INSPECTION DEVICE

An inspection device includes an imaging device attached to an operator to image an imaging range, and a determinator configured to determine a quality of an inspection object. The determinator is configured: to receive image data of the imaging range transmitted from the imaging device; to identify an image area in which the inspection object exists in the image data of the imaging range; to set a predetermined area within the image area in which the inspection object exists, as an inspection area; and to collate the image data of the inspection area with a pre-registered collation image data to determine whether the quality of the inspection object is defective or not. Therefore, it is possible to more accurately determine the quality of the inspection object to be inspected.

TECHNICAL FIELD

The present disclosure relates to an inspection device used for inspecting an inspection object.

BACKGROUND

An inspection device attached to an operator may include a code reader, a camera, and a tablet. The code reader reads a code indicating the type of work to be inspected. The camera takes an image of the work. A microcomputer of the tablet sends an imaging command to the camera in response to that the code reader reads the work code as a trigger. Based on this imaging command, the camera captures an image of the work and acquires the captured image. The microcomputer selects a reference image of the work corresponding to the code read by the code reader from among reference images of a plurality of types of works stored in advance in a memory, and compare the reference image and the captured image of the selected work with each other, so as to determine whether or not the selected work is a non-defective product (i.e., good product). However, in this case, it may be difficult to accurately determine a defective product or non-defective product.

SUMMARY

An inspection device according to an aspect of the present disclosure is used for inspecting an inspection object to be inspected, and includes an imaging device and a determinator. The imaging device can be attached to an operator to image an imaging range. The determinator is configured to determine a quality of the inspection object. The determinator is configured: to receive image data of the imaging range transmitted from the imaging device; to identify an image area in which the inspection object exists in the image data of the imaging range; to set a predetermined area within the image area in which the inspection object exists, as an inspection area; and to collate the image data of the inspection area with a pre-registered collation image data to determine whether the quality of the inspection object is defective or not. Therefore, it is possible to more accurately determine the quality of the inspection object to be inspected.

DESCRIPTION OF EMBODIMENT

An inspection device attached to an operator may include a code reader, a camera, and a tablet. The inspection device can be used, for example, when inspecting whether or not a predetermined part is assembled at an appropriate position of a work. When the inspection device is used in such an inspection, a similar product may be erroneously detected as the inspection object if the similar part similar to the predetermined part is present in the imaging range of the camera. In such a situation, it becomes difficult to appropriately determine the quality of the work.

An object of the present disclosure is to provide an inspection device capable of inspecting an inspection object and to more accurately determine the quality of the inspection object.

An inspection device according to an exemplar of the present disclosure can be used for inspecting an inspection object, and includes an imaging device and a determinator. The imaging device can be attached to an operator to image an imaging range. The determinator is configured to determine a quality of the inspection object. The determinator is configured: to receive image data of the imaging range transmitted from the imaging device; to identify an image area in which the inspection object exists in the image data of the imaging range; to set a predetermined area within the image area in which the inspection object exists, as an inspection area; and to collate the image data of the inspection area with a pre-registered collation image data, to determine whether the quality of the inspection object is defective or not.

According to this configuration, the image data of a non-defective inspection object can be used as the collation image data. In this case, when a predetermined part is assembled to the predetermined area of the inspection object by an operator, it is determined that the inspection object is a non-defective product if collation between the image data of the inspection area and the collation image data is established. If the operator assembles the predetermined part in an area different from the predetermined area of the inspection object, the collation between the image data in the inspection area and the collation image data cannot be established, and thereby, it is determined that the inspection object is a defective product. According to the above configuration, it is possible to easily determine the quality of the inspection object. Further, even when a similar object that is similar to the predetermined part exists in the vicinity of the inspection object, the quality of the inspection object is not determined based on the similar object if the similar object exists at a position outside the inspection area of the inspection object. Therefore, it is possible to more accurately determine the quality of the inspection object to be inspected. The determinator may be configured to determine that the inspection object is a defective product when a collation between the image data of the inspection area and the collation image data is not established.

For example, the determinator may be configured to re-obtain the image data of the imaging range transmitted from the imaging device, if the determinator determines that the inspection object does not exist in the image data of the imaging range after receiving the image data of the imaging range transmitted from the imaging device.

The he inspection area may include a first inspection area and a second inspection area. In this case, the determinator is configured

to set the first inspection area within the image area in which the inspection object exists, and to set the second inspection area within the first inspection area, and

to determine the quality of the inspection object by collating image data of the second inspection area with pre-registered collation image data.

