Patent ID: 12247928

DESCRIPTION OF EMBODIMENTS

Overall Configuration of Inspection Device

In the following, an embodiment of the present invention will be described with reference to the accompanying drawings.FIG.1is a block diagram illustrating an overall configuration of an inspection device1for a sheet layer according to an embodiment of the present invention. The inspection device1includes a scanning device S including an articulated robot2A (movement mechanism) and a laser sensor3, a workpiece rotation mechanism4(support mechanism), and a controller5that controls operations of these components and performs required calculation processing. The inspection device1is a device that inspects sheet layers constituting a workpiece W laminated on a mold6(laminated mold) as a base substrate.

The scanning device S is a device that optically scans the workpiece W formed on the mold6for three-dimensional shape recognition of the workpiece W. The laser sensor3measures a two-dimensional shape of an inspection object by a light cutting method using laser slit light3R. The laser sensor3includes a laser light source, an optical component that converts laser light emitted from the laser light source into the laser slit light3R spreading in a fan shape and irradiates an inspection object with the laser slit light, and a light receiving unit that receives a reflected light of the laser slit light3R from the inspection object. In the present embodiment, the inspection object is the mold6alone or the mold6on which the workpiece W made of a laminated body of one or a plurality of sheet layers is formed.

The articulated robot2A is a movement mechanism that moves the laser sensor3in a predetermined scanning direction. The laser sensor3measures a two-dimensional shape of an inspection object at a predetermined measurement pitch while being moved by the articulated robot2A. The articulated robot2A may have a function other than the movement mechanism for the laser sensor3. For example, the articulated robot may have a function of forming the workpiece W on the mold6(illustrated inFIG.9) or may be equipped with a camera that captures 2D images of the workpiece W and the mold6.

The articulated robot2A includes a base stand20, a plurality of robot arms21erected on the base stand, a plurality of joint shafts22connecting the robot arms21, and a wrist part23arranged at a distal end of the robot arm21. The laser sensor3is mounted on a robot distal end2T which is an arm tip of the articulated robot2A, and can be freely changed in position. In a case where long distance scanning is required, it is desirable that the base stand20is assembled on a stage movable at least in either an X direction or a Y direction to make the articulated robot2A itself movable. As the articulated robot2A, for example, a general-purpose industrial robot equipped with six rotation shafts can be used.

The movement mechanism of the laser sensor3is not limited to the articulated robot2A.FIG.1also illustrates an orthogonal axis robot2B as another example of the movement mechanism. The orthogonal axis robot2B includes an X-axis frame24X, a Y-axis frame24Y, and a Z-axis frame24Z which are three moving shafts orthogonal to each other. The X-axis frame24X supports the Z-axis frame24Z so as to be movable in an X-axis direction. The Z-axis frame24Z supports the Y-axis frame24Y so as to be movable in a Z-axis direction. The Y-axis frame24Y moves the robot distal end2T in the Y direction. The laser sensor3is mounted on the robot distal end2T which is a distal end of the Y-axis frame24Y. Such orthogonal axis robot2B may be used instead of the articulated robot2A. In addition, the laser sensor3may be configured to move in a predetermined direction by a movement mechanism other than an industrial robot, for example, by a ball screw mechanism or the like.

The workpiece rotation mechanism4is a mechanism for changing a posture of the mold6on which the workpiece W is formed. The workpiece rotation mechanism4includes a workpiece holding unit41and a drive motor42. The workpiece holding unit41includes a rotation shaft that rotatably supports the mold6about the shaft, and an input unit for a rotation driving force. The drive motor42applies a rotation driving force to the input unit to rotate the mold6about the shaft. In a case where it is not necessary to rotate the mold6, that is, where the workpiece W is formed only on one surface that can be always opposed to the laser sensor3, the workpiece rotation mechanism4can be omitted.

The controller5is electrically connected to the scanning device S and the workpiece rotation mechanism4. A monitor11and a data server12are connected to the controller5. The monitor11is a display for performing various displays related to the inspection device1, and displays an inspection result of the workpiece W and the like in the present embodiment. The data server12stores various set values and data related to the inspection device1. For example, in the data server12, data related to a size of tapes constituting the mold6or the workpiece W, shape data set in advance as a design value of the mold6on which a sheet layer has been laminated, and the like are stored.

The controller5is configured with a microcomputer or the like, and operates to functionally include a robot control unit51, a sensor control unit52, a workpiece rotation control unit53, a first recognition unit54, a second recognition unit55, a determination unit56, and a display control unit57as a result of execution of a predetermined program.

