechanism31in accordance with the newly rewritten unit sorting information d1at the timing of the rewriting of the sorting operation storage region33cb.

Thereafter, at a given time t2, the sorting information receiving component33areceives sorting information D2including sets of unit sorting information d2to d6. At this time, the content of the sorting information storage region33cais rewritten from the sorting information D1to the newly received sorting information D2. At this time, the content of the sorting operation storage region33cbis not changed. In this way, the timing of the reception of the sorting information D does not affect the timing of the rewriting of the sorting operation storage region33cb. Therefore, even if the timing of the reception of the sorting information D varies, this does not affect the timing when the sorting device30executes the sorting operation of the inspection articles P.

Next, when at a given time t3the fall of the reference signal S (expressed as Soff inFIG. 6) received by the reference signal receiving component33bis detected, at time t4after the elapse of Δt from the time t3, the content of the sorting operation storage region33cbis rewritten from the unit sorting information d1that has been stored until then to the oldest set of unit sorting information d2in the sorting information D2stored in the sorting information storage region33ca. When the content of the sorting operation storage region33cbis switched, the command generating component33dbstarts controlling the air sorting mechanism31in accordance with the newly rewritten unit sorting information d2at the timing of the rewriting of the sorting operation storage region33cb.

As what follows thereafter is similar, description thereof will be omitted.

It should be noted that, here, because it is supposed that the conveyance speed of the conveyance device10is fixed at the conveyance speed V, the rise or fall of the reference signal S that is switched on or off each time the conveyance distance of the conveyance device10becomes equal to the width L occurs at a fixed time interval. Therefore, in a case where the conveyance speed V is not changed, a reference signal S sent at fixed conveyance time interval may be used instead. Furthermore, because the conveyance speed of the conveyance device10is fixed at the conveyance speed V, Δt also becomes a fixed value.

However, the conveyance speed of the conveyance device10does not need to be fixed, and the conveyance speed of the conveyance device10may vary. In a case where the conveyance speed varies, the rise or fall of the reference signal S does not occur at a fixed time interval, and the rise or fall of the reference signal S is detected each time the conveyance distance of the conveyance device10becomes equal to the width L. Furthermore, in a case where the conveyance speed of the conveyance device10is not fixed, Δt becomes appropriately changed.

The inspection and sorting system100pertaining to the first embodiment is provided with the conveyance device10serving as an example of a conveying means, the X-ray inspection device20serving as an example of an inspection device, and the sorting device30. The conveyance device10conveys the inspection articles P (articles). The X-ray inspection device20inspects the inspection articles P conveyed by the conveyance device10. The sorting device30has the air sorting mechanism31that executes the sorting operation in which the inspection articles P conveyed by the conveyance device10are sorted. The air sorting mechanism31is an example of a sorting mechanism. The sorting device30has the sorting information receiving component33aserving as an example of a first receiving component, the reference signal receiving component33bserving as example of a second receiving component, and the sorting mechanism control component33d. The sorting information receiving component33areceives the sorting information D relating to the sorting of the inspection articles P based on the inspection results of the X-ray inspection device20. The reference signal receiving component33breceives the fixed-interval reference signal S relating to the conveyance by the conveyance device10. The sorting mechanism control component33dcontrols the air sorting mechanism31to execute the sorting operation based on the sorting information D at a timing adjusted by the reference signal S.

In this inspection and sorting system100, the air sorting mechanism31executes the sorting operation based on the fixed-interval reference signal S relating to the conveyance by the conveyance device10for adjusting the timing of the execution of the sorting operation as well as the sorting information relating to the sorting. For that reason, the sorting operation can be executed at an appropriate timing regardless of variations in the reception timing of the sorting information D. As a result, the inspection articles P conveyed from the X-ray inspection device20can be sorted, based on the inspection results, at a high processing speed and with good precision.

It should be noted that it is also conceivable to provide a separate photoelectric sensor or the like as another measure to adjust the timing of the execution of the sorting operation. However, for example, in a case where there are variations in the height of the inspection articles P, chattering of the photoelectric sensor is often caused if the inspection articles P are detected with the photoelectric sensor and the inspection articles P to be sorted may be misidentified. Furthermore, providing a separate photoelectric sensor leads to an increase in the manufacturing cost of the inspection and sorting system. In that respect, in the inspection and sorting system100of the above embodiment, it is easy to suppress the occurrence of misidentification of the inspection articles P to be sorted because the sorting operation of the air sorting mechanism31is not affected by the height of the inspection articles P.

In the inspection and sorting system100pertaining to the above embodiment, the reference signal S is a signal transmitted to the reference signal receiving component33bwhile the conveyance device10conveys the width L, each time the conveyance device10conveys a distance (a first distance) of two times the width L.

Here, the reference signal receiving component33breceives the reference signal S each time the conveyance device10conveys a fixed distance. The inspection articles P conveyed from the X-ray inspection device20can be therefore sorted at a high processing speed and with good precision based on a timing adjusted by the reference signal S and the inspection results of the X-ray inspection device20.

In the inspection and sorting system100pertaining to the above embodiment, the X-ray inspection device20has the line sensor23. The line sensor23images, in every single imaging, a predetermined width (the imaging width u) along the conveyance direction of the conveyance device. The distance (the first distance) of two times the width L is an integral multiple of the predetermined width. Specifically, the distance of two times the width L is N×2 times the imaging width u.

Here, the reference signal S is sent each time the conveyance distance of the conveyance device10becomes equal to the integral multiple of the predetermined width (the imaging width u) for which the line sensor23of the X-ray inspection device20images. It is therefore easy to execute the sorting operation at an appropriate timing matching the inspection results of the X-ray inspection.

In the inspection and sorting system100pertaining to the above embodiment, the X-ray inspection device20inspects the non-defective/defective of the inspection articles P by performing a foreign matter inspection of the inspection articles P.

Here, the inspection articles P can be sorted by the sorting device30based on the non-defective/defective of the inspection articles P.

