Patent Application
20220099587
This patent application is based on and claims priority pursuant to 35 U.S.C. § 119(a) to Japanese Patent Application No. 2020-162221, filed on Sep. 28, 2020, in the Japan Patent Office, the entire disclosure of which is hereby incorporated by reference herein.
Embodiments of the present disclosure relate to an inspection apparatus, an inspection system, and an inspection method.
Conventionally, there is known an inspection apparatus that irradiates an inspection target with light, captures reflected light from a surface of the inspection target as image data, and detects an abnormality of the inspection target based on the image. In such an inspection apparatus, the inspection target is placed on a mount. To apply the irradiation light to the inspection target on the mount, for example, the position of the mount and the position of a light source of the inspection apparatus are set in accordance with the type and shape of the inspection target.
SUMMARY An embodiment of the present disclosure provides an inspection apparatus that includes a projector and an imaging device. The projector irradiates an inspection target with light according to pattern image data associated with the inspection target. The pattern image data specifies a pattern of light irradiation of the inspection target. The imaging device captures an image of the inspection target being irradiated with the light from the projector and outputs image data of the captured image.
Another embodiment of the present disclosure provides an inspection system that includes the above-described inspection apparatus and a management apparatus connected to the inspection apparatus to communicate with the inspection apparatus. The management apparatus includes a pattern image memory that stores the pattern image data, and circuitry to transmit the pattern image data to the inspection apparatus.
Another embodiment of the present disclosure provides a method for inspecting an inspection target. The method includes irradiating the inspection target with light according to pattern image data associated with the inspection target, capturing an image of the inspection target being irradiated with the light, and outputting image data of the captured image. The pattern image data specifies a pattern of light irradiation of the inspection target.
A more complete appreciation of the disclosure and many of the attendant advantages and features thereof can be readily obtained and understood from the following detailed description with reference to the accompanying drawings, wherein:
The accompanying drawings are intended to depict embodiments of the present invention and should not be interpreted to limit the scope thereof. The accompanying drawings are not to be considered as drawn to scale unless explicitly noted. Also, identical or similar reference numerals designate identical or similar components throughout the several views.
In describing embodiments illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the disclosure of this specification is not intended to be limited to the specific terminology so selected and it is to be understood that each specific element includes all technical equivalents that have a similar function, operate in a similar manner, and achieve a similar result.
In an inspection apparatus, in a case where the position of a mount and the position of a light source of are fixed, it is necessary to adjust the position of the light source and the position of the mount every time the type or shape of the inspection target changes, or it is necessary to introduce a new inspection apparatus for a new inspection target. It is difficult for such an inspection apparatus to inspect other inspection targets than a particular inspection target to which the inspection apparatus is dedicated. Thus, the conventional inspection apparatus has poor versatility.
Referring now to the drawings, embodiments of the present disclosure are described below. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.
Descriptions are given of a first embodiment of the present disclosure with reference to the drawings.
An inspection system 100 according to the present embodiment includes an inspection apparatus 200 and a management apparatus 300. In the inspection system 100, the inspection apparatus 200 and the management apparatus 300 are connected via a wired or wireless network to communicate with each other.
The inspection apparatus 200 according to the present embodiment includes a projector 210 and an imaging device 260. In the inspection apparatus 200, the projector 210 irradiates an inspection target with light according to pattern image data transmitted from the management apparatus 300. The imaging device 260 captures the reflected light from the inspection target as image data. The inspection apparatus 200 outputs (transmits) the captured image data to the management apparatus 300. The pattern image data according to the present embodiment is image data specifying the position at which the inspection target is irradiated with the light emitted from the projector 210. That is, the pattern image data specifies a pattern of light irradiation of the inspection target.
The management apparatus 300 may be, for example, a general information processing device including an arithmetic processor, a memory, and a communication interface. The management apparatus 300 includes a pattern image memory 310 that stores the pattern image data for each inspection target. The pattern image memory 310 may be a part of a storage device (storage area) included in the management apparatus 300, for example.
The pattern image memory 310 stores the pattern image data generated in advance for each inspection target. In other words, the pattern image memory 310 stores information for identifying an inspection target and pattern image data in association with each other.
