JP7547981B2 - Inspection device and method for manufacturing concrete wall members - Google Patents

Description

The present invention relates to an inspection device for use in the manufacturing process of concrete wall members, and a manufacturing method for such wall members.

Patent Document 1 discloses a manufacturing method for producing precast concrete exterior wall materials by pouring ready-mixed concrete into a formwork. The formwork is installed on the top surface of a base that moves along a production line. After the ready-mixed concrete is poured into the formwork, reinforcing bars and a steel frame are embedded in the exterior wall material before the ready-mixed concrete (exterior wall material) hardens. After the exterior wall material hardens (cures), it is removed from the formwork.

JP 2000-246722 A

The thickness of the manufactured wall members is measured. If the measured thickness is not within the specified range, the manufactured wall member is discarded as defective. The occurrence of defective wall members reduces the yield.

The present invention was made in consideration of the above-mentioned circumstances, and its purpose is to provide a technology that improves the yield in the manufacture of concrete wall components.

(1) The inspection device according to the present invention includes a sensor group having a first distance measuring sensor and a second distance measuring sensor arranged at a distance from each other in a parallel direction and emitting a measurement wave in the same direction, a holder that holds the sensor group so as to be movable in a scanning direction that intersects the parallel direction and is along a horizontal direction, a drive device that drives the holder, a controller that controls the driving of the sensor group and the drive device, and a memory. The controller executes a scanning process that alternately executes a measurement process that drives the sensor group to perform a measurement, and a movement process that drives the drive device to move the sensor group in the scanning direction by a predetermined distance stored in the memory. The measurement process includes a first process that causes the first distance measuring sensor to emit a measurement wave toward the upper surface of a formwork extending in the scanning direction and along the horizontal direction, and causes the second distance measuring sensor to emit a measurement wave toward the upper wall surface of a wall member made of concrete in the formwork, and a second process that acquires a first measurement distance output by the first distance measuring sensor and a second measurement distance output by the second distance measuring sensor. The controller executes a calculation process to calculate a value corresponding to the difference between the first measurement distance and the second measurement distance measured simultaneously as a thickness corresponding value corresponding to the thickness of the wall member, and a storage process to store the thickness corresponding value in the memory.

The wall member is formed by fresh concrete poured into the formwork. The inspection device moves the sensor group in the scanning direction and performs measurements at predetermined distances. The first distance measuring sensor of the sensor group emits a detection wave to the top surface of the formwork in each measurement and outputs a first measured distance indicating the distance to the top surface of the formwork, and the second distance measuring sensor emits a detection wave to the upper wall surface of the wall member in each measurement and outputs a second measured distance indicating the distance to the upper wall surface of the wall member. The controller calculates a value corresponding to the difference between the first measured distance and the second measured distance as a thickness corresponding value corresponding to the thickness of the wall member. That is, the thickness corresponding value indicating the thickness of the wall member is measured at predetermined distances along the scanning direction. After checking the thickness corresponding value stored in the memory, the worker, for example, adds fresh concrete to the thinner part in an amount corresponding to the thickness corresponding value, removes fresh concrete from the thicker part in an amount corresponding to the thickness corresponding value, or smoothes the upper wall surface of the wall member, thereby bringing the thickness of the wall member within the appropriate standard range.

(2) The inspection device according to the present invention may further include a display device that displays an image indicated by image data input from the controller. The controller further executes a result display process that causes the display device to display an inspection result image indicating the thickness correspondence value or a value corresponding to the thickness correspondence value and the position on the upper wall surface where the thickness correspondence value was measured.

This configuration allows the worker to easily identify the thin and thick parts of the wall member.

(3) The controller may further execute a determination process for determining whether the thickness corresponding value or a value corresponding to the thickness corresponding value exceeds a threshold value stored in the memory, and an error notification process for indicating in the inspection result image that the thickness corresponding value or the value corresponding to the thickness corresponding value exceeds the threshold value based on the determination that the thickness corresponding value or the value corresponding to the thickness corresponding value exceeds the threshold value.