The robot control unit51moves the laser sensor3to a required position by controlling operation of the articulated robot2A (or the orthogonal axis robot2B). Specifically, the robot control unit51performs control to move the laser sensor3from a scan start position to an end position in a predetermined direction and at a predetermined speed. The sensor control unit52controls the laser sensor3to measure two-dimensional shapes of the mold6and the workpiece W. Specifically, the sensor control unit52causes the laser sensor3to emit the laser light source at each measurement position in the scanning direction, thereby irradiating the mold6and the workpiece W with the laser slit light3R. The workpiece rotation control unit53controls the workpiece rotation mechanism4to change the posture of the mold6to a required rotation posture.

The first recognition unit54performs calculation to obtain three-dimensional shape data of the mold6and the workpiece W by associating a plurality of pieces of two-dimensional shape data obtained by the laser sensor3with position data of the laser sensor3at the measurement of the two-dimensional shape. The second recognition unit55performs calculation for deriving a three-dimensional shape of the sheet layer by obtaining a difference between three-dimensional shape data before and after lamination of the sheet layer constituting the workpiece W. The operations of the first recognition unit54and the second recognition unit55will be described in detail later.

The determination unit56performs processing of determining whether a sheet layer is normal or not on the basis of a three-dimensional shape of the sheet layer derived by the second recognition unit55. The display control unit57performs control for causing the monitor11to display a determination result of the determination unit56in a predetermined display form. For example, when a defect is detected in a laminated state of the sheet layer, the display control unit57displays the defective part in color or the like to call for the operator's correction.

[Formation of Sheet Layer]

As described above, in the present embodiment, the workpiece W on the mold6is formed by laminating a plurality of sheet layers.FIGS.2A to2Dare schematic views showing a mode of lamination of sheet layers.FIG.2Ainclude a side view (left view) of the mold6and a perspective view (right view) thereof. Here, for simplification of illustration, a simple mold6made of a rectangular parallelepiped long in one direction is illustrated.

The mold6includes a surface61on which the sheet layer is laminated. The surface61is a surface that forms a shape of the workpiece W. For example, when the workpiece W is a simple flat plate-shaped member, the surface61is a horizontal plane as illustrated inFIG.2A. When the workpiece W is a member having a curved surface, the surface61is a plane having a planar shape along the intended curved surface. A plurality of sheet layers are sequentially laminated using the mold6having such surface61as described above as a base substrate.

FIG.2Billustrates a state in which a first sheet layer W11is laminated on the surface61of the mold6. The first sheet layer W11is formed, for example, by placing or attaching a sheet body processed in advance into a required shape and having a predetermined thickness on or to the surface61, or by arranging tape-type sheet pieces in parallel (FIG.3). As the sheet body or the sheet piece, a sheet made of metal, resin, or rubber, a composite sheet of resin and reinforcing fiber such as FRP, or the like can be used. In a subsequent sheet layer, a formed product in which the first sheet layer W11is formed on the mold6serves as a base substrate. In other words, the first sheet layer W11serves as a basic sheet layer WB on which the subsequent sheet layer is laminated.

FIG.2Cillustrates a state in which a second sheet layer W12is laminated on the first sheet layer W11. A mode of formation of the second sheet layer W12is similar to that of the first sheet layer W11.FIG.2Dillustrates a state in which a third sheet layer W13is further laminated on the second sheet layer W12. Specifically, the third sheet layer W13is laminated with the second sheet layer W12as the basic sheet layer WB. In lamination of the subsequent sheet layer, the third sheet layer W13serves as the basic sheet layer WB. Hereinafter, similar lamination work of sheet layers is performed as many times as the required number of layers.

When the work of laminating the sheet layers is completed and the workpiece W having a predetermined shape is formed on the mold6, the formed product is subjected to subsequent processing. The subsequent stage processing is, for example, vacuum processing and heating processing. Specifically, the mold6on which the workpiece W is formed is covered with a sealed bag and vacuumed to remove air and volatiles between the sheet layers. Next, heating processing is performed under a predetermined pressure to integrate the plurality of sheet layers constituting the workpiece W. Then, the workpiece W is released from the mold6to obtain a required molded component (or a complicated-shaped component).

FIG.3is a view schematically illustrating a formation example of one sheet layer (e.g., the first sheet layer W11). Here, an example is illustrated in which a sheet layer is formed by attaching a plurality of tape pieces7(sheet pieces) cut out from a tape roll70. The tape roll70is, for example, a roll around which a tape having a predetermined tape width is wound. A tape7A fed out from the tape roll70is pressed against the surface61of the mold6by an attaching roller26provided in an attaching head, and is attached to the surface61.

When the tape7A is attached from one end to the other end of the surface61, the tape7A is cut by a cutter (not illustrated). By this operation, the tape piece7for one pass is laminated on the surface61. Similarly, the tape piece7for the next one pass is laminated adjacent to the side of the laminated tape piece7. By such work, the first sheet layer W11formed by arranging the plurality of tape pieces7in parallel is laminated on the surface61. A plurality of tape rolls70and a plurality of attaching rollers26may be arranged in parallel to simultaneously attach a plurality of tape pieces7to the surface61. Similarly, the second sheet layer W12and the third sheet layer W13laminated on the first sheet layer W1can also be formed by parallel arrangement of the tape pieces7.