In the inspection and sorting system100pertaining to the above embodiment, the timing when the air sorting mechanism31executes the sorting operation based on the sorting information D is determined based on the fixed delay time Td determined by the characteristics of the air sorting mechanism31. Specifically, the timing is adjusted from the point in time of the rise or fall of the reference signal S by a time calculated as {(delay adjustment width α/conveyance speed V of conveyance device10)−delay time Td}.

Here, the timing of the sorting operation of the air sorting mechanism31is determined based on the fixed delay time Td determined by the characteristics of the air sorting mechanism31. Therefore, even in a case where the conveyance speed V of the conveyance device10is changed, the sorting operation can be executed at an appropriate timing.

Second Embodiment

An inspection and sorting system200pertaining to a second embodiment of the present invention will be described.

(1) Overall Configuration

The inspection and sorting system200pertaining to the second embodiment is a system that inspects the rank of inspection articles P (articles), such as food articles, being conveyed and sorts the inspection articles P based on the inspection results. Specifically, the inspection and sorting system200sorts the inspection articles P by rank according to their weight based on the results of a weight estimation of the inspection articles P.

The inspection and sorting system200is mainly provided with a conveyance device10, an X-ray inspection device220, and a sorting device230(seeFIG. 7).

The conveyance device10is the same as the one in the first embodiment, so description thereof will be omitted.

The X-ray inspection device220performs a weight estimation of the inspection articles P conveyed by the conveyance device10and classifies the inspection articles P into plural ranks (here, three ranks) in accordance with their weight. The sorting device230executes a sorting operation that sorts the inspection articles P conveyed by the conveyance device10based on the inspection results of the X-ray inspection device220.

(2) Detailed Configuration

The X-ray inspection device220and the sorting device230of the inspection and sorting system200will be described below in detail.

The X-ray inspection device220is an example of an inspection device that inspects the inspection articles P conveyed by the conveyance device10. The X-ray inspection device220irradiates X-ray to the inspection articles P continuously conveyed by the conveyance device10, estimates the weights of the inspection articles P based on the amount of X-ray that has been transmitted through the inspection articles P, and classifies the inspection articles P into three ranks according to their weights.

The X-ray inspection device220mainly has a shield box21, an X-ray emitter22, a line sensor23, a monitor25having a touch panel function, and a controller224(seeFIG. 8). The shield box21, the X-ray emitter22, and the monitor25having the touch panel function are the same as the ones in the X-ray inspection device20of the first embodiment, so description thereof will be omitted. The line sensor23is also the same except that the X-ray transmission signal is used for the weight estimation of the inspection articles P rather than for a foreign matter inspection of the inspection articles P, so description thereof will be omitted.

The controller224is a computer that controls each part of the X-ray inspection device220. The controller224, like the controller24of the first embodiment, has a CPU that performs calculation and control, a ROM, a RAM, a hard disk and the like that serve as storage components storing information.

The controller224has a sorting information sending component224aand a reference signal sending component24bthat send information/signals to a controller233of the sorting device230described later (seeFIG. 8). It should be noted that the reference signal sending component24bis the same as the one in the first embodiment, so description thereof will be omitted below. The controller224has a storage component224cand a control component224d(seeFIG. 8). The control component224dmainly has a CPU and executes a program stored in the storage component224cto thereby generate X-ray images, estimate the weights of the inspection articles P based on the generated X-ray images, and determine rank based on the estimated weights. Furthermore, the control component224dcontrols the operation of each part of the X-ray inspection device220, such as the X-ray emitter22and the line sensor23. Various inspection parameters used in the rank inspection are stored in the storage component224c. For example, a weight conversion table for converting the gray scale values of the X-ray images into weight values and plural threshold values (here, two threshold values) for determining rank in accordance with the weights of the inspection articles P are stored in the storage component224c. Furthermore, later-described unit sorting information e generated by the control component224das a result of the rank inspection of the inspection articles P is stored in the storage component224c.

The controller224is electrically connected to the X-ray emitter22, the line sensor23, and the monitor25. Furthermore, the controller224is also electrically connected to the conveyor motor12and the encoder13of the conveyance device10(seeFIG. 8). The controller224acquires data relating to the rotation speed of the conveyor motor12from the encoder13and grasps, based on the acquired data, the conveyance distance and conveyance speed of the inspection articles P.

Furthermore, the controller224is connected to the controller233of the sorting device230by a communication line90such as the Internet in order to send later-described sorting information E and a reference signal S to the sorting device230(seeFIG. 8). In contrast to the controller24of the first embodiment, the dedicated signal line91is not used for connecting the controller224to the controller233of the sorting device230.

The controller224detects the timings when the inspection articles P pass over the line sensor23based on the X-ray transmission signals sent from the line sensor23. When the inspection articles P pass through the fan-shaped X-ray emission range Y, the controller224acquires, for each fixed moving distance of the inspection articles P (each imaging width u), the X-ray transmission signals corresponding to that moving distance (equivalent to one line) from the line sensor23. In a case where the moving speed of the inspection articles P (the conveyance speed of the conveyance device10) is fixed, the controller224acquires from the line sensor23the X-ray transmission signals at every fixed time interval. Additionally, the controller224, particularly the control component224d, creates the X-ray images of the inspection articles P based on the X-ray transmission signals acquired from the line sensor23.

The control component224dperforms, based on the X-ray images of the inspection articles P, a weight estimation of those inspection articles P. Specifically, the control component224dcreates, based on the gray scale value of each pixel configuring the X-ray image of the inspection article P, a histogram representing a number of pixels for every gray scale value. Thereafter, the controller224uses the created histogram and the weight conversion table stored in the storage component224cto add the weight values corresponding to all the pixels together and estimate the weights of the inspection articles P. Moreover, the controller224compares the estimated weights of the inspection articles P with the two threshold values stored in the storage component224cto thereby classify the inspection articles into three ranks.

Moreover, the control component224dgenerates, based on the results of the rank inspection, unit sorting information e relating to the sorting of the inspection articles P for a segment with a predetermined width L along the conveyance direction of the conveyance device10. The unit sorting information e is information representing the positions and ranks of the inspection articles P on the conveyance surface of the conveyor belt11that has passed over the line sensor23in a period from the rise to the fall of the reference signal S outputted by the reference signal sending component24bor in a period from the fall to the rise of the reference signal S.

