JP4044720B2 - Parts counting and sorting device - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a component counting / sorting device that determines the quality of a component such as a screw and sorts and counts the component, and more particularly to a component counting / sorting device that can accurately provide the number of non-defective products.
[0002]
[Prior art]
2. Description of the Related Art Conventionally, a CCD camera is used in a component counting / sorting device for judging whether a part such as a screw is good or bad, and sorting out a good product or a defective product, thereby speeding up the sorting. In general, this type of component counting / sorting device is located between these parts supply unit, the quality determination unit for determining the quality of the component, the quality product recovery unit for recovering the determined quality product, and determined as defective. And a parts removing unit for removing the parts.
[0003]
[Problems to be solved by the invention]
The parts counting and sorting apparatus is configured such that the parts stored in the non-defective product collecting unit are counted and the parts are excluded by a shutter or the like when they reach a set quantity. Even if the number of parts reaches the desired number and the subsequent parts are to be removed, there is a drawback that the shutter does not operate in time, and more parts than the desired number are stored in the non-defective product collecting unit.
[0004]
An object of the present invention is to eliminate the above-mentioned drawbacks, and to provide a component counting and sorting apparatus that can accurately provide a set number of non-defective components.
[0005]
[Means for Solving the Problems]
A pass / fail judgment unit equipped with a drive motor for a transfer unit that mounts the components and passes the front of the CCD camera, a component supply unit that supplies the components onto the transfer unit, and two defective products located at the front and rear It has a parts exclusion unit with an exclusion part and a non- defective product collection part , stores the location information of the defective product exclusion part for each defect judgment of the pass / fail judgment part , and transfers the position information of the part that has reached the defective product exclusion part In the component counting and sorting apparatus configured to control the component exclusion unit depending on whether or not the position information of the drive motor that drives the table is within a predetermined allowable range,
While storing the position information of the defective product exclusion part of the front by the defect determination of the pass / fail determination unit, while storing the position information of the defective product exclusion part of the rear by the non-defective product determination,
At the front defective product exclusion part, when the position information of the part and the position information of the drive motor are within a predetermined allowable range, the part is excluded,
At the rear defective product exclusion part, when the position information of the part and the position information of the drive motor are within the predetermined allowable range, the part is passed without being excluded, and the position information of the part and the position information of the drive motor are within the predetermined allowable range. It is configured to eliminate parts when it is not.
[0008]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings. In FIG. 1, reference numeral 1 denotes a component counting / sorting device, and a component (not shown) is provided on a pass / fail judgment unit 2 having a CCD camera 2 a and a rotating disk 2 c as an example of a transfer unit constituting the pass / fail judgment unit 2. Component supply unit 3, component rejection unit 4 that eliminates components determined to be defective by quality determination unit 2, non-defective product collection unit 5, down counter 6 a that counts pulses of pulse encoder 2 e described later, and non-defective product determination The control unit 6 includes a counter 6b, an OK counter 6c, and a storage unit 6d. The pass / fail judgment unit 2 pulses in accordance with the rotation of the rotating disk 2c that receives the rotation of the driving motor 2b that rotates at a constant speed and the CCD camera 2a and the illuminating unit 2d and the driving motor 2b positioned so as to sandwich the vicinity of the circumference. It consists of a pulse encoder 2e that outputs a signal. In the pass / fail judgment unit 2, when a component placed and moved near the circumference of the rotating disk 2c passes between the CCD camera 2a and the illumination unit 2d, the shape of the component is taken into the CCD camera 2a from the silhouette. Then, the image signal is sent to the control unit 6 to determine whether the part is good or bad. The CCD camera 2a is a line sensor, and is configured so that the shape of the entire component is captured as the component passes, but an area sensor (not shown) may be used. In addition, you may use the conveyor provided with the flat belt as a transfer part.
[0009]
The component supply unit 3 includes a vibratory bowl feeder 3a that supplies components with the component head down, and a linear feed feeder 3b that is connected to the components and supplies the components to the vicinity of the circumference of the rotating disk 2c. It is made up of.
[0010]
The component exclusion unit 4 includes an exclusion blade 4a and an air injection nozzle (not shown) disposed above the rotating disk 2c and at two defective product exclusion locations located at a predetermined distance from the CCD camera 2a. ) And a passage sensor that detects the passage of parts in front of the air injection nozzle. Upon receipt of the exclusion blade drive command signal and the air injection nozzle drive command signal from the control unit, the removal blade 4a and the air injection nozzle Each is configured to operate.
[0011]
The non-defective product collecting unit 5 is provided close to the rotating disk 2c, and further drops from the rotating disk 2c with a guide block 5a for dropping a component placed on the rotating disk 2c onto a non-defective box (not shown). It consists of a non-defective sensor (not shown) that detects the passage of parts.