The threshold value is, for example, a value that corresponds to the standard range of the wall member specifications. If the thickness corresponding value exceeds the threshold value, i.e., if the thickness of the wall member is outside the standard range of the specifications, an error is reported.

(4) The inspection result image may have a rectangular frame object representing the formwork or the wall member, and the thickness correspondence value or a value corresponding to the thickness correspondence value superimposed on the corresponding measurement position in the frame object.

By overlaying thickness corresponding values on a frame object representing a formwork or wall member, workers can easily recognize which parts of the wall member are thin or thick.

(5) The value corresponding to the thickness corresponding value may be an average value of a predetermined number of the thickness corresponding values measured continuously, and the value corresponding to the thickness corresponding value may be displayed on the display device in the result display process.

Because the average value of a predetermined number of thickness corresponding values is displayed on the display device, the inspection device of the present invention allows the worker to check the thickness of the wall member more easily than if all thickness corresponding values were displayed.

(6) The sensor may include two sensor groups, a first sensor group and a second sensor group, and the holder may hold the first sensor group and the second sensor group spaced apart from each other in the parallel direction.

When measuring the thickness of both ends of a wall member in the parallel direction, if only one sensor group is used, the scanning process must be performed twice. By arranging the first center group and the second sensor group side by side in the parallel direction, it is possible to measure the thickness of both ends of the wall member with a single scanning process. As a result, the time required to inspect the wall member is reduced.

(7) The manufacturing device for wall members according to the present invention comprises a conveyor device having a table on which a formwork is placed and a pedestal that supports the table so as to be movable in a conveying direction, and an inspection device having a measuring device and a control device fixed to the pedestal. The measuring device has a sensor group having a first distance measuring sensor and a second distance measuring sensor that are arranged at a distance from each other in a parallel direction and emit measurement waves in the same direction, a holder that holds the sensor group so as to be movable in a scanning direction that intersects the parallel direction and is along the horizontal direction, and a drive device that drives the holder. The control device has a controller that controls the driving of the conveyor device and the inspection device, and a memory. The controller executes a scanning process that alternates between a measurement process that drives the sensor group to perform a measurement, and a movement process that moves the sensor group in the scanning direction by a predetermined distance stored in the memory. The measurement process includes a first process of causing the first distance measuring sensor to emit a measurement wave toward the upper surface of the formwork extending in the scanning direction and along the horizontal direction, and causing the second distance measuring sensor to emit a measurement wave toward the upper wall surface of a wall member made of concrete in the formwork, and a second process of acquiring the first measurement distance output by the first distance measuring sensor and the second measurement distance output by the second distance measuring sensor. The controller executes a calculation process of calculating a value corresponding to the difference between the first measurement distance and the second measurement distance measured at the same time as a thickness corresponding value corresponding to the thickness of the wall member, and a storage process of storing the thickness corresponding value in the memory.

The present invention can also be seen as a manufacturing device for wall members.

(8) The method for manufacturing a wall member according to the present invention uses a conveyor device having a table on which a formwork is placed and a pedestal that supports the table so as to be movable in a conveying direction, a measuring device fixed to the pedestal, and a control device. The measuring device has a sensor group having a first distance measuring sensor and a second distance measuring sensor that are arranged at a distance from each other in a parallel direction and emit measurement waves in the same direction, a holder that holds the sensor group so as to be movable in a scanning direction that intersects the parallel direction and is along the horizontal direction, and a drive device that drives the holder. The control device has a controller that controls the driving of the conveyor device and the measuring device, and a memory. The controller executes a scanning process that alternates between a measurement process that drives the sensor group to perform a measurement and a movement process that drives the drive device to move the sensor group in the scanning direction by a predetermined distance stored in the memory. The measurement process includes a first process of making the first distance measuring sensor emit a measurement wave toward the upper surface of the formwork extending in the scanning direction and along the horizontal direction, and making the second distance measuring sensor emit a measurement wave toward the upper wall surface of the wall member made of concrete in the formwork, and a second process of acquiring the first measurement distance output by the first distance measuring sensor and the second measurement distance output by the second distance measuring sensor. The controller executes a calculation process of calculating a value corresponding to the difference between the first measurement distance and the second measurement distance measured at the same time as a thickness corresponding value corresponding to the thickness of the wall member, and a storage process of storing the thickness corresponding value in the memory. The manufacturing method of the wall member according to the present invention includes a formwork installation process of installing the formwork on the table, a casting process of pouring ready-mixed concrete into the formwork, an inspection process of making the inspection device measure the wall member, and a curing process of curing the wall member after the inspection process is performed.