Here, whether or not the sheet layers W11, W12, and W13are laminated as specified is crucial for maintaining the quality of the workpiece W. In particular, as illustrated inFIG.3, in a case where one sheet layer is formed by arranging a plurality of tape pieces7in parallel, an overlap, a gap, and the like between the tape pieces7may occur. Therefore, it is necessary to inspect a laminated state of the sheet layer every time the sheet layer W11, W12, W13is laminated, and when a defect is detected in a sheet layer, it is necessary to modify the sheet layer.

FIG.4is a view illustrating a state in which shape recognition operation for the first sheet layer W11and the mold6is performed for the inspection of the first sheet layer W11(workpiece W). The laser slit light3R is emitted from the laser sensor3attached to the robot distal end2T which is the distal end of the robot arm21. The laser slit light3R is radiated over the entire width of the first sheet layer W11. The robot control unit51moves the robot distal end2T in a scanning direction F inFIG.4. Accordingly, the laser sensor3also moves in the scanning direction F, and the first sheet layer W11is scanned with the laser slit light3R. At the time of this scanning, a two-dimensional shape of the first sheet layer W11is measured at a predetermined pitch by a light cutting method. Then, a three-dimensional shape of the first sheet layer W11is obtained by connecting the acquired plurality of pieces of two-dimensional shape data.

Conventionally, a laminated state of a sheet layer has been evaluated only on the basis of three-dimensional shape data of the sheet layer. For example, in a case of inspecting the first sheet layer W11, evaluation has been performed on the basis of only a recognition result of a three-dimensional shape of the mold6on which the first sheet layer W1is laminated, the three-dimensional shape being acquired by the method illustrated inFIG.4. In this case, highly accurate recognition of a three-dimensional shape is required in order to detect minute irregularities or the like. Therefore, it is necessary to use a laser sensor having a high resolution as the laser sensor3.

In general, a high-resolution laser sensor3is extremely expensive, and application of the laser sensor3causes an increase in cost of the inspection device1. In addition, an inspection width by the laser slit light3R tends to be narrowed as a higher resolution is demanded. For this reason, as illustrated inFIG.4, a high-resolution laser sensor3having an inspection width which enables the entire width of the first sheet layer W11to be inspected in one scan is not actually put on the market. Therefore, a plurality of times of scanning is required in inspection of one sheet layer, resulting in causing a problem that takt time of an inspection process becomes long.

In view of such a problem, in the present embodiment, a relatively inexpensive laser sensor3having a wide inspection width although not having a high resolution is used. For example, the laser sensor3is used which has a resolution of about 0.04 mm to 1.6 mm, preferably about 0.1 mm to 1.2 mm, and an inspection width by the laser slit light3R of about 50 mm to 200 mm, preferably about 80 mm to 160 mm. Then, there is provided an inspection method enabling a laminated state of a sheet layer to be accurately evaluated while using such a laser sensor3.

[Shape Recognition on the Basis of Difference]

In the present embodiment, a three-dimensional shape of a sheet layer is derived and evaluated by obtaining a difference between three-dimensional shape data before and after lamination of the sheet layer. This method will be described with reference toFIGS.5and6.FIG.5Ais a diagram illustrating the state ofFIG.2A, i.e., a mode of measuring a three-dimensional shape of the mold6(first inspection object) before the first sheet layer W11is laminated. The surface61of the mold6is irradiated with the laser slit light3R from the laser sensor3. When a long side direction of the mold is defined as the X direction, the robot control unit51(FIG.1) of the controller5controls the articulated robot2A so that the laser slit light3R moves in the X direction and scans the surface61.

The sensor control unit52causes the laser sensor3to measure two-dimensional shape data of the surface61of the mold6at measurement points X=p1, p2, p3, p4, p5. . . p (n−2), p (n−1), and pn in the X direction. Each measurement pitch between p1and pn is, for example, 0.1 mm. The first recognition unit54obtains three-dimensional shape data (referred to as “first three-dimensional shape data”) of the surface61of the mold6by associating the measurement points p1to pn acquired by the laser sensor3with the position data of the laser sensor3at the measurement points p1to pn, respectively. As the position data of the laser sensor3, position control data of the robot distal end2T obtained by the robot control unit51can be used.