[0012]
When the control unit 6 receives the work start signal, as shown in FIG.
1) An operation command signal is output to the component supply unit (accuracy determination unit, drive motor, CCD camera and illumination unit operation, each flag = 0).
2) The image signal captured by the CCD camera is read.
3) It is determined whether or not the part center passage flag = 1, and when it is 1, the process jumps to 6).
4) It is determined whether or not the passage of the center of the part is detected. When the center of the part is not detected, the process returns to 2).
5) The value K of the down counter that counts the pulses from the pulse encoder is read, and this value K is temporarily stored (set to the part center passage flag = 1).
6) It is determined whether or not the part detection is completed. If this is not completed, the process returns to 2).
7) The feature value obtained from the image signal captured by the CCD camera is compared with the reference value of the component corresponding to this, and the quality of the component is determined. When the component is determined to be defective, the process jumps to 9). .
8) It is determined whether or not the determination end flag is not 0. When the determination end flag is not 0, the number of pulses N1 corresponding to the distance between the center of the CCD camera and the passing sensor is subtracted from the temporarily stored down counter value K. The obtained value is calculated as the position information of the part, and this is stored, and (jump address number + 1) is jumped to 11).
9) A value obtained by subtracting the pulse number N2 corresponding to the distance between the center of the CCD camera and the exclusion blade from the temporarily stored value K of the down counter is calculated as position information of the part, and this is stored (defective product address) Number +1).
10) Set the NG flag = 1 and return to 2).
11) The non-defective product determination counter is incremented.
12) It is determined whether or not the value of the non-defective product determination counter ≧ the value immediately before the inspection end, and whether or not the non-inspected part end flag = 0 is satisfied. When the part end flag is not 0, the process jumps to 15).
13) A stop command signal is output to the component supply unit (vibrating bowl feeder and linear feed feeder stop).
14) Set the uninspected part end flag = K−N3 (N3 is the number of encoder pulses corresponding to the distance from the tip of the linear feed feeder to the CCD camera).
15) It is determined whether or not the value of the non-defective product judgment counter ≧ the desired number. If the count value of the non-defective product judgment counter ≧ the desired number, the process returns to 2).
16) Set the determination end flag = K−N4 (N4 is the number of encoder pulses corresponding to the distance from the CCD camera to the non-defective sensor), and return to 2).
It is configured as follows.
[0013]
Further, the control unit 6 performs interrupt control every predetermined time, as shown in FIG.
1) It is determined whether or not the value K of the down counter when the center of the component is detected is equal to or less than the determination end flag.
2) It is determined whether or not K ≦ uninspected part end flag, determination end flag = 0, and feeder timer time ≠ 0, and K ≦ not inspected part end flag or determination end flag = 0. Or when feeder timer time ≠ 0, jump to 5).
3) An operation command signal is output to the component supply unit.
4) Set the jogging time to the feeder time.
5) It is determined whether or not the feeder timer time is not 0. When the feeder timer time is not 0, the process jumps to 8).
6) Feeder timer time = feeder timer time−1.
7) It is determined whether the feeder timer time = 0, and when the feeder timer time = 0, the process jumps to 9).
8) It is determined whether or not the determination end flag is not 0, and when the determination end flag is not 0, the process jumps to 12).
9) Output a stop command signal from the component supply unit, and jump to 12).
10) It is determined whether or not the value of the non-defective product determination counter ≦ the value of the OK counter. When the value of the non-defective product determination counter ≦ the value of the OK counter is not satisfied, the determination end flag = 0 and the non-defective product determination counter value = the OK counter value 2) Return to.
11) Output a stop command signal to the component supply unit.
12) Return.
It is comprised so that.
[0014]
Further, the control unit 6 performs an interrupt operation every predetermined time, and as shown in FIG. 4, 1) calls up the position information of the part corresponding to the read defective product address number.
2) It is determined whether or not the position information of this part and the value of the down counter are values within a predetermined allowable range. If they are not within the predetermined allowable range, the process jumps to 4).
3) An exclusion blade drive command signal is output (read defective product address number + 1).
4) Return.
It is comprised so that.
[0015]
Further, when the control unit 6 receives a passage signal from the passage sensor, it performs an interruption operation, as shown in FIG.
1) Call position information of the part corresponding to the read non-defective product address number.
2) It is determined whether or not the position information of this part and the value of the down counter are values within a predetermined range. If they are within the predetermined range, the read good product address number is incremented and the process jumps to 4).
3) An air injection nozzle drive command signal is output.
4) Return.
It is comprised so that.
[0016]
In addition, when the component exclusion part 4 is only any one of the exclusion blade | wing 4a and an air injection nozzle, you may memorize | store the position information of components at the time of any determination at the time of inferior goods determination.