Because the wall components are measured (inspected) before the curing process, the thickness of the wall components can be partially adjusted by adding or removing fresh concrete to the wall components based on the measurement results. As a result, the yield of the wall components can be improved compared to when inspection is performed after the wall components are cured.

(9) The method for manufacturing a wall member according to the present invention may further include an embedding step, which is performed after the inspection step and before the curing step, of embedding an attachment member in the wall member from the upper wall surface.

The inspection process is carried out before the attachment members are embedded in the wall member. In other words, the work of adding, removing, and leveling the ready-mix concrete by the worker based on the measurement results is carried out with the attachment members not attached to the wall member. As a result, it becomes easier for the worker to add, remove, and level the ready-mix concrete.

The present invention can improve the yield in the production of concrete wall components.

FIG. 1 is a diagram showing a manufacturing line 10 for an exterior wall panel 80 . FIG. 2 is a perspective view of an exterior wall panel 80. FIG. 3 is a functional block diagram of the production line 10. FIG. 4 is a perspective view of formwork 30 placed on pallet 90. FIG. 5 is an explanatory diagram for explaining the casting of the exterior wall panel 80. FIG. 6 is an explanatory diagram for explaining the configuration and operation of the measuring device 60. As shown in FIG. FIG. 7 is an explanatory diagram showing measurement positions on the panel body 81. 8A is a diagram showing a test value specification table stored in the memory 72, and FIG. 8B is a diagram showing a test result table stored in the memory 72. As shown in FIG. FIG. 9 is a flow chart of a portion of the manufacturing process. FIG. 10 is a flow chart of another portion of the manufacturing process. FIG. 11 is a flow chart of the remainder of the manufacturing process. FIG. 12 is a diagram showing an image of the inspection result displayed on the display device 57. As shown in FIG. FIG. 13(A) is an explanatory diagram illustrating the first sensor group 65 and the second sensor group 66 relating to variant example 1, and FIG. 13(B) is an explanatory diagram illustrating the first sensor group 65, the second sensor group 66, and the third sensor group 123 relating to variant example 2. FIG. 14 is a diagram showing an inspection result image according to the first modification. FIG. 15 is an explanatory diagram illustrating the operation of the first sensor group 65 according to the third modification.

Below, an embodiment of the present invention will be described. Note that the embodiment described below is merely one example of the present invention, and it goes without saying that the embodiment of the present invention can be modified as appropriate without changing the gist of the present invention. For example, the order of execution of each process executed by control program 78 (FIGS. 9 to 11) may be modified as appropriate without changing the gist of the present invention, and some of the processes executed by control program 78 (FIGS. 9 to 11) may be omitted without changing the gist of the present invention.

In this embodiment, a manufacturing line 10 shown in FIG. 1 will be described. The manufacturing line 10 is a line for manufacturing a concrete exterior wall panel 80 (FIG. 2). As shown in FIG. 2, the exterior wall panel 80 comprises a rectangular plate-shaped panel body 81 made of concrete, a reinforcing bar member 82 (FIG. 5(B)) embedded in the panel body 81, and two rail members 83. The exterior wall panel 80 is an example of a wall member. The manufacturing line 10 is an example of a manufacturing device for a wall member.