FIG.5Bis a diagram illustrating the state ofFIG.2B, i.e., a mode of measuring a three-dimensional shape of a formed product (second inspection object) in which the first sheet layer W11has been laminated on the surface61of the mold6. After the first sheet layer W11is laminated, three-dimensional shape data is obtained by the same procedure as described above. Specifically, the robot control unit51controls the articulated robot2A to scan the formed product with the laser slit light3R. The sensor control unit52causes the laser sensor3to measure two-dimensional shape data of the mold6including the first sheet layer W11at each of the measurement points X=p1to pn in the X direction. Then, the first recognition unit54obtains three-dimensional shape data (referred to as “second three-dimensional shape data”) of the mold6including the first sheet layer W11by associating the measurement points p1to pn acquired by the laser sensor3with the position data of the laser sensor3at the measurement points p1to pn, respectively.

When the first three-dimensional shape data and the second three-dimensional shape data are acquired by the first recognition unit54, the second recognition unit55performs processing of obtaining a difference between the two pieces of three-dimensional shape data.FIG.6Aschematically illustrates the processing performed by the second recognition unit55on the first sheet layer (first sheet layer W11). Shape data (1) on the left side indicates first three-dimensional shape data D11at the measurement point X=p2. In other words, the data is the shape data of the mold6at the position of X=p2before the first sheet layer W11is laminated.

On the other hand, shape data (2) indicates second three-dimensional shape data D12at the measurement point X=p2. Specifically, the data is the shape data at the position of X=p2of the formed product in which the first sheet layer W11has been laminated using the mold6as the base substrate. The second three-dimensional shape data D12includes a shaped portion DA protruding upward from the first three-dimensional shape data DI by an amount of lamination of the first sheet layer W11.

Accordingly, the difference between the shape data (1) and the shape data (2) serves as evaluation data of the first sheet layer W11. In other words, when the difference is obtained, the protruding shaped portion DA in the second three-dimensional shape data D12remains without being canceled. This shaped portion DA forms a three-dimensional shape of the first sheet layer W11laminated on the mold6. The determination unit56evaluates the three-dimensional shape of the first sheet layer W11on the basis of the three-dimensional shape derived by the second recognition unit55. In other words, with the first three-dimensional shape data D11as a reference, whether or not the thickness has increased as designed by an amount corresponding to the thickness of the first sheet layer W11is evaluated on the basis of the second three-dimensional shape data D12.

FIG.6Bschematically illustrates difference processing performed by the second recognition unit55on the second sheet layer (second sheet layer W12). In the lamination of the second sheet layer, a formed product in which a basic sheet layer including a laminated body of the first sheet layer W11is formed on the mold6serves as a base substrate (first inspection object). Therefore, in the second layer, the shape data (2) obtained by the previous measurement serves as first three-dimensional shape data D21.

Shape data (3) is three-dimensional shape data at the measurement point X=p2after the second sheet layer W12is further laminated on the first sheet layer W11of the basic sheet. The three-dimensional shape data serves as second three-dimensional shape data D22in the second layer. The second three-dimensional shape data D22includes a shaped portion DB protruding upward from the first three-dimensional shape data D21by an amount of further lamination of the second sheet layer W12. Then, a difference between the shape data (2) and the shape data (3) serves as evaluation data of the second sheet layer W12. In other words, when the difference is obtained, the protruding shaped portion DB in the second three-dimensional shape data D22remains without being canceled. The shaped portion DB forms a three-dimensional shape of the second sheet layer W12. On the basis of the three-dimensional shape, the determination unit56evaluates a three-dimensional shape of the second sheet layer W12. Hereinafter, the same applies to third, fourth . . . sheet layers.

Determination processing in the determination unit56is relatively simple. When a thickness of one sheet layer is known, it can be evaluated that a sheet layer to be evaluated is not formed at a portion where the thickness of one layer does not appear in a three-dimensional shape of the sheet layer, the three-dimensional shape being obtained on the basis of the difference. For example, it is assumed that a portion where a thickness corresponding to the thickness of the second sheet layer W12does not appear is detected in three-dimensional shape evaluation data of the second sheet layer W12. It can be found that the second sheet layer W12is not formed as specified due to, for example, missing of the tape piece7(FIG.3), a gap between the tape pieces7, and the like. When there is a portion where a thickness of two or more layers appears, it can be evaluated that the sheet layers are excessively laminated due to overlapping of the tape pieces7or the like.

As described above, adopting the evaluation method based on a difference between before and after lamination of the sheet layer means that the laser sensor3having a relatively low resolution is sufficient. Specifically, as long as the laser sensor3has a resolution enabling determination of a thickness of one sheet layer (tape piece7) to be laminated, it is possible to find missing or overlapping of the tape piece7. For example, if a thickness of one sheet layer is 0.2 mm, the laser sensor3having a resolution on the order of 0.1 mm can be used. Since the laser sensor3having such a degree of resolution is put on the market as a relatively inexpensive general-purpose laser sensor, the cost of the manning device S can be reduced. Assuming that the thickness of one sheet layer is T, a resolution R of the laser sensor3can be selected from the range of R=0.8T to 0.2T, preferably 0.3T to 0.6T from the viewpoint of enabling presence identification of the sheet layer and not requiring excessive resolution.