In the first embodiment the unit sorting information d was N bits of binary (expressed as “0” or “1”) information, but the unit sorting information e differs in that it is N number of multi-value (expressed as “0”, “1”, “2”, and “3”) information (seeFIG. 9). This is because in the first embodiment it sufficed for the unit sorting information d to express only whether or not there exist inspection articles P contaminated with foreign matter, but in the second embodiment, the unit sorting information e expresses which of the three ranks the inspection articles P belong to.

The control component224ddivides the width L into N number of sections (divides the width L by every single imaging width u of the line sensor23) and determines whether there exists the inspection article P in each of the sections into which the width L has been divided, and, when there exists the inspection article P, the rank to which that inspection article P belongs. Additionally, the control component224dgenerates unit sorting information e in which each divided section is expressed by one numerical value using the determination results. In the unit sorting information e, a numerical value of “0” means that an inspection article P does not exist in the position corresponding to that numerical value. Furthermore, in the unit sorting information e, a numerical value of “1”, “2”, or “3” means that an inspection article P belonging to a rank indicated by that numerical value exists in the position corresponding to that numerical value.

The generated unit sorting information e is stored in the storage component224cof the controller224. Furthermore, when the unit sorting information e is generated, the sorting information sending component224asends, via the communication line90, sorting information E to the controller233of the sorting device230described later. The sorting information E is information, relating to the sorting of the inspection articles P, in which the unit sorting information e that has just been generated and plural (in the present embodiment, four) sets of unit sorting information e of segments on the downstream side of the generated unit sorting information e as viewed from the conveyance direction of the conveyance device10are connected together. That is to say, the sorting information E is information representing the positions and ranks of the inspection articles P in an interval spanning a distance of five times the width L.

The sorting device230performs sorting of the inspection articles P based on the results of the rank inspection by the X-ray inspection device220. Specifically, the sorting device230sorts, based on the results of the rank inspection by the X-ray inspection device220, the inspection articles P to three conveyors not shown in the drawings according to their rank.

The sorting device230mainly has first to third air sorting mechanisms231a,231b, and231cand the controller233(seeFIG. 8).

(2-2-1) Air Sorting Mechanisms

Each of the first to third air sorting mechanisms231a,231b, and231cis the same as the air sorting mechanism31of the first embodiment. The first air sorting mechanism231ahas a first nozzle232aand an electromagnetic valve (not shown in the drawings) that opens and closes an air pathway that supplies high-pressure air to the first nozzle232a. The second air sorting mechanism231bhas a second nozzle232band an electromagnetic valve (not shown in the drawings) that opens and closes an air pathway that supplies high-pressure air to the second nozzle232b. The third air sorting mechanism231chas a third nozzle232cand an electromagnetic valve (not shown in the drawings) that opens and closes an air pathway that supplies high-pressure air to the third nozzle232c. The first to third air sorting mechanisms231a,231b, and231care mechanisms controlled independently of each other by the controller233.

The first to third nozzles232a,232b, and232care attached diagonally above the conveyance surface of the conveyor belt11of the conveyance device10. The first to third nozzles232a,232b, and232care attached so as to discharge the high-pressure air in a direction intersecting the conveyance direction (see the arrow A inFIG. 7) of the conveyance device10, particularly a direction orthogonal to the conveyance direction, as viewed in a plan view. The first to third nozzles232a,232b, and232care installed in this order from the upstream side to the downstream side in the conveyance direction (see the arrow A inFIG. 7) of the conveyance device10(seeFIG. 7). The first nozzle232aand the second nozzle232bare installed a distance B1apart from each other, and the first nozzle232aand the third nozzle232care installed a distance B2apart from each other. When the electromagnetic valve of the first air sorting mechanism231a, the second air sorting mechanism231b, or the third air sorting mechanism231cis opened by a command from a sorting mechanism control component233d, the high-pressure air comes out from the first nozzle232a, the second nozzle232b, or the third nozzle232c, respectively. Additionally, when the air is blown onto the inspection article P on the conveyor belt11, the inspection article P is sorted to the non-illustrated corresponding conveyor disposed below the conveyor belt11.

The controller233is a computer that controls each part of the sorting device230. The controller233has a CPU that performs calculation and control, a ROM, a RAM, and a hard disk, and the like that serve as storage components that store information.

The controller233has a sorting information receiving component233aand a reference signal receiving component233bthat receive information/signals from the controller224of the X-ray inspection device220(seeFIG. 8). Furthermore, the controller233has a storage component233cand a sorting mechanism control component233d(seeFIG. 8). The sorting mechanism control component233dmainly has a CPU and executes a program stored in the storage component233cto thereby cause the first to third air sorting mechanisms231a,231b, and231cto execute the sorting operation that sorts the inspection articles P. The storage component233cstores the program executed by the sorting mechanism control component233dand various types of information. The storage component233cincludes a sorting information storage region233ca, which stores the sorting information E sent from the X-ray inspection device220, and a sorting operation storage region233cb, which is used when the sorting mechanism control component233dcauses the first to third air sorting mechanisms231a,231b, and231cto execute the sorting operation. The information stored in the sorting information storage region233cbis the aforementioned unit sorting information e.

The controller233is electrically connected to the first to third air sorting mechanisms231a,231b, and231c. Furthermore, the controller233is also electrically connected to the encoder13of the conveyance device10(seeFIG. 8). The controller233acquires data relating to the rotation speed of the conveyor motor12from the encoder13and grasps, based on the acquired data, the conveyance distance and conveyance speed of the inspection articles P.

Furthermore, the controller233is connected to the controller224of the X-ray inspection device220by the communication line90in order to receive the sorting information E and the reference signal S (seeFIG. 8).