As shown in FIG. 1, the manufacturing line 10 includes a multi-story warehouse 20, a formwork 30, a conveyor device 40, a tag reader 51, a hopper 52, sensors 53, 54, 55, 56, a display device 57, a measuring device 60, an embedding device 25, a demolding device 26, and a control device 70. The measuring device 60 and the control device 70 are examples of inspection devices.

The formwork 30 stored in the multi-story warehouse 20 is placed on the conveyor device 40 and transported. Ready-mix concrete held in a hopper 52 is poured into the formwork 30. The ready-mix concrete poured into the formwork 30 forms the panel body 81 of the exterior wall panel 80. A value corresponding to the thickness of the device body 61 is measured by the measuring device 60. After the measuring device 60 measures (inspects) the exterior wall panel 80 and before the ready-mix concrete hardens, the reinforcing bar member 82 and rail member 83 (FIG. 5(B)) are embedded in the panel body 81. After curing, the exterior wall panel 80 is removed from the formwork 30. The production line 10 will be described in detail below.

The multi-story warehouse 20 stores various forms 30. The multi-story warehouse 20 includes a transport device 21 (FIG. 3) that transports the stored forms 30 to the conveyor device 40, and a controller 22 (FIG. 3) that controls the driving of the transport device 21. The transport device 21 is, for example, a crane device. The configuration of the multi-story warehouse 20 is well known, so a detailed explanation is omitted, but the controller 22 of the multi-story warehouse 20 is connected to the control device 70 by a signal line 11. The controller 22 drives the transport device 21 based on a control signal input from the control device 70, and transports the type of form 30 indicated by the control signal to the conveyor device 40. In other words, the control device 70 can specify the type of form 30 and install it on the conveyor device 40 based on the control signal input to the multi-story warehouse 20. The signal line 11 is, for example, a LAN cable.

The multi-story warehouse 20 does not have to be connected to the control device 70. For example, a worker operates an operation panel attached to the multi-story warehouse 20 to cause the transport device 21 to transport the formwork 30 to the conveyor device 40.

The transport device 21 of the multi-story warehouse 20 may be a device that transports the formwork 30 to the conveyor device 40 and sets the formwork 30 on the conveyor device 40, or may be a device that transports the formwork 30 to the conveyor device 40. In this case, the formwork 30 transported to the conveyor device 40 is set on the conveyor device 40 by a worker.

The formwork 30 is placed on a pallet 90 as shown in FIG. 4. The pallet 90 is a rectangular plate, and is placed on the conveyor device 40 with one main surface facing down and the other main surface facing up. The formwork 30 may be stored in the multi-story warehouse 20 while still placed on the pallet 90.

The formwork 30 is placed on the top surface of the pallet 90 and fixed to the pallet 90. The state in which the formwork 30 is fixed to the pallet 90 will be described below.

The formwork 30 is a rectangular box that is open at the top and includes a rectangular bottom plate 31 and four side walls 32, 33, 34, and 35. The top surface of the bottom plate 31 has a pattern 37 formed by projections and recesses. The pattern 37 forms a pattern on the surface (surface facing outdoors) of the panel body 81. The bottom plate 31 is, for example, a rubber molded product.

The side walls 32 and 33 face each other in the horizontal direction. The formwork 30 is transported by the conveyor device 40 in a direction in which the side walls 32 and 33 face each other. In the following description, the direction in which the formwork 30 is transported is referred to as transport direction 9, and the side walls 32 are also referred to as the front side walls 32 and the side walls 33 are also referred to as the rear side walls 33.

The side walls 34 and 35 face each other in the vertical direction and in the width direction 8 perpendicular to the conveying direction 9. In the following description, the side wall 34 will also be referred to as the left side wall 34, and the side wall 35 will also be referred to as the right side wall 35.