In the present embodiment, for example, a plurality of pattern image data may be associated with one inspection target. In this case, when the inspection target is identified, the management apparatus 300 transmits, to the inspection apparatus 200, pattern image data corresponding to the inspection target.
In the present embodiment, as described above, the inspection apparatus 200 irradiates the inspection target with light according to the plurality of pattern image data, and captures the reflected light of he plurality of pattern image data. Thus, the position of the irradiation light on the inspection target can be easily changed.
Further, in the present embodiment, the pattern image memory 310 stores the pattern image data for each inspection target. This enables the inspection apparatus 200 to inspect the inspection target regardless of the type or shape of the inspection target.
In the present embodiment, when the pattern image data corresponding to the inspection target is not stored in the pattern image memory 310, the management apparatus 300 can generate the pattern image data corresponding to the inspection target, to enable the inspection.
In addition, the pattern image data associated with the inspection target may be determined as follows. For example, the pattern image data according to which an inspection target 250 is irradiated is sequentially switched among a plurality of pattern image data stored in the pattern image memory 310. Then, one of the plurality of pattern image data with which the imaging device 260 obtains most appropriate image data is determined as the pattern image data for the inspection target 250.
As described above, the present embodiment is advantageous in, for example, inspecting a small quantity of various kinds of inspection targets. By switching the pattern image data in accordance with the inspection target, the inspection apparatus 200 can inspect each inspection target of various kinds of inspection targets. Thus, the versatility of the inspection apparatus 200 improves.
A description is given of the inspection apparatus 200 according to the present embodiment, with reference to
The inspection apparatus 200 of the present embodiment includes the projector 210 (see
The projector 210 is fixed to the frame 225 and covered with the cover 215. In this state, the projector 210 is fixed to the upper side of the housing 220. The projector 210 irradiates the inside of the housing 220 with light according to the pattern image data transmitted from the inspection apparatus 200.
The housing 220 is attached to the frame 226 so as to cover the periphery of the frame 226 and prevents the inspection target from being irradiated with external light. The inside of the housing 220 is black. In the present embodiment, the housing 220 enables the inspection apparatus 200 to perform inspection with high reproducibility without being affected by environmental changes depending on the installation location of the inspection apparatus 200.
The housing 220 has an opening 240 into which the mount 230 is inserted.
The mount 230 is manufactured in advance for each inspection target 250 in accordance with the type, the shape, and the like of the inspection target 250. The mount 230 on which the inspection target 250 is placed is inserted into the opening 240.
In the example illustrated in
The frame 225 is a member for securing the projector 210 and the cover 215. To the frame 226, a fixing member 270 to which the imaging device 260 is fixed is attached. The imaging device 260 is fixed to an end of the fixing member 270. Note that the fixing member 270 and the imaging device 260 are disposed not to block the light emitted to the inspection target 250 (workpiece).
The imaging device 260 captures an image of the inspection target being irradiated with the light from the projector 210, and transmits the captured image data to the management apparatus 300.
Next, a description is given of the pattern image data transmitted from the management apparatus 300 to the projector 210 according to the present embodiment, with reference to
The management apparatus 300 may generate the pattern image data stored in the pattern image memory 310 in advance, or acquire pattern image data from an external device. The pattern image data can be generated in any pattern by any method.
The pattern image 51 is a projection image obtained by projecting such pattern image data that a rectangular region 51a in a central area is irradiated with the light. When the inspection target 250 is irradiated with the light according to the pattern image data of the pattern image 51, only a portion of the inspection target 250 corresponding to the rectangular region 51a is irradiated with the light.
Therefore, for example, in a case where the upper surface of the inspection target 250 is larger than the rectangular region 51a and includes the rectangular region 51a, only a portion of the upper surface of the inspection target 250 corresponding to the rectangular region 51a is irradiated with the light.
The pattern image 52 in
In addition, for example, in a case where the upper surface of the inspection target 250 is smaller than the rectangular region 52a, the side face of the inspection target 250 is also irradiated with the light from the projector 210.
The pattern image 53 in
When the pattern image 53 is projected onto the inspection target 250, a portion of the inspection target 250 corresponding to the region 53a is irradiated with light having a wavelength different from that of light with which other regions are irradiated.