[0017]
In the above-described component counting / sorting device, the pass / fail judgment unit 2 and the component supply unit 3 are actuated by the work start signal, and on the circumference of the rotating disk 2c where the components rotate at a constant speed from the vibratory bowl feeder 3a and the linear feed feeder 3b. And is supplied in front of the CCD camera 2a. Therefore, every time a component passes in front of the CCD camera 2a, the silhouette of the component is captured as an image signal. If the center position of the part passes in front of the CCD camera 2a by the completion of the capturing of the silhouette of the part, the value K of the down counter 6a for counting the pulses from the pulse encoder 2e at that time is read (parts passing flag) = 1), this is temporarily stored. When the capturing of the silhouette of the part is completed, the quality of the part is determined based on a comparison between the value of the feature point and a reference value set in advance corresponding thereto. If a failure is determined during the pass / fail determination, a value obtained by subtracting the number of pulses N2 corresponding to the distance between the center of the CCD camera and the removal blade from the value K of the down counter 6a , that is, the position of the defective component removal portion ahead. The information is calculated as the position information of the part, and this is stored in the storage unit 6d corresponding to the defective product address number (defective product address number + 1), and the NG flag = 1 is set, and the next part is awaited.
[0018]
Further, when the quality determination is made at the time of the quality determination, the value passes through the center of the CCD camera from the value K of the down counter 6a until the value of the quality determination counter 6b reaches the desired number (when the determination end flag = 0). The value obtained by subtracting the number of pulses N1 corresponding to the distance from the sensor , that is, the position information of the rear defective product exclusion part is calculated as the position information of the part, and this is stored in the storage unit 6d corresponding to the non-defective product address number ( The non-defective product address number + 1) and the value of the non-defective product determination counter 6b are incremented. After the value of the non-defective product determination counter 6b reaches the desired number (when determination end flag ≠ 0), the value of the down counter 6a is changed from the value K of the down counter 6a to the distance between the center of the CCD camera and the exclusion blade 4a for each subsequent determination. The value obtained by subtracting the corresponding pulse number N2, that is, the position information of the front defective product exclusion location is calculated as the position information of the component, and this is stored in the storage unit 6d corresponding to the defective product address number (defective product address number). +1) and NG flag = 1.
[0019]
While the pass / fail determination is repeated, interrupt control is activated at predetermined time intervals, and the value of the down counter 6a is compared with the position information of the component stored corresponding to the read defective product address number (initial value = 0). The When both values are within the predetermined allowable range, it is determined that the defective determination part is passing, and the rejection blade 4a located at the front defective product exclusion point is driven (read defective address number +1) and passes below. Defective parts are eliminated. When the two values are not within the predetermined allowable range, the exclusion blade 4a is not driven and the component passes.
[0020]
Further, when the part passes in front of the passage sensor located at the rear defective product exclusion part , the interrupt control is activated, and the part stored corresponding to the value of the down counter 6a and the read good product address number (initial value = 0). Is compared with the position information. When both values are within the predetermined allowable range, it is determined that the non- defective product determination part is passing, the air injection nozzle does not operate (read good product address number +1), and the interrupt control ends. On the other hand, when the two values are not within the predetermined allowable range, it is determined that a part other than the non-defective product judging part is passing, the air injection nozzle is activated, and the part passing in front of the part is excluded from the rotating disk 2c. . Therefore, can not detect the passage of the subsequent defect determination part when failure the determined component is reached below the exclusion blade 4a continuously Moreover close, and if the defect determination part is not eliminated, the front of the defective exclusion Of course, if there is an error in rejecting a defective judgment part at a part, even if the part is mixed on the rotating disk 2c without passing through the pass / fail judgment part, these parts are injected at the rear defective part exclusion nozzle. , The air from the air injection nozzle is surely excluded from the rotating disk 2c.
[0021]
Accordingly, only the parts determined to be non-defective in the determination of good or bad pass through the part exclusion unit 4 to reach the non-defective product collecting unit 5, and can be dropped to the non-defective product storage box from the circumference of the rotating disk 2c by the guide block 5a. . At this time, each time one component falls, a pass detection signal is output from the non-defective sensor, and this is integrated by the OK counter 6c.