In the examples illustrated inFIGS.5A and5B, there is shown an example in which both the first three-dimensional shape data and the second three-dimensional shape data are obtained by actual measurement. Specifically, there is illustrated an example in which the mold6and the first sheet layer W11are actually scanned by the laser sensor3, and the first recognition unit54obtains each three-dimensional shape data. According to this method, since both the first three-dimensional shape data and the second three-dimensional shape data are acquired by actual measurement, the second recognition unit55can obtain a difference between both pieces of the data according to an actual laminated state.

Alternatively, for one of the first and second three-dimensional shape data, not an actual measurement value but shape data set in advance as a design value may be used. For example, when a three-dimensional shape of the mold6is known, the three-dimensional shape data is stored in the data server12(FIG.1) in advance. Then, programming may be prepared so that the three-dimensional shape data is read from the data server12as the first three-dimensional shape data when the second recognition unit55performs the processing of obtaining a difference. Alternatively, when a three-dimensional shape of the first sheet layer W11is known, the three-dimensional shape data is stored in the data server12in advance. Then, while the first three-dimensional shape data is acquired by actually measuring the three-dimensional shape of the mold6, the three-dimensional shape data of the first sheet layer W11may be read from the data server12as the second three-dimensional shape data. According to this method, acquiring one of the first three-dimensional shape data and the second three-dimensional shape data from the data server12brings an advantage that the scan time by the scanning device S can be shortened.

[Case of Sheet Layer Extending Across Plurality of Surfaces]

In the examples illustrated inFIGS.5A and5B, there is shown the example in which the first sheet layer W11is formed only on one surface61of the mold6. The sheet layer may be formed across a plurality of flat surfaces and curved surfaces.FIG.7Ais a perspective view illustrating an example in which a sheet layer WR is provided across a plurality of surfaces of the mold60. The mold60includes a first surface62, a second surface63(second surface having a different plane direction) orthogonal to the first surface62, and a curved surface portion64located therebetween. The sheet layer WR is formed across the first surface62to the second surface63.

FIG.7(B)is a side view of the mold60illustrating a state before the sheet layer WR is laminated and a state after the sheet layer WR is laminated. Even in such a lamination mode of the sheet layer, first three-dimensional shape data before the lamination of the sheet layer WR and second three-dimensional shape data after the lamination of the sheet layer WR are acquired similarly to the examples illustrated inFIGS.5A and5B. However, since not all the pieces of three-dimensional shape data of the first surface62, the second surface63, and the curved surface portion64can be acquired in one scan, each surface is scanned. At this time, the workpiece rotation control unit53(FIG.1) controls the workpiece rotation mechanism4(drive motor42) to rotate the mold60so that the mold60changes its posture to a posture suitable for scanning each surface.

FIGS.7C to7Eare views illustrating modes of scanning each surface.FIG.7Cis a view illustrating a state in which the first surface62is scanned with the laser slit light3R. At this time, the workpiece rotation mechanism4supports the mold60in a posture in which the first surface62is irradiated with the laser slit light3R from the opposed direction.FIG.7Dillustrates a state in which the curved surface portion64is scanned with the laser slit light3R. The curved surface portion64is a curved surface located at an intersection between the first surface62and the second surface63orthogonal to each other. Therefore, the workpiece rotation mechanism4rotates the mold60in a counterclockwise direction from the posture shown inFIG.7C, and supports the mold60in a posture in which the curved surface portion64is irradiated with the laser slit light3R from the opposed direction.FIG.7Eillustrates a state in which the second surface63is scanned with the laser slit light3R. The workpiece rotation mechanism4further rotates the mold60in the counterclockwise direction from the posture shown inFIG.7D, and supports the mold60in a posture in which the second surface63is irradiated with the laser slit light3R from the opposed direction.

In this case, before the sheet layer WR is laminated, the first recognition unit54acquires three-dimensional shape data of the first surface62, the second surface63, and the curved surface portion64of the mold60by each scan, and combines them to obtain first three-dimensional shape data. Then, after the sheet layer WR is laminated, three-dimensional shape data of the first surface62, the second surface63, and the curved surface portion64of the mold60are acquired by each scan, and are combined to obtain second three-dimensional shape data. The second recognition unit55derives a three-dimensional shape of the sheet layer WR by obtaining a difference between the first three-dimensional shape data and the second three-dimensional shape data.

[Example of Defect of Sheet Layer]

As illustrated inFIG.3, one sheet layer is formed by tightly attaching the tape pieces7having a predetermined width to the surface61of the mold6. If end edges of adjacent tape pieces7are arranged without gaps and without overlapping, the sheet layer becomes a sheet layer as designed unless other problem occurs. On the other hand, when a state of attachment of the tape pieces7to the surface61is insufficient, the sheet layer becomes a sheet layer having a defect.