(2-2-2-1) Sorting Information Receiving Component

The sorting information receiving component233areceives the sorting information E, which relates to the sorting of the inspection articles P based on the inspection results of the X-ray inspection device220and is sent by the sorting information sending component224aof the controller224of the X-ray inspection device220. The sorting information receiving component233ais the same as the one in the first embodiment except that the content of the information it receives is different (the information the sorting information receiving component233areceives is not the sorting information D but rather the sorting information E), so detailed description thereof will be omitted.

(2-2-2-2) Reference Signal Receiving Component

The reference signal receiving component233bis the same as the one in the first embodiment, so description thereof will be omitted.

(2-2-2-3) Storage Component

(2-2-2-3-1) Sorting Information Storage Region

The sorting information E received by the sorting information receiving component233ais stored in the sorting information storage region233ca. The sorting information E is, as described above, information including (N×5) number of numerical values where five sets of the unit sorting information e are connected together. When the sorting information receiving component233areceives the sorting information E, the content stored in the sorting information storage region233cais rewritten to the received (most recent) sorting information E.

(2-2-2-3-2) Sorting Operation Storage Region

The set of unit sorting information e furthest downstream in the conveyance direction of the conveyance device10, or in other words the oldest N number of numerical value information in terms of the time series, in the sorting information E stored in the sorting information storage region233cais written to the sorting operation storage region233cbby a sorting operation storage rewriting component233daof the sorting mechanism control component233ddescribed later and stored in the sorting operation storage region233cb. The content of the sorting operation storage region233cbis rewritten at a timing adjusted by the reference signal S received by the reference signal receiving component233b.

(2-2-2-4) Sorting Mechanism Control Component

The sorting mechanism control component233dcontrols the first to third air sorting mechanisms231a,231b, and231cto execute the sorting operation based on the sorting information E received by the sorting information receiving component233aat the timing adjusted by the reference signal S received by the reference signal receiving component233b.

The sorting mechanism control component233dmainly has, as sub-function components, the sorting operation storage rewriting component233daand a command generating component233db(seeFIG. 8).

(2-2-2-4-1) Sorting Operation Storage Rewriting Component

The sorting operation storage rewriting component233darewrites the content stored in the sorting operation storage region233cbbased on the sorting information E stored in the sorting information storage region233caat the timing adjusted by the reference signal S received by the reference signal receiving component233b. As described later, when the content of the sorting operation storage region233cbis rewritten, the command generating component233dbstarts, at that timing, the control of the first to third air sorting mechanisms231a,231b, and231cbased on the rewritten content. Therefore, the timing of the rewriting of the content of the sorting operation storage region233cbdetermines the timing of the sorting operation of the first to third air sorting mechanisms231a,231b, and231c.

The timing when the sorting operation storage rewriting component233darewrites the information in the sorting information storage region233cawill be described in detail.

Like the air sorting mechanism31of the aforementioned embodiment, in the first to third air sorting mechanisms231a,231b, and231c, a delay also occurs between the time when the first to third air sorting mechanisms231a,231b, and231creceive a command to operate and the time when the first to third air sorting mechanisms231a,231b, and231cactually execute the operation. Therefore, the sorting device230is given, for controlling the first to third air sorting mechanisms231a,231b, and231c, the sorting information E prepared such that in a case where it is supposed that the first air sorting mechanism231apositioned furthest upstream in the conveyance direction could operate without delay when it receives a command to operate, air would be discharged from the first nozzle232awhen the inspection article P to be sorted by the first air sorting mechanism231apasses a point located before the actual position of the first nozzle232aby the delay adjustment width α when controlling the first air sorting mechanism231abased on the sorting information E.

It should be noted that the delay adjustment width α is determined in such a way that, in a case where the conveyance speed of the conveyance device10is set to a maximum conveyance speed Vmax, by sending the air discharge command to the first air sorting mechanism231awhen the inspection article P to be sorted by the first air sorting mechanism231ais being conveyed at the point located before the position of the first nozzle232aby the delay adjustment width α in the conveyance direction, air will be discharged to the inspection article P to be sorted when that inspection article P to be sorted passes in front of the first nozzle232a.

The delay time Td, determined by the characteristics of the first to third air sorting mechanisms231a,231b, and231c, from when the command to execute the sorting operation is received to when the sorting operation is actually executed is fixed regardless of the conveyance speed of the conveyance device10. The sorting operation storage rewriting component33dadetermines, based on the fixed delay time Td determined by the characteristics of the first to third air sorting mechanisms231a,231b, and231c, the timing when it rewrites the information in the sorting information storage region233ca. It should be noted that the delay time Td is given by (delay adjustment width α/maximum conveyance speed Vmax).

For example, in a case where the conveyance speed of the conveyance device10acquired based on the data sent from the encoder13is the maximum conveyance speed Vmax, the sorting operation storage rewriting component233darewrites the information in the sorting information storage region233caat the timing when the reference signal S received by the reference signal receiving component233brises (when the reference signal switches from off to on) or when the reference signal S falls (when the reference signal switches from on to off).

For example, in a case where the conveyance speed of the conveyance device10acquired based on the data sent from the encoder13is the conveyance speed V (V<Vmax), the sorting operation storage rewriting component233darewrites the information in the sorting information storage region233caafter the elapse of {(delay adjustment width α/conveyance speed V)−delay time Td} from the point in time when the reference signal S received by the reference signal receiving component233brises or falls.

(2-2-2-4-2) Command Generating Component

The command generating component233dbgenerates a command to the first to third air sorting mechanisms231a,231b, and231cwith the content stored in the sorting operation storage region233cband sends the command to the first to third air sorting mechanisms231a,231b, and231c. Specifically, at the timing when the content of the sorting operation storage region233cbis rewritten, the command generating component233dbgenerates a command for the first to third air sorting mechanisms231a,231b, and231cand sends the command to the first to third air sorting mechanisms231a,231b, and231c, so that the first to third air sorting mechanisms231a,231b, and231cexecute the operation according to the time series information stored in the sorting operation storage region233cbin order starting from the beginning of the time series. This will be described specifically below.