The pattern image 54 in
Therefore, the region of the inspection target 250 irradiated with the light differs between the case where the inspection target 250 is irradiated with the pattern image data representing the pattern image 54A and the case where the inspection target 250 is irradiated with the pattern image data representing the pattern image 54B.
As described above, in the present embodiment, by causing the projector 210 to emit light according to the pattern image data specifying the light irradiation position, the light irradiation position on the inspection target 250, the wavelength of the light, and the like can be specified in advance.
In the present embodiment, the pattern image data can be generated by the management apparatus 300. Therefore, in the present embodiment, generating the pattern image data according to the type or the shape of the inspection target 250 enables the inspection system 100 to specify the light irradiation position, the wavelength of the light, or the like for each inspection target 250.
In other words, according to the present embodiment, the light irradiation position and the wavelength of the light are changed in accordance with the inspection target, and it is not necessary to adjust the position of the mount or the position of the light source for each inspection target. Thus, the versatility of the inspection apparatus improves.
A description is given of a second embodiment of the present disclosure with reference to the drawings. The second embodiment is different from the first embodiment in that the inspection apparatus includes a reflector that reflects light inside the housing and a diffuser that diffuses light, both disposed inside the housing of the inspection apparatus. Accordingly, in the description of the second embodiment below, different points from the first embodiment will be described. Components having substantially the same functions and configurations as those in the first embodiment are denoted by the same reference numerals as in the first embodiment, and redundant descriptions are omitted.
The inspection apparatus 200A illustrated in
Although the inspection apparatus 200A illustrated in
The reflectors 281 and 282 are secured to the frame 226. In other words, the reflectors 281 and 282 are disposed on the inner faces of the side walls of the housing 220. The reflectors 281 and 282 reflect light emitted from the projector 210 toward the center side of the housing 220. The reflectors 281 and 282 according to the present embodiment may be attachable to and detachable from the frame 226.
The diffuser 290 is made of, for example, a milky white resin. The diffuser 290 diffuses the light emitted from the projector 210 to a region corresponding to the shape of the diffuser 290. The diffuser 290 may be made of translucent glass or the like.
In addition, the diffuser 290 prevents the projector 210 from being reflected in a captured image of the inspection target 250, for example, in a case where the surface of the inspection target 250 is mirror-finished. The diffuser 290 according to the present embodiment may be attachable to and detachable from the frame 226. In the present embodiment, the imaging device 260 is disposed below the diffuser 290. That is, the diffuser 290 is disposed so as to cover the inspection target 250 and the imaging device 260.
A description is given below of an optical path of light emitted from the projector 210 in a case where the reflector 281 and the diffuser 290 are provided, with reference to
In
In
For example, it is assumed that the pattern image data at this time represents a projection image in which the region corresponding to the light L1 is red and the region corresponding to the light L2 is blue. In such a case, the region R1 of the inspection target 250 is irradiated with red light, and the region R2 is irradiated with blue light.
In another case where the pattern image data at this time represents a projection image in which the region corresponding to the light L1 is black and the region corresponding to the light L2 is white, the region R1 of the inspection target 250 is not irradiated with light, and the region R2 is irradiated with light.
In the present embodiment, the reflectors 281 and 282 and the diffuser 290 provided in this manner can irradiate the inspection target 250 with the light from different angles.
Further, in the present embodiment, by switching the pattern image data, the color and the angle of the light to the inspection target 250 and the light irradiation position can be changed.
In the present embodiment, the inspection apparatus 200A may further include a reflection plate 217 disposed, for example, as illustrated in
Further, as illustrated in
In the present embodiment, as illustrated in
The inspection apparatus 200A according to the present embodiment includes the reflectors 281 and 282 and the diffuser 290, but the structure of the inspection apparatus 200A is not limited thereto. Alternatively, the inspection apparatus 200A includes, for example, either the reflectors 281 and 282 or the diffuser 290.
To be specific, the inspection apparatus 200A may include only the reflectors 281 and 282, or only the diffuser 290.
Next, a description is given below of operation performed by the management apparatus 300 according to the present embodiment, with reference to
The management apparatus 300 determines the presence or absence of abnormality of the inspection target based on the image data transmitted from the imaging device 260 of the inspection apparatus 200.