Examples (A) to (E) ofFIG.8are views listing specific examples of defective taping of the tape pieces7to the mold6. The example (A) ofFIG.8illustrates defects of tape missing and a gap between tapes. The left view of the example (A) illustrates an example in which a tape missing portion M1occurs due to a lack of attachment of the tape piece7for one pass due to some defect. The right view shows an example in which a gap M21is generated between an ending edge of the tape piece71and a starting edge of the tape piece72in one pass, and an example in which a gap M22is generated between side edges of adjacent tape pieces7.

When the second recognition unit55derives a three-dimensional shape of such a defective sheet layer, the sheet layer has a three-dimensional shape in which no sheet thickness exists in parts corresponding to the tape missing portion M1, and the gaps M21and M22. The determination unit56determines that there is a defect in the sheet layer on the basis of the fact that no sheet thickness is detected in a part where the sheet thickness should originally exist. In addition, the display control unit57urges the operator to correct the sheet layer by displaying an image of the sheet layer on the monitor11, the image having the parts corresponding to the tape missing portion M1, the gaps M21and M22color-coded, and the like.

The example (B) ofFIG.8illustrates a defective tape overlapping. An end of a tape piece751overlaps a linearly attached tape piece73to form an overlapping portion M31. An end of a tape piece752overlaps both of tape pieces73and74arranged in parallel to form an overlapping portion M32. Further, tape pieces753and754overlap on the tape pieces73and74in a multiple manner to form an overlapping portion M33. When a three-dimensional shape of a sheet having such a defect is derived, in the overlapping portions M31and M32, detected at parts where the tape thickness of one layer of the tape piece73,74respectively should originally exist is a tape thickness of two layers including the thickness of the tape piece751,752superimposed. As for the overlapping portion M33, there are detected a portion having a tape thickness of two layers and a portion having a tape thickness of three layers.

The example (C) ofFIG.8shows defects such as tape peeling and tape loosening. The left view of the example (C) illustrates a loosening portion M41generated as a result of loosening of an end7E of the tape piece7from the surface61of the mold6. The right view shows a loosening portion M42generated as a result of loosening of an intermediate portion of the tape piece7from the surface61. Apart where such loosening portion M41, M42is generated is also detected as a portion where an excessively larger thickness is present than the original thickness of one layer of the tape piece7in a three-dimensional shape of a sheet layer derived by the second recognition unit55.

The example (D) ofFIG.8illustrates a defect of tape twisting. The left view of the example (D) illustrates a twisted portion M51in which the tape piece7is twisted once, and the right view illustrates a twisted portion M52in which the tape piece7is twisted twice. In the twisted portions M51and M52, the tape piece7has a rising part. The example (E) ofFIG.8illustrates a folded portion M6generated as a result of folding-back of the end7E of the tape piece7. A part where such twisted portion M51, M52or folded portion M6is generated is also detected as a portion where an excessively larger thickness is present than the original thickness of one layer of the tape piece7in a three-dimensional shape of a sheet layer derived by the second recognition unit55.

[Example of Preferred Use of Articulated Robot]

The articulated robot2A is allowed to execute various works. WhileFIG.1illustrates the use of the articulated robot2A as a mechanism for moving the laser sensor3, the articulated robot may also perform work of attaching the tape piece7to the mold6(work of forming a sheet layer on a base substrate).FIG.9is a schematic view illustrating an example in which a taping head TH and the laser sensor3are mounted on the articulated robot2A.

The articulated robot2A is a six-axis robot including the robot arm21and six joint shafts J1, J2, J3, J4, J5, and J6. The articulated robot2A is placed and fixed on the base stand20movable in the X direction. On the base stand20, a tape supply7S is mounted, the tape supply7S housing a plurality of the tape rolls70which are wound bodies of the long tape7A.

A tip fitting25is attached to the robot distal end2T. The tip fitting25can freely move in the XYZ directions and rotate about pitch, low, and yaw axes by the operations of the six joint shafts J1to J6. The taping head TH and the laser sensor3are attached to the tip fitting25. The tape supply7S supplies the long tape7A to the taping head TH.

The taping head TH includes the attaching roller26, a guide roller27, and a tape cutter (not illustrated). The attaching roller26presses the long tape7A supplied from the tape supply7S against the surface61of the mold6while rotationally traveling in a direction of an arrow F (scanning direction F). The guide roller27is a pair of rollers to which a rotation driving force is applied, and feeds the long tape7A toward the attaching roller26. The tape cutter (not illustrated) cuts the long tape7A into a length corresponding to a taping length of one pass from one end to the other end of the surface61to form one tape piece7.