As described above, the information written in the sorting operation storage region233cbis the unit sorting information e generated by the X-ray inspection device220, and is information including N number of numerical values. When the numerical value is “1”, the command generating component233dbgenerates a command to discharge air for the first air sorting mechanism231aand generates a command to prohibit the discharge of air for the second air sorting mechanism231band the third air sorting mechanism231c. When the numerical value is “2”, the command generating component233dbgenerates a command to discharge air for the second air sorting mechanism231band generates a command to prohibit the discharge of air for the first air sorting mechanism231aand the third air sorting mechanism231c. When the numerical value is “3”, the command generating component233dbgenerates a command to discharge air for the third air sorting mechanism231cand generates a command to prohibit the discharge of air for the first air sorting mechanism231aand the second air sorting mechanism231b. When the numerical value is “0”, the command generating component233dbgenerates a command to prohibit the discharge of air and sends it to all of the first to third air sorting mechanisms231a,231b, and231c.

It should be noted that the time in which the first to third air sorting mechanisms231a,231b, and231cdischarge air or prohibit the discharge of air based on each piece of numerical value information is the time in which the conveyance device10conveys the inspection article P a distance given by (width L/N) or in other words a single imaging width u of the line sensor23. That is to say, the time in which the air sorting mechanism31discharges air or prohibits the discharge of air based on each piece of numerical value information is a time obtained by dividing the distance given by (width L/N) by the conveyance speed V of the conveyance device10. It should be noted that the width L here is, as described above, a predetermined distance along the conveyance direction of the conveyance device10for which the control component224dof the X-ray inspection device220generates a set of unit sorting information e. N is the number of numerical values included in the unit sorting information e.

The command for the first air sorting mechanism231amay be generated by the command generating component233dbin the same way as the command for the air sorting mechanism31is generated in the first embodiment. In contrast, the commands for the second air sorting mechanism231band the third air sorting mechanism231cby the command generating component233dbare generated as follows.

The timing when the sorting operation storage rewriting component233darewrites the sorting operation storage region233cbis determined so as to match the timing when the inspection article P passes in front of the first nozzle232aof the first air sorting mechanism231a. On the other hand, the second nozzle232bof the second air sorting mechanism231bis disposed the distance B1apart from the first nozzle232aon the downstream side in the conveyance direction of the conveyance device10(seeFIG. 7). The third nozzle232cof the third air sorting mechanism231cis disposed the distance B2apart from the first nozzle232aon the downstream side in the conveyance direction of the conveyance device10(seeFIG. 7). Consequently, if the operation of the second air sorting mechanism231band the third air sorting mechanism231cis controlled at the timing when the inspection article P passes in front of the first nozzle232aof the first air sorting mechanism231a, air cannot be discharged at an appropriate timing. Therefore, the command generating component233dbgenerates for the second air sorting mechanism231ba control command to be executed after the elapse of a time calculated by distance B1/conveyance speed V based on the conveyance speed V of the conveyance device10sent from the encoder13and the distance B1between the first nozzle232aand the second nozzle232bwhich is stored in the storage component233c. Also, the command generating component233dbgenerates for the third air sorting mechanism231ca control command executed after the elapse of a time calculated by distance B2/conveyance speed V based on the conveyance speed V of the conveyance device10sent from the encoder13and the distance B2between the first nozzle232aand the third nozzle232cwhich is stored in the storage component233c.

(3) Process Executed by Sorting Device

The rewriting processes of the sorting information storage region233caand the sorting operation storage region233cbare the same as the ones in the first embodiment, so here detailed description thereof will be omitted.

The inspection and sorting system200has the same characteristics as (4-1) to (4-3) and (4-5) of the inspection and sorting system100pertaining to the first embodiment. In addition, the inspection and sorting system200pertaining to the second embodiment has the following characteristic.

In the inspection and sorting system200pertaining to the above embodiment, the X-ray inspection device220can perform a rank inspection based on the weights of the inspection articles P.

Here, the inspection articles P can be sorted based on the ranks of the inspection articles P using the sorting device230.

Third Embodiment

An inspection and sorting system300pertaining to a third embodiment of the present invention will be described.

(1) Overall Configuration

The inspection and sorting system300pertaining to the third embodiment, similar to the inspection and sorting system100of the first embodiment, sorts the inspection articles P so that non-defective articles not contaminated with foreign matter is conveyed to a downstream process (e.g., a boxing process) and defective articles contaminated with foreign matter is removed from the line based on the results of the foreign matter inspection of inspection articles P. The inspection and sorting system300also checks whether the sorting is properly carried out by the sorting device30.

The inspection and sorting system300is mainly provided with the conveyance device10, an X-ray inspection device320, the sorting device30, and a checking device40(seeFIG. 10).

The conveyance device10receives the inspection articles P conveyed thereto by the upstream conveyor unit60and conveys the received inspection articles P. The arrow A inFIG. 10indicates the conveyance direction of the conveyance device10. The X-ray inspection device320performs the foreign matter inspection of the inspection articles P conveyed by the conveyance device10. The sorting device30executes a sorting operation that sorts the inspection articles P conveyed by the conveyance device10based on the inspection results of the X-ray inspection device320. The checking device40judges, on the downstream side of the sorting device30in the conveyance direction of the conveyance device10, whether the operation of sorting the inspection articles P has been appropriately executed by the sorting device30.

The conveyance device10and the sorting device30are the same as the ones in the first embodiment. The X-ray inspection device320differs from the X-ray inspection device20in the first embodiment in that the X-ray inspection device320is also connected, by a communication line90such as the Internet, to the checking device40and also sends the sorting information D and the reference signal S, via the communication line90, to the checking device40. Furthermore, the X-ray inspection device320differs from the one in the first embodiment in that the X-ray inspection device320sends both the sorting information D and the reference signal S to the sorting device30by the communication line90such as the Internet. In other respects, the X-ray inspection device320and the X-ray inspection device20are the same.

(2) Detailed Configuration

The checking device40of the inspection and sorting system300will be described below in detail. Description regarding the conveyance device10, the X-ray inspection device320, and the sorting device30will be omitted.