[0022]
On the other hand, when these series of operations are repeated and the value of the non-defective product determination counter 6b reaches the value immediately before the inspection end, the component supply unit 3 stops (uninspected component end flag = K−N3). Thereafter, the pass / fail determination is repeated for the parts on the rotating disk 2c, and when the value of the down counter 6a reaches the desired number (determination end flag = K−N4), the pass / fail determination is made in the subsequent pass / fail determination. At this time, the interrupt control is activated every predetermined time, and it is monitored whether or not the value of the down counter 6a becomes equal to or smaller than the value of the determination end flag, and the value of the down counter 6a becomes equal to or smaller than the value of the determination end flag. Then, it is confirmed that the last non-defective product determination component placed on the rotating disk 2c has reached the non-defective product collecting unit 5. Thereafter, the value of the OK counter 6c is compared with the desired number, and when they match, the counting and sorting operation is completed. When the values do not match, the value of the OK counter 6c is set to the value of the non-defective product determination counter 6b (determination end flag = 0), and the component supply unit 3 is reactivated for a short time. The quality determination is repeated until the parts supply unit 3 is restarted, the value of the OK counter 6c matches the desired number, and the number of parts collected by the non-defective product collection unit 5 reaches the desired number. Moreover, since the number of parts collected by the non-defective product collecting unit 5 reaches the desired number, there is no part that is judged to be non-defective, so that all parts on the rotating disk 2c are excluded and the next work is performed. Can be provided.
[0023]
【The invention's effect】
As described above, the present invention is a pass / fail judgment unit including a drive motor for a transfer unit that mounts components and passes the front of the CCD camera, a component supply unit that supplies components onto the transfer unit, a component exclusion section having defective exclusion point of the two positions located before and after, and a good recovery unit, and stores the position information of the defective exclusion points for each defect determination of the acceptability judging section, the defective exclusion point In the component counting and sorting apparatus configured to control the component exclusion unit according to whether the position information of the reached component and the position information of the drive motor that drives the transfer table are within a predetermined allowable range,
While storing the position information of the defective product exclusion part of the front by the defect determination of the pass / fail determination unit, while storing the position information of the defective product exclusion part of the rear by the non-defective product determination,
At the front defective product exclusion part, when the position information of the part and the position information of the drive motor are within a predetermined allowable range, the part is excluded,
At the rear defective product exclusion part, when the position information of the part and the position information of the drive motor are within the predetermined allowable range, the part is passed without being excluded, and the position information of the part and the position information of the drive motor are within the predetermined allowable range. The configuration is such that parts are excluded when not.
According to this configuration, when the parts approach and pass through the pass / fail judgment unit and these parts are continuously judged to be defective, the leading part is surely removed at the front defective part exclusion point. Subsequent parts will pass through the defective part exclusion part ahead because of the part elimination time. In this case, since this part does not have the position information at the time of the non-defective product determination even if it reaches the rear defective product exclusion location, these can be surely eliminated at the rear defective product exclusion location. In addition, since all the parts that do not have the location information at the time of non-defective product judgment are excluded at this rear defective product exclusion location, of course, if there is a rejection error at the front defective product exclusion location, the pass / fail judgment section Even parts that have entered the transfer section without passing through can be reliably excluded, and only the parts that have been judged as good can be selected.
[Brief description of the drawings]
FIG. 1 is an overall explanatory diagram of a component counting / counting sorting apparatus according to the present invention.
FIG. 2 is a flowchart illustrating a main operation of a control unit according to the present invention.
FIG. 3 is a flowchart for explaining a component supply unit re-operation of a control unit according to the present invention.
FIG. 4 is a flowchart for explaining an exclusion blade driving operation of a control unit according to the present invention.
FIG. 5 is a flowchart illustrating an air injection nozzle driving operation of a control unit according to the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Parts count sorter 2 Pass / fail judgment part 2a CCD camera 2b Drive motor 2c Rotating disk 2d Illumination part 2e Pulse encoder 3 Parts supply part 3a Vibrating bowl feeder 3b Linear feed bowl feeder 4 Parts exclusion part 4a Exclusion blade 5 Non-defective goods collection part 5a Guide block 6 Control unit 6a Down counter 6b Non-defective product determination counter 6c OK counter 6d Storage unit

Claims (1)

A pass / fail judgment unit equipped with a drive motor for a transfer unit that mounts the components and passes the front of the CCD camera, a component supply unit that supplies the components onto the transfer unit, and two defective products located at the front and rear It has a parts exclusion unit with an exclusion part and a non- defective product recovery part , stores the location information of the defective product exclusion part for each failure judgment of the pass / fail judgment part , and transfers the location information of the part that reached the defective product exclusion part In the component counting and sorting apparatus configured to control the component exclusion unit depending on whether or not the position information of the drive motor that drives the table is within a predetermined allowable range,
While the defect determination of the acceptability judging section stores the position information of the front of the defective exclusion points, stores the positional information of the rear defective exclusion point by non-defective determination,
In the front defective product exclusion part, when the position information of the part and the position information of the drive motor are within a predetermined allowable range, the part is excluded,
At the rear defective product exclusion point, when the position information of the part and the position information of the drive motor are within the predetermined allowable range, the part is passed without being excluded, and the position information of the part and the position information of the drive motor are within the predetermined allowable range. A component counting and sorting apparatus characterized in that the component is excluded when not in operation .

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