Alternatively, the determinator may be configured to set a plurality of the inspection areas in the image area in which the inspection object exists, and to collate the image data of the plurality of the inspection areas with collation image data to determine the quality of the inspection object.

Hereinafter, an inspection device of the present disclosure will be described with reference to the drawings. In order to facilitate the understanding, the same reference numerals are attached to the same constituent elements in each drawing where possible, and redundant explanations are omitted.

First Embodiment

First, an inspection device10according to the first embodiment shown inFIG. 1will be described. The inspection device10according to the first embodiment is used in a manufacturing process of a product of any device such as a heat exchanger, an electrical device or the like. Specifically, the inspection device1is used in an intermediate manufacturing stage before a finished product, to inspect whether or not an inspection object such as a workpiece20is a good product (i.e., non-defective product). Specifically, the workpiece20is flowing on a production line while being placed on a conveyor30. In the vicinity of the conveyor30, a plurality of operators (e.g., workers) H are lined up along a flow direction of the workpiece20. When the workpiece20is positioned in front of the worker H, the worker H performs an assembling work for assembling a predetermined part or predetermined plural parts at the position of the workpiece20. At that time, the inspection device10inspects and determines whether or not the workpiece20, to which the predetermined part(s) is assembled, is a non-defective product (good product). The inspection device10is a wearable inspection device that can be attached to the worker H, for example. Each worker H sequentially performs the assembly work of predetermined parts so that a finished product is manufactured. In this embodiment, the workpiece20is an example of the inspection object (i.e., an object to be inspected).

As shown inFIG. 2, the inspection device10includes an imaging device11, a wireless communication device12, and a terminal device13. The wireless communication device12and the terminal device13are not shown inFIG. 1.

As shown inFIG. 1, the imaging device11is attached to the worker H to image an imaging range. The imaging device11is fixedly attached to a helmet21worn on the head of the worker H. The imaging range of the imaging device11is set to a predetermined range in the direction in which the face of the worker H is facing, that is, in front of the worker H. When the worker H turns his/her face toward the workpiece20in order to assemble a predetermined part to the workpiece20, the entire workpiece20is positioned within the imaging range of the imaging device11. The imaging device11constantly images the imaging range regardless of whether or not the workpiece20is present in the imaging range, and transmits the image data of the captured imaging range to the wireless communication device12shown inFIG. 2. In the present embodiment, the imaging device11corresponds to an example of an image pickup unit such as a camera, a radar or the like.

The wireless communication device12is connected to the imaging device11by a wire or a wireless communication. The wireless communication device12sequentially transmits the image data transmitted from the imaging device11to the terminal device13by wireless communication.

The terminal device13is a portable tablet terminal, a stationary personal computer, or the like. The terminal device13determines the quality of the workpiece20based on the image data wirelessly transmitted from the imaging device11via the wireless communication device12, and notifies the worker H of the determination result. The terminal device13includes a wireless communicator130, a determinator131, and a speaker132.

The wireless communicator130receives the image data sequentially transmitted from the wireless communication device12, and transmits the received image data to the determinator131.

The determinator131is mainly configured by a microcomputer having a CPU131a, a memory131b, and the like. The determinator131is configured to perform an image process for extracting an image data of the workpiece20from the image data in the imaging range by executing a program stored in advance in the memory131b, and to perform a determination process for determining the quality of the workpiece20based on the extracted image data of the workpiece20. The determinator131notifies the speaker132of the quality determination result of the workpiece20obtained through the determination process. Specifically, when the determinator131determines that the workpiece20is a non-defective product (good product), the determinator131outputs a first sound indicating the non-defective product from the speaker132. When the determinator131determines that the workpiece20is a defective product (bad product), the determinator131outputs a second sound indicating a defective product from the speaker132. The first sound and the second sound are different sounds.

Next, a specific procedure of processes executed by the imaging device11and the terminal device13will be described. The imaging device11and the terminal device13repeatedly execute the processes shown inFIG. 3with a predetermined cycle.

First, the determinator131of the terminal device13reads a collation image data Im from the memory131bin the process of step S101. The collation image data Im is image data obtained by imaging a non-defective work in advance, and is, for example, image data as shown inFIG. 4. As shown inFIG. 4, the collation image data Im is the image data of the workpiece20in which a plurality of parts P1to P3are assembled. The region A1shown by the broken line in the collation image data Im inFIG. 4indicates an assembling position of the part P1on the workpiece20. The collation image data Im is registered in the memory131bin advance.

As shown inFIG. 3, the determinator131transmits an image pickup command to the imaging device11in the process of step S102following step S101. Then, at the process of step S103, the determinator131determines whether image data of the imaging range transmitted from the imaging device11is received.