(2-1) Checking Device

The checking device40is a device that checks whether the inspection articles P have been properly sorted by the sorting device30based on the results of the foreign matter inspection by the X-ray inspection device320.

The checking device40mainly has a photoelectric sensor41and a controller43(seeFIG. 11).

The photoelectric sensor41is an example of a conveyance checking sensor that detects the inspection articles P on the downstream side of the nozzle32of the air sorting mechanism31in the conveyance direction of the conveyance device10(seeFIG. 10). The photoelectric sensor41includes a light emitter41aand a light receiver41bthat form a pair and are disposed on either side of the conveyor belt11(seeFIG. 10). Whether or not the photoelectric sensor41detects the inspection article P, or in other words whether or not the light receiver41bdetects the light emitted by the light emitter41a, is continuously sent to the controller43.

The controller43is a computer that controls each part of the checking device40. The controller43has a CPU that performs calculation and control, a ROM, a RAM, a hard disk, and the like that serve as storage components that store information.

The controller43has a sorting information receiving component43aand a reference signal receiving component43bthat receive information/signals from the controller24of the X-ray inspection device320(seeFIG. 11). Furthermore, the controller43has a storage component43cand a processing component43d(seeFIG. 11). The processing component43dmainly has a CPU and executes a program stored in the storage component43cto thereby judge, based on the detection results of the inspection articles P by the photoelectric sensor41, the success or failure of the sorting by the sorting device30. The storage component43cstores the program executed by the processing component43dand various types of information. The storage component43cincludes a sorting information storage region43ca, which stores the sorting information D sent from the X-ray inspection device320, and a sorting operation storage region43cb, which is used when the processing component43djudges the success or failure of the sorting by the sorting device30(seeFIG. 11). The information stored in the sorting operation storage region43cbis the aforementioned unit sorting information d.

The controller43is electrically connected to the photoelectric sensor41. Furthermore, the controller43is also electrically connected to the encoder13of the conveyance device10(seeFIG. 11). The controller43acquires data relating to the rotation speed of the conveyor motor12from the encoder13and grasps, based on the acquired data, the conveyance distance and conveyance speed of the inspection articles P.

Furthermore, the controller43is connected to the controller24of the X-ray inspection device320by the communication line90in order to receive the sorting information D and the reference signal S (seeFIG. 11).

(2-1-2-1) Sorting Information Receiving Component

The sorting information receiving component43areceives the sorting information D, which relates to the sorting of the inspection articles P based on the inspection results of the X-ray inspection device320and is sent by the sorting information sending component24aof the controller24of the X-ray inspection device320. The function of the sorting information receiving component43ais the same as that of the sorting information receiving component33aof the sorting device30. Here, detailed description regarding the sorting information receiving component43awill be omitted.

(2-1-2-2) Reference Signal Receiving Component

The reference signal receiving component43breceives the fixed-interval reference signal S relating to the conveyance by the conveyance device10. The function of the reference signal receiving component43bis the same as that of the reference signal receiving component33bof the sorting device30. Here, detailed description regarding the reference signal receiving component43bwill be omitted.

(2-1-2-3) Storage Component

(2-1-2-3-1) Sorting Information Storage Region

The sorting information D received by the sorting information receiving component43ais stored in the sorting information storage region43ca. The function of the sorting information storage region43cais the same as that of the sorting information storage region33caof the sorting device30. Here, detailed description regarding the sorting information storage region43cawill be omitted.

(2-1-2-3-2) Sorting Operation Storage Region

The set of unit sorting information d furthest downstream in the conveyance direction of the conveyance device10, or in other words the oldest N bits of information in terms of the time series, in the sorting information D stored in the sorting information storage region43cais written to the sorting operation storage region43cbby a sorting operation storage rewriting component43daof the processing component43ddescribed later and stored in the sorting operation storage region43cb. The content of the sorting operation storage region43cbis rewritten at a timing adjusted by the reference signal S received by the reference signal receiving component43b.

(2-1-2-4) Processing Component

The processing component43djudges the success or failure of the sorting by the air sorting mechanism31based on the sorting information D received by the sorting information receiving component43aand in accordance with whether or not the photoelectric sensor41detects the inspection articles P at the timing adjusted by the reference signal S received by the reference signal receiving component43b. The processing component43dis an example of a judging component.

The processing component43dmainly has, as sub-function components, a sorting operation storage rewriting component43daand a determining component43db(seeFIG. 11).

(2-1-2-4-1) Sorting Operation Storage Rewriting Component

The sorting operation storage rewriting component43darewrites the content stored in the sorting operation storage region43cbbased on the sorting information D stored in the sorting information storage region43caand at the timing adjusted by the reference signal S received by the reference signal receiving component43b. As described later, when the content of the sorting operation storage region43cbis rewritten, the determining component43dbstarts, using that timing, the judging based on the rewritten content. Therefore, the timing of the rewriting of the content of the sorting operation storage region43cbdetermines the timing of the determination by the determining component43db.

The timing when the sorting operation storage rewriting component43darewrites the information in the sorting operation storage region43cbwill be described in detail.

The sorting information D is, as described above, information for controlling the air sorting mechanism31so that in a case where it is supposed that the air sorting mechanism31could operate without delay when it receives a command to operate, air would be discharged from the nozzle32when the inspection article P to be sorted passes a point located before the actual position of the nozzle32by the delay adjustment width α when controlling the air sorting mechanism31based on the sorting information D. However, the photoelectric sensor41of the checking device40is installed a predetermined distance C away on the downstream side of the position of the nozzle32in the conveyance direction of the conveyance device10(seeFIG. 10). Furthermore, as the photoelectric sensor41detects the presence or absence of the inspection articles P using light, virtually no detection delay arises. For that reason, if the sorting operation storage rewriting component43darewrites the information in the sorting operation storage region43cbat the same time as the rise or fall of the reference signal S, the detection result of the photoelectric sensor41is compared with inappropriate information by the later-described determining component43dbwithout being compared with the content of the sorting operation storage region43cbthat should be compared with the content of the detection result.