The laser sensor3is attached to a rear side of the attaching roller26in a traveling direction (the arrow F). Therefore, while performing the work of attaching the long tape7A to the mold6by the attaching roller26, it is possible to immediately inspect an attaching state of the long tape7A. In other words, after the tape piece7for one pass is attached, the laminated state of the tape piece7can be inspected. Accordingly, an inspection time can be reduced. In addition, it is possible to immediately correct defective attachment of the tape piece7. In this case, a laminated state of the tape piece7for one pass is evaluated on the basis of a difference between three-dimensional shape data of the surface61before attachment of the tape piece7and three-dimensional shape data after attachment of the tape piece7for one pass.

[Example of Preferred Use of Orthogonal Axis Robot]

It is difficult for the orthogonal axis robot2B to also perform the work of attaching the tape piece7to the mold6. On the other hand, in the example of the articulated robot2A that performs inspection every time the tape piece7is attached, it is difficult to assume a mode in which the entire one sheet layer formed by attaching the plurality of tape pieces7in parallel is inspected by the laser sensor3. By contrast, in the orthogonal axis robot2B, since the laser sensor3that emits the laser slit light3R having a large irradiation width is used, it is easy to assume a mode in which the laser sensor3is moved (caused to scan) after the arrangement of all the tape pieces7for one sheet layer is completed. An advantage of this mode is that an inclination angle of the tape piece7can be determined.

FIG.10Ais a plan view illustrating an example in which the tape pieces7are attached obliquely to a mold60A having a reference hole for determining XY coordinates. In a case where the tape piece7is made of FRP, in order to direct a fiber direction of the tape piece to an intended direction, taping may be performed with an inclination with respect to a reference XY direction of the mold60A. When the inclination angle of the tape piece7deviates from a predetermined directional angle, quality of the workpiece W can be deteriorated.FIG.10Bis a view illustrating a defect of the inclination angle of the tape piece7. When an inclination angle D degree per length L (mm) of the tape piece7is larger than a predetermined threshold angle, an attachment defect occurs.

The mold60A includes four reference holes6R-1,6R-2,6R-3, and6R-4at corner portions outside a region to which the tape piece7is attached on the surface61. These reference holes6R-1to6R-4are holes whose shape can be recognized by scanning with the laser slit light3R. For example, a straight line connecting the reference holes6R-1and6R-2serves as an X-direction reference line, and a straight line connecting the reference holes6R-1and6R-3serves as a Y-direction reference line. In other words, it is possible to cause the inspection device1to know the XY coordinates on the surface61by scanning the surface including the reference holes6R-1to6R-4. Then, the inclination angle of the tape piece7can be evaluated on the basis of the XY coordinates.

According to the inspection device1(inspection method) for a sheet layer of the present embodiment described above, a three-dimensional shape of a sheet layer is evaluated on the basis of a difference between the first three-dimensional shape data and the second three-dimensional shape data, instead of depending only on three-dimensional shape data after lamination of the sheet layer. In other words, with the first three-dimensional shape data as a reference, whether or not the thickness of the sheet layer is increased as designed by the thickness corresponding to one layer is evaluated on the basis of the second three-dimensional shape data. Therefore, it is possible to use an inexpensive general-purpose laser sensor having a relatively low resolution as the laser sensor3of the scanning device S. Therefore, according to the inspection device1of the present embodiment, inspection of a laminated state of a sheet layer can be automated, and cost can be reduced.

Inventions Included in Above Embodiment

An inspection device for a sheet layer according to one aspect of the present invention is an inspection device that inspects a sheet layer laminated on a base substrate, the inspection device including: a scanning device including a laser sensor that measures a two-dimensional shape of an inspection object using laser slit light, and a movement mechanism that moves the laser sensor in a predetermined direction; a first recognition unit that obtains three-dimensional shape data of an inspection object by associating a plurality of two-dimensional shape data obtained by the laser sensor with position data of the laser sensor at the time of measuring the two-dimensional shape; and a second recognition unit that derives a three-dimensional shape of a sheet layer by obtaining a difference between first three-dimensional shape data indicating a three-dimensional shape of a first inspection object before the sheet layer is laminated on the base substrate and second three-dimensional shape data indicating a three-dimensional shape of a second inspection object after the sheet layer is laminated on the base substrate.

An inspection method for a sheet layer according to another aspect of the present invention is an inspection method for inspecting a sheet layer laminated on a base substrate, the inspection method including: moving a laser sensor that measures a two-dimensional shape of an inspection object using laser slit light so as to scan the inspection object with the laser slit light; obtaining three-dimensional shape data of an inspection object by associating a plurality of two-dimensional shape data obtained by the laser sensor with position data of the laser sensor at the time of measuring the two-dimensional shape; and deriving a three-dimensional shape of a sheet layer by obtaining a difference between first three-dimensional shape data indicating a three-dimensional shape of a first inspection object before the sheet layer is laminated on the base substrate and second three-dimensional shape data indicating a three-dimensional shape of a second inspection object after the sheet layer is formed on the base substrate.