The side walls 34, 35 are made of metal, for example. That is, the top surfaces 38 of the side walls 34, 35 can reflect laser light emitted by the first distance measuring sensor 101 and the third distance measuring sensor 103 (FIG. 6(B)) of the measuring device 60 described below. Note that the side walls 34, 35 may be made of resin, rubber, wood, etc., as long as they are capable of reflecting laser light, or a member such as metal foil that reflects laser light may be attached to the top surfaces 38 of the side walls 34, 35. The top surface 38 is an example of the top surface of the formwork.

An IC tag 92 (Figure 3) is affixed to the formwork 30 or the pallet 90. As shown in Figure 3, the IC tag 92 has an IC memory. The IC memory stores formwork information including the type and number of the formwork 30. The formwork type is information that allows the control device 70 to identify the size and type of pattern of the formwork 30. The formwork number is identification information that individually identifies the formwork 30. The formwork information is read by the tag reader 51 and input to the control device 70 via the signal line 11. In other words, the control device 70 can identify the type of formwork 30 being transported by the conveyor device 40.

As shown in FIG. 1, the conveyor device 40 includes a base 41, a table 42, and a transport device 43. The base 41 is placed on the factory floor and supports the table 42. The table 42 supports a pallet 90. The transport device 43 includes, for example, a drive motor and a chain driven by the drive motor. The driven chain moves the table 42 in the transport direction 9. The transport device 43 is connected to the control device 70 by a signal line 11. The drive motor of the transport device 43 is driven by a control signal input from the control device 70, and moves the table 42 in the transport direction 9. That is, the control device 70 can control the transport of the formwork 30 in the conveyor device 40 by inputting a control signal to the transport device 43.

The tag reader 51 is installed at a predetermined position relative to the conveyor device 40. Specifically, the tag reader 51 is installed at a position where it can perform near field wireless communication with the IC tag 92 of the formwork 30 being transported by the conveyor device 40.

The hopper 52 is a member that holds the ready-mixed concrete and allows the held ready-mixed concrete to flow into the formwork 30. The hopper 52 is installed in a position downstream of the tag reader 51 in the transport direction 9 of the formwork 30 transported by the conveyor device 40, and above the transported formwork 30. As shown in FIG. 5(A), the worker operates the hopper 52 to pour the ready-mixed concrete held by the hopper 52 into the formwork 30.

1 is a sensor for the control device 70 to detect that the formwork 30 conveyed by the conveyor device 40 has reached the hopper position below the hopper 52. The first sensor 53 is, for example, a mechanical switch such as a microswitch or limit switch having a pressing portion that is pressed by the formwork 30 or pallet 90 that has reached the hopper position. Alternatively, the first sensor 53 is a laser sensor, radio wave sensor, or sound wave sensor that emits light, radio waves, or sound waves that are reflected by the formwork 30 or pallet 90 that has reached the hopper position. The first sensor 53 is connected to the control device 70 by a signal line 11, and inputs detection information to the control device 70. When the control device 70 determines that the formwork 30 has reached the hopper position based on the detection information input from the first sensor 53, it controls the drive of the conveyor device 40 to stop the conveyance of the formwork 30. That is, the control device 70 can stop the formwork 30 at the hopper position.

The second sensor 54 is a sensor for the control device 70 to detect that the formwork 30 transported by the conveyor device 40 has reached the inspection position, which is the installation position of the measuring device 60 described later. The second sensor 54 is installed at a position downstream of the hopper 52 in the transport direction 9 of the formwork 30 transported by the conveyor device 40. For example, a sensor having the same configuration as the first sensor 53 is used for the second sensor 54. The second sensor 54 is connected to the control device 70 by a signal line 11 and inputs detection information to the control device 70. When the control device 70 determines that the formwork 30 has reached the inspection position based on the detection information input from the second sensor 54, it controls the drive of the conveyor device 40 to stop the transport of the formwork 30. In other words, the control device 70 can stop the formwork 30 at the inspection position.

The third sensor 55 is a sensor for the control device 70 to detect that the formwork 30 being transported by the conveyor device 40 has reached the embedding position of the reinforcing bar member 82 and the rail member 83. The third sensor 55 is installed at a position downstream of the second sensor 54 in the transport direction 9 of the formwork 30 being transported by the conveyor device 40. In other words, the reinforcing bar member 82 and the rail member 83 are embedded in the panel body 81 after the panel body 81 has been inspected.

The third sensor 55 may be, for example, a sensor having the same configuration as the first sensor 53. The third sensor 55 is connected to the control device 70 by a signal line 11, and inputs detection information to the control device 70. When the control device 70 determines that the formwork 30 has reached the burial position based on the detection information input from the third sensor 55, it controls the driving of the conveyor device 40 to stop the transport of the formwork 30. In other words, the control device 70 can stop the formwork 30 at the burial position.

The fourth sensor 56 is a sensor for the control device 70 to detect that the formwork 30 transported by the conveyor device 40 has reached the demolding position. The fourth sensor 56 is installed at a position downstream of the third sensor 55 in the transport direction 9 of the formwork 30 transported by the conveyor device 40. For example, a sensor having the same configuration as the first sensor 53 is used for the fourth sensor 56. The fourth sensor 56 is connected to the control device 70 by a signal line 11, and inputs detection information to the control device 70. When the control device 70 determines that the formwork 30 has reached the demolding position based on the detection information input from the fourth sensor 56, it controls the drive of the conveyor device 40 to stop the transport of the formwork 30. In other words, the control device 70 can stop the formwork 30 at the demolding position.

The embedding device 25 is a device that embeds the reinforcing bar member 82 and the rail member 83 in the panel body 81. The embedding device 25 is installed at the embedding position. The embedding device 25 includes, for example, a device body, a slide device, and an electromagnet. The slide device supports the electromagnet so that it can move up and down relative to the device body. The slide device is, for example, a hydraulic cylinder or an electric cylinder. The electromagnet attracts and holds the rail member 83 that holds the reinforcing bar member 82. The rail member 83 and the reinforcing bar member 82 held by the electromagnet are moved downward by the slide device, and as shown in FIG. 5(B), the rail member 83 and the reinforcing bar member 82 are embedded in the panel body 81. The rail member 83 and the reinforcing bar member 82 are examples of attachment members.

The demolding device 26 shown in FIG. 1 is a device that removes the exterior wall panel 80 from the formwork 30. The demolding device 26 is installed at the demolding position. The demolding device 26 has the same configuration as the embedding device 25, and includes a device body, a slide device, and an electromagnet. The worker operates the demolding device 26 to attract the electromagnet to the rail member 83, and then moves the electromagnet upward to remove the exterior wall panel 80 from the formwork 30 as shown in FIG. 5 (C).

The measuring device 60 is installed at the inspection position. Specifically, the measuring device 60 is installed at a position downstream of the hopper 52 in the conveying direction 9 of the formwork 30 conveyed by the conveyor device 40, and upstream of the embedding position in the conveying direction 9. That is, the thickness of the panel body 81 is inspected after the panel body 81 is formed and before the reinforcing bar members 82 and rail members 83 are embedded in the panel body 81. However, the thickness of the panel body 81 may also be inspected after the reinforcing bar members 82 and rail members 83 are embedded in the panel body 81 and before the panel body 81 is cured.

As shown in FIG. 6, the measuring device 60 includes a device body 61, an arm device 62, a driving device 63 (FIG. 3), an attachment member 64, a first sensor group 65, and a second sensor group 66.

The device body 61 is fixed to the base 41 (FIG. 1) of the conveyor device 40. For example, the device body 61 is fixed to a frame fixed to the base 41 using fasteners such as bolts.

The arm device 62 has a plurality of arms 67. Each arm 67 is connected to a joint mechanism 68 so that it can move relative to one another. The tip of the arm device 62