When the imaging device11receives the image pickup command transmitted from the determinator131of the terminal device13in the process of step S201, the imaging device11takes an image of the image pickup range at the process of step S202. Then, the imaging device11transmits the image data of the imaging range to the terminal device13in the process of step S203. Hereinafter, the image data of the imaging range transmitted from the imaging device11to the terminal device13will be referred to as “image data of the imaging device11”.

If the determinator131of the terminal device13has not received the image data of the imaging device11after transmitting the image pickup command in the process of step S102, the determinator131of the terminal device13makes a negative determination in the process of step S103and continuously performs the determination process at step S103. That is, the determinator131monitors whether or not the image data of the imaging device11has been received. Then, when the determinator131receives the image data of the imaging device11, the determinator11makes a positive determination in the process of step S103, and determines whether or not the image data of the workpiece20is included in the image data of the imaging device11in the subsequent process of step S104.

Specifically, in the process of step S104, the determinator131extracts a feature amount of the image data of the imaging device11by performing image processing such as edge detection process with respect to the image data of the imaging device11. The determinator131determines whether or not the feature amount of the extracted image data of the imaging device11includes the feature amount of the workpiece20of the collation image data Im, so as to determine whether or not the image data of the imaging device11includes the image data of the workpiece20to be inspected. As the process of comparing the feature amounts, any process such as a pattern matching or an edge shape evaluation or the like can be used.

When the determinator131determines that the feature amount of the image data of the imaging device11does not include the feature amount of the workpiece20of the collation image data Im in the process of step S104, step S104determines that the image data of the workpiece20is not included in the image data of the imaging device11. In this case, the determinator131makes a negative determination in the process of step S104, and returns to the process of step S102. Then, at step S102, the image pickup command is transmitted again from the determinator131to the imaging device11. Therefore, the determinator131continuously acquires the image data of the imaging device11until the image data of the imaging device11includes the image data of the workpiece20.

Then, when the image data of the workpiece20is included in the image data of the imaging device11, the determinator131makes a positive determination in the process of step S104, and an inspection area of the image data is set in the subsequent process of step S105.

Specifically, in the process of step S105, the determinator131compares the feature amount of the image data of the imaging device11with the feature amount of the workpiece20of the collation image data Im, so that the image area in which the workpiece20exists is specified from the image data of the imaging device11. For example, when the image data shown inFIG. 5is acquired as the image data of the imaging device11, the range shown by the broken line B1inFIG. 5is specified as the image range in which the workpiece20exists. Subsequently, the determinator131sets a predetermined area within the image range B1of the workpiece20as an inspection area. For example, when the working process of the worker H is a process of assembling a part P1to the position A1of the workpiece20shown inFIG. 4, an area B11corresponding to the position A1in the image range B1of the workpiece20is set as an inspection area as shown inFIG. 5.

As shown inFIG. 3, the determinator131determines whether or not the workpiece20is a non-defective product in the process of step S106. Specifically, the determinator131extracts the feature amount of the inspection area B11of the image data in the process of step S106, and determines whether or not the feature amount of the extracted inspection area B11matches the position A1of the collation image data Im. As the process of comparing the feature amounts, any process such as a pattern matching or an edge shape evaluation or the like can be used. In the present embodiment, the process of determining whether or not the feature amount of the inspection area B11matches the feature amount of the position A1of the collation image data Im corresponds to the collation process for collating the image data of the inspection area and the collation image data.

When the worker H properly assembles the part P1at the position A1of the workpiece20, the feature amount of the inspection area B11and the feature amount of the collation image data Im at the position A1come to match. In this case, the collation between the image data of the inspection area B11and the collation image data Im is established. Thus, the determinator131makes the positive determination in the process of step S106, that is, determines that the workpiece20is a non-defective product, and causes the speaker132to output the first sound indicating that the workpiece20is a non-defective product in the process of step S107. Based on the first sound output from the speaker132, the worker H can know that his/her work has been properly completed.

In contrast, for example, when the worker H assembles the part P1at a position different from the position A1of the workpiece20, the feature amount of the inspection area B11and the feature amount of the collation image data Im at the position A1do not match from each other. In this case, the collation between the image data in the inspection area B11and the collation image data Im is not established. Thus, the determinator131makes the negative determination in the process of step S106, that is, determines that the workpiece20is a defective product, and causes the speaker132to output the second sound indicating that the workpiece20is a defective product in the process of step S108. Based on the second sound output from the speaker132, the worker H can know that the workpiece20is a defective product.

According to the inspection device10of this embodiment described above, operations and effects described in the following (i) to (iii) can be obtained.(i) As shown inFIG. 5, even in a case where a similar part Pa that is similar to the part P1exists in the vicinity of the workpiece20, the quality of the workpiece20is not determined based on the similar product Pa if the similar part Pa exists at a position outside the inspection area B11of the workpiece20. Therefore, it is possible to more accurately determine the quality of the workpiece20.(ii) The determinator131acquires again the image data of the imaging device11by re-transmitting the image pickup command to the imaging device11, if the workpiece20does not exist in the image data of the imaging device11after the determinator131obtains the image data of the imaging device11. According to this configuration, it is possible to continuously determine the quality of the workpiece20without requiring the worker H to perform any operation.(iii) When the collation between the image data in the inspection area B11and the collation image data Im is not established, the determinator131determines that the workpiece20is a defective product. According to this configuration, it is possible to easily determine whether or not the workpiece20is a defective product.

Second Embodiment

Next, an inspection device10of the second embodiment will be described. Hereinafter, differences from the inspection device10of the first embodiment will be mainly described.

As shown inFIG. 6, a work of assembling a part P1to the position A1of the workpiece20and then a work of further assembling a part P11to the position A11of the part P1may be combined as the work of the worker H, for example. In the inspection device10of the present embodiment, the image data of the workpiece20shown inFIG. 6is used as a collation image data Im.

As shown inFIG. 7, the determinator131of the terminal device13of the present embodiment sets a first inspection area B11within the image range B1of the workpiece20, and then further sets a second inspection area B12within the first inspection area B11. In the present embodiment, the first inspection area B11corresponds to an inspection area of the part P1, and the second inspection area B12corresponds to an inspection area of the part P11. When the determinator131determines that the feature amount of the first inspection area B11and the feature amount of the collation image data Im at the position A1match from each other, it is further determined whether or not the feature amount of the second inspection area B12matches the feature amount of the collation image data Im at the position A11shown inFIG. 6. When the determinator131determines that the feature amount of the second inspection area B12matches the feature amount of the collation image data Im at the position A11, the determinator131determines that the workpiece20is a non-defective product (i.e., good product).

According to the inspection device10of this embodiment described above, operations and effects described in the following (iv) can be further obtained in addition to the above (i) to (iii) of the first embodiment.(iv) The determinator131of the terminal device13of the present embodiment sets the first inspection area B11within the image range B1in which the workpiece20exists, and then further sets the second inspection area B12within the first inspection area B11. The determinator131determines the quality of the workpiece20by collating the image data of the second inspection area B12with the collation image data Im. According to this configuration, since the details of the workpiece20can be inspected, it is possible to determine the quality of the workpiece20in detail.

Third Embodiment

Next, an inspection device10of the third embodiment will be described. Hereinafter, differences from the inspection device10of the first embodiment will be mainly described.

As the work of the worker H, a work of assembling all of plural parts (e.g., three parts) P1to P3shown inFIG. 8to the workpiece20can be considered. As shown inFIG. 9, the determinator131of the terminal device13of the present embodiment sets three inspection areas B11to B13within the image range B1of the workpiece20, and then the quality of the workpiece20is determined by collating the image data of the inspection areas B11to B13with the collation image data Im.

According to the inspection device10of this embodiment described above, operations and effects described in the following (v) can be further obtained in addition to the above (i) to (iii) of the first embodiment.(v) Since a plurality of the inspection areas B11to B13are set in the image range B1of the workpiece20, it is possible to accurately determine the quality of the workpiece20even when an operator performs the work of assembling the plurality of parts P1to P3to the workpiece20.

OTHER EMBODIMENTS

The preceding embodiments may be practiced in the following modes.

In the process of step S106shown inFIG. 3, the determinator131may perform the process of comparing and collating the image data of the inspection area with the collation image data by a plurality of times.

The process of comparing and collating the feature amount of the image data of the imaging device11with the feature amount of the collation image data Im is not limited to the process such as the pattern matching or the edge shape evaluation, but a determination such as color determination or dimension determination may be used. Alternatively, it is possible to use a determination method of learning image data using AI or the like.

The present disclosure is not limited to the specific examples described above. The specific examples described above which have been appropriately modified in design by those skilled in the art are also encompassed in the scope of the present disclosure so far as the modified specific examples have the features of the present disclosure. Each element included in each of the specific examples described above, and the placement, condition, shape, and the like of the element are not limited to those illustrated, and can be modified as appropriate. Each element included in each of the specific examples described above can be appropriately combined together as long as there is no technical contradiction.