Therefore, considering the delay adjustment width α and the distance C between the nozzle32and the photoelectric sensor41, the sorting operation storage rewriting component43dawrites to the sorting operation storage region43caa set of unit sorting information d furthest downstream in the conveyance direction of the conveyance device10in the sorting information D stored, at the point in time of the detection of the rise or fall of the reference signal S, in the sorting information storage region43ca, after a time calculated by (delay adjustment width α+distance C)/conveyance speed V from the rise or fall of the reference signal S.

(2-1-2-4-2) Determining Component

The determining component43dbdetermines, based on the content stored in the sorting operation storage region43cband the detection result of the photoelectric sensor41which is sent in real time, whether the inspection article P that should have been sorted by the sorting device30is being conveyed by the conveyor belt11. Specifically, when the content of the sorting operation storage region43cbis rewritten, the determining component43dbstarts, at that timing, a comparison between the content of the sorting operation storage region43cband the detection result of the photoelectric sensor41which is sent in real time, in order to check whether the sorting operation according to the time series information stored in the sorting operation storage region43cbwas executed or not by the air sorting mechanism31. This will be specifically described below.

As described above, the information written in the sorting operation storage region43cbis the unit sorting information d generated by the X-ray inspection device320, and is N bits of binary information. When the value of the bit is “1”, the determining component43dbdetermines whether the light receiver41bof the photoelectric sensor41is receiving the light at a timing corresponding to that bit. When the light receiver41bis receiving the light (when there is no inspection article P), the determining component43dbdetermines that the sorting was properly executed by the air sorting mechanism31. On the other hand, when the light receiver41bis not receiving the light (when there is an inspection article P), the determining component43dbdetermines that the sorting was not properly executed by the air sorting mechanism31.

It should be noted that the time during which the determining component43dbperforms the determination based on each bit of information is the time in which the conveyance device10conveys the inspection article P a distance given by (width L/N) or in other words a single imaging width u of the line sensor23. That is to say, the time in which the determining component43dbperforms the determination based on each bit of information is a time obtained by dividing the distance given by (width L/N) by the conveyance speed V of the conveyance device10. It should be noted that the width L here is, as described above, a predetermined distance along the conveyance direction of the conveyance device10for which the control component24dof the X-ray inspection device320generates a unit sorting information d. N is the number of bits of the unit sorting information d.

(3) Process Executed by Sorting Device

The process executed by the sorting device30is the same as the one in the first embodiment, so here detailed description thereof will be omitted.

(4) Process Executed by Checking Device

The process executed by the checking device40, and particularly the process of rewriting the sorting information storage region43caand the sorting operation storage region43cb, will be described usingFIG. 12.

First, as a premise, it is supposed that at a given time (point in time t0inFIG. 12) the sorting information D2including the sets of unit sorting information d2to d6is stored in the sorting information storage region43ca. It should be noted that the smaller the numbers added to the sets of unit sorting information d2to d6are, the further downstream the information is in the conveyance direction of the conveyance device10(in other words, the older the information is). Furthermore, it is supposed that at the point in time t0inFIG. 12the sorting mechanism control component33ddetects the rise of the reference signal S (expressed as Son inFIG. 12) received by the reference signal receiving component43b. It should be noted that, here, it is supposed that the conveyance speed of the conveyance device10is fixed at the conveyance speed V.

In this case, the sorting operation storage rewriting component43darewrites the content of the sorting operation storage region43cbfrom the unit sorting information that has been stored until then to the oldest set of unit sorting information d2in the sorting information D2that had been stored, at the point in time t0(the point in time of the detection of the rise of the reference signal S), in the sorting information storage region43caat time t4after the elapse of a time calculated by {(delay adjustment width α+distance C)/conveyance speed V} from the point in time t0when the rise of the reference signal S was detected. When the content of the sorting operation storage region43cbis rewritten, the determining component43dbjudges the success or failure of the sorting of the inspection articles P in accordance with the newly rewritten unit sorting information d2at the timing of the rewriting of the sorting operation storage region43cb.

Furthermore, it is supposed that at a given time t2the sorting information receiving component43areceives sorting information D3including sets of unit sorting information d3to d7. At this time, the content of the sorting information storage region43cais rewritten from the sorting information D2to the newly received sorting information D3. At this time, the content of the sorting operation storage region43cbis not changed. In this way, the timing of the reception of the sorting information D does not affect the timing of the rewriting of the sorting operation storage region43cb. Therefore, even if the timing of the reception of the sorting information D varies, this does not affect the timing when the checking device40checks the success or failure of the sorting of the inspection articles P.

Next, when at a given time t3the fall of the reference signal S (expressed as Soff inFIG. 12) received by the reference signal receiving component43bis detected, at time t7after the elapse of a time calculated by {(delay adjustment width α+distance C)/conveyance speed V} from the time t3, the content of the sorting operation storage region43cbis rewritten from the unit sorting information d2that has been stored until then to the oldest set of unit sorting information d3in the sorting information D3that is stored in the sorting information storage region43caat the point in time t3(the point in time of the detection of the fall of the reference signal S). When the content of the sorting operation storage region43cbis rewritten, the determining component43dbjudges the success or failure of the sorting of the inspection articles P in accordance with the newly rewritten unit sorting information d3at the timing of the rewriting of the sorting information storage region43cb.

As what follows thereafter is similar description thereof will be omitted.

The checking device40executes a predetermined operation when the processing component43djudges that the sorting by the air sorting mechanism31has failed. The predetermined operation is, for example, a notification of the failure of the sorting to the operator and/or the transmission of a signal for stopping the operation of the inspection and sorting system300.

The inspection and sorting system300has the same characteristics as those of the inspection and sorting system100pertaining to the first embodiment.

Another characteristic of the inspection and sorting system300pertaining to the third embodiment is described below.