The inspection target 250a illustrated in
In the example illustrated in
Therefore, in the example illustrated in
Specifically, the first and second pattern image data in
The management apparatus 300 according to the present embodiment acquires image data respectively representing the image 91 and the image 92 illustrated in
In
In
In
In the present embodiment, as described above, the management apparatus 300 determines the presence or absence of an abnormality in the inspection target 250a based on a plurality of pattern images of the inspection target 250a, and the plurality of pattern images are obtained by irradiation of the inspection target 250a according to a plurality of pattern image data, respectively.
As a result, the protrusions and a pit are detected from the image 91, and the flaw is detected from the image 92. As described above, in the present embodiment, by irradiating one inspection target 250a according to a plurality of pattern image data, the accuracy of detecting an abnormality in the inspection target 250a improves.
The management apparatus 300 may determine the presence or absence of an abnormality based on, for example, a change in the continuity of pixel values in image data representing the images 91 and 92, respectively. The management apparatus 300 may store in advance the image data of the inspection target 250 having determined as being fee of abnormality. Then, the management apparatus 300 detects the presence or absence of abnormality by comparing the image acquired from the inspection apparatus 200A with the image stored in advance.
The inspection target 250b illustrated in
In the example illustrated in
The inspection target 250b is associated with pattern image data that specifies irradiating the inspection target 250b, from directly above, with a striped pattern of light including bright regions and dark regions, and another pattern image data that specifies irradiating the inspection target 250b with a striped pattern in which the bright regions and the dark regions are reversed.
In the example illustrated in 10A to 10C-4, the inspection target 250b is associated with three pattern image data. In the following description, pattern image data corresponding to an image 101 in
The second pattern image data corresponding to
The management apparatus 300 according to the present embodiment acquires the image data representing the image 101, the image data representing the image 102, and the image data representing the image 103 from the inspection apparatus 200A, and determines whether there is an abnormality.
In
In
In
In
As described above, in the present embodiment, the management apparatus 300 determines that the inspection target 250b has an abnormality when determining that there is an abnormality in at least one of the plurality of image data respectively acquired by irradiation of the inspection target 250b according to the plurality of pattern image data.
In the present embodiment, as described above, use of a plurality of pattern image data enables detection of a local defect which is generally easily overlooked. Further, in the present embodiment, since a plurality of pattern image data is selectively used, local defects having different characteristics, such as white haze and pinholes, can be detected by a single inspection.
As described above, in the present embodiment, providing at least one of the reflectors 281 and 282 and the diffuser 290 increases variations of the angle of light with which the inspection target 250 is irradiated. In other words, in the present embodiment, providing at least one of the reflectors 281 and 282 and the diffuser 290 enables the inspection apparatus 200A to irradiate the inspection target 250 with light from various angles.
In addition, in the present embodiment, selective use of the pattern image data dedicated to each inspection target in irradiating the inspection target is advantageous in that the position of the irradiation light on the inspection target 250 and angle of the irradiation light to the inspection target 250 can be easily changed.
Therefore, according to the present embodiment, when the type or the shape of the inspection target is changed, the inspection can be performed only by switching the pattern image data. That is, the inspection apparatus 200A according to the present embodiment can inspect various types of inspection targets, and the versatility of the inspection apparatus improves.
In the above-described embodiment, the inspection apparatus includes a single projector, but the number of projectors is not limited to one. The inspection apparatus may include a plurality of projectors. In this case, an image based on the pattern image data may be projected into the space inside the housing using a plurality of projectors.
Aspects of the present disclosure are described based on the above-described embodiments, but the present disclosure are not limited to the elements of the above-described embodiments. The elements of the above-described embodiments can be modified without departing from the gist of the present disclosure, and can be appropriately determined according to the application form. Thus, numerous additional modifications and variations are possible in light of the above teachings. For example, elements and/or features of different illustrative embodiments may be combined with each other and/or substituted for each other within the scope of the present invention.
Any one of the above-described operations may be performed in various other ways, for example, in an order different from the one described above.
Each of the functions of the described embodiments may be implemented by one or more processing circuits or circuitry. Processing circuitry includes a programmed processor, as a processor includes circuitry. A processing circuit also includes devices such as an application specific integrated circuit (ASIC), a digital signal processor (DSP), a field programmable gate array (FPGA), and conventional circuit components arranged to perform the recited functions.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2020-162221 | Sep 2020 | JP | national |