According to the inspection device or the inspection method, a three-dimensional shape of a sheet layer is evaluated on the basis of a difference between the first three-dimensional shape data and the second three-dimensional shape data, instead of depending only on three-dimensional shape data after lamination of the sheet layer. In other words, with the first three-dimensional shape data as a reference, whether or not the thickness of the sheet layer is increased as designed by the thickness corresponding to one layer is evaluated on the basis of the second three-dimensional shape data. Then, when a thickness of the sheet layer is known, it can be evaluated that the sheet layer is not formed at a portion where the thickness of one layer does not appear in the three-dimensional shape based on the difference. In addition, a portion where the thickness of two or more layers appears can be evaluated as being excessively laminated with the sheet layers. Therefore, in the scanning device, a relatively low resolution is sufficient for the laser sensor. In other words, scanning using a relatively inexpensive general-purpose laser sensor that measures a two-dimensional shape of an inspection object using laser slit light is sufficient. Therefore, according to the above inspection device, inspection of a laminated state of a sheet layer can be automated, and cost can be reduced.

In the above-described inspection device for a sheet layer, it is desirable that the base substrate serving as the first inspection object is a laminated mold having a surface on which a sheet layer is laminated, or a formed product in which a basic sheet layer in which one or a plurality of sheet layers are laminated on the laminated mold is formed, and the second inspection object is a formed product in which a sheet layer is formed on the surface of the laminated mold, or a formed product in which a sheet layer is further formed on the basic sheet layer.

According to this inspection device, it is possible to sequentially evaluate laminated states of a sheet layer first laminated in the laminated mold and each sheet layer sequentially laminated on the sheet layer thereafter on the basis of a difference between the first three-dimensional shape data and the second three-dimensional shape data.

In the above-described inspection device for a sheet layer, it is desirable that both the first three-dimensional shape data and the second three-dimensional shape data are data obtained by actual measurement by the scanning device and the first recognition unit.

According to this inspection device, since both the first three-dimensional shape data and the second three-dimensional shape data are acquired by actual measurement, it is possible to obtain a difference between both pieces of the data according to an actual laminated state.

In the above-described inspection device for a sheet layer, it is desirable that one of the first three-dimensional shape data and the second three-dimensional shape data is shape data set in advance as a design value.

According to this inspection device, since one of the first three-dimensional shape data and the second three-dimensional shape data is acquired from the design value, scan time of the inspection object by the scanning device can be shortened.

In the above-described inspection device for a sheet layer, it is desirable that one of the sheet layers is formed by arranging a plurality of sheet pieces on the base substrate in parallel, and the movement mechanism of the scanning device moves the laser sensor after the arrangement of all of the plurality of sheet pieces is completed.

According to this inspection device, scanning operation can be simplified as compared with a case where the laser sensor is moved every time one sheet piece is arranged.

It is desirable that the above-described inspection device for a sheet layer further includes a support mechanism that supports the base substrate such that the base substrate has a changeable posture, in which the base substrate includes a first surface and a second surface having a plane direction different from a plane direction of the first surface, the sheet layer being laminated across the first surface and the second surface, and the support mechanism supports the base substrate such that the posture of the base substrate is changeable between a posture in which at least the first surface is irradiated with the laser slit light and a posture in which the second surface is irradiated with the laser slit light.

According to this inspection device, it is possible to efficiently evaluate a laminated state of a sheet layer laminated across a plurality of surfaces having different plane directions by changing the posture of the base substrate by the support mechanism.

In the above-described inspection device for a sheet layer, one of desirable modes is a mode in which the movement mechanism is an articulated robot, and the laser sensor is mounted on a robot distal end of the articulated robot.

According to this inspection device, since the laser sensor is mounted on the robot distal end of the articulated robot, an inspection object can be easily scanned with the laser slit light even if a planar shape of the sheet layer is complicated.

In this case, the articulated robot is desirably a robot that also performs work of forming the sheet layer on the base substrate.

This inspection device enables inspection of a laminated state of a sheet layer while forming the sheet layer on the base substrate.

In the above-described inspection device, one of desirable modes is a mode in which the movement mechanism is an orthogonal axis robot, and the laser sensor is mounted on a robot distal end of the orthogonal axis robot.

According to this inspection device, since the laser sensor is mounted on the robot distal end of the orthogonal axis robot, it is possible to quickly scan an inspection object with laser slit light.

According to the present invention, it is possible to provide an inspection device and an inspection method for a sheet layer which enable cost reduction to be achieved while automating inspection of a laminated state of the sheet layer.