The inspection and sorting system300pertaining to the third embodiment is provided with the photoelectric sensor41serving as an example of a conveyance checking sensor and the processing component43dserving as an example of a judging component. The photoelectric sensor41detects the inspection articles P on the downstream side of the air sorting mechanism31in the conveyance direction of the conveyance device10. The processing component43djudges, based on the detection result of the photoelectric sensor41, the success or failure of the sorting by the air sorting mechanism31. The processing component43djudges the success or failure of the sorting by the air sorting mechanism31based on the sorting information D and in accordance with whether or not the photoelectric sensor41detects the inspection articles P at a check timing adjusted by the reference signal S.

Here, the photoelectric sensor41which detects the inspection articles P conveyed on the downstream side of the air sorting mechanism31is installed, and the success or failure of the sorting is judged based on the sorting information D and in accordance with whether or not an inspection article P is detected at the check timing adjusted by the reference signal S. That is to say, here, the presence or absence of an inspection article P is judged at an accurate check timing adjusted by the reference signal S in the same way as the timing of the operation of the air sorting mechanism31, and the success or failure of the sorting is thereby judged. For that reason, the success or failure of the sorting can be judged at a high processing speed and accurately.

MODIFICATIONS

The first to third embodiment may be combined with each other to the extent that they do not contradict each other. For example, the inspection and sorting system may be provided with both the sorting device30of the first embodiment and the sorting device230of the second embodiment, and the sorting of the inspection articles P may be performed in accordance with the non-defective/defective of the inspection articles P and the rank of the inspection articles P based on the results of the foreign matter inspection and the rank inspection performed by the X-ray inspection device20.

Modifications of the embodiments will be described below. It should be noted that plural modifications may also be appropriately combined.

(1) Modification A

In the above embodiments, the sorting devices30and230have the sorting operation storage regions33cband233cband adjust, with the reference signal S, the timing when the sorting operation storage rewriting components33daand233daperform the rewriting, but the sorting devices30and230are not limited to this.

For example, the sorting devices30and230may not have the sorting operation storage regions33cband233cb, and the command generating components33dband233dbmay directly reference the sorting information storage regions33caand233cato generate the commands that control the air sorting mechanisms31,231a,231b, and231c. And, the air sorting mechanisms31,231a,231b, and231cmay be made to perform the same operations as in the above embodiments by changing the reference positions in the sorting information storage regions33caand233ca(the positions referenced by a pointer) at the timing adjusted by the reference signal S.

It is similar for the checking device40.

(2) Modification B

In the above embodiments, the sorting devices30and230execute the sorting of the inspection articles P with air discharged from the air sorting mechanisms31,231a,231b, and231c, but the sorting mechanism is not limited to this kind of a mechanism that sorts the inspection articles P by discharging air. For example, the sorting mechanism may be a mechanism that sorts the inspection articles P by driving an arm driven by a motor or an air cylinder.

(3) Modification C

In the above embodiments, the inspection device is the X-ray inspection devices20and220, but the inspection device is not limited to this. For example, the inspection device may be a near-infrared inspection device that inspects the non-defective/defective of the inspection articles P by detecting near-infrared radiation transmitted through the inspection articles P and performing an inspection of the sealing of seal portions or the like, or a metal detection device detecting metal contamination in the inspection articles P by using the detection results of a magnetic field.

(4) Modification D

In the third embodiment, the sorting device30and the checking device40are separate devices, but the embodiment is not limited to this. The controller33of the sorting device30may be configured to judge the success or failure of the sorting by the air sorting mechanism31based on the detection results of the photoelectric sensor41.

(5) Modification E

In the above embodiments, the X-ray inspection devices20and220send the reference signal S, but the inspection and sorting system is not limited to this. For example, the inspection and sorting system may also be configured so that, instead of the X-ray inspection devices20and220sending the reference signal S, the conveyance device10sends a signal that is the same as the reference signal S.

(6) Modification F

In the above embodiments, the reference signal S is a signal that is switched on or off each time the conveyance distance of the conveyance device10becomes equal to the width L, but the reference signal S is not limited to this.

For example, the reference signal S may be a signal that is switched on or off each time the conveyance distance of the conveyance device10becomes a distance equal to half the width L. In this case, the timing of the sorting operation of the air sorting mechanisms31,231a,231b, and231cmay be adjusted based on either one of the rise or fall of the reference signal S.

(7) Modification G

In the above embodiments, the air sorting mechanisms31,231a,231b, and231care controlled to always discharge air while the inspection article P to be sorted passes in front of the nozzles32,232a,232b, and232c, but the inspection and sorting system is not limited to this. It is sufficient if the unit sorting information d and e which determines the sorting operation of the air sorting mechanisms31,231a,231b, and231chas a content with which the inspection articles P to be sorted can be sorted with the sorting operation executed by the air sorting mechanisms31,231a,231b, and231c.

(8) Modification H

In the above embodiments, the discharge/stopping of the air by the air sorting mechanisms31,231a,231b, and231cis switched each time the conveyance distance of the conveyance device10becomes equal to the imaging width u of the line sensor23at the shortest case, but it is not limited to this. For example, the discharge/stopping of the air by the air sorting mechanisms31,231a,231b, and231cmay be controlled so as to not be switched unless the conveyance distance of the conveyance device10becomes equal to an integral multiple (e.g., three times) of the imaging width u of the line sensor23at the shortest.

(9) Modification I

In the above embodiments, the reference signal S is a signal transmitted to the reference signal receiving component33beach time the conveyance device10conveys a predetermined distance, but it is not limited to this. For example, in a case where the conveyance speed of the conveyance device10is fixed, the fixed-interval reference signal relating to the conveyance by the conveyance device10may be a signal transmitted at a fixed time interval.

(10) Modification J

In the above embodiments, the sorting device30removes, with air, the inspection articles P from the conveyor belt11of the conveyance device10, but it is not limited to this. For example, instead of removing the inspection articles P from the conveyor belt11, the sorting device may execute a sorting operation that sorts the inspection articles P by driving a marking mechanism or the like based on the non-defective/defective of the inspection articles P and thereby marking on the inspection articles P (e.g., by marking only defective articles).

INDUSTRIAL APPLICABILITY

The present invention is useful as an inspection and sorting system that can sort articles conveyed by a sorting mechanism based on the inspection results at a high processing speed and with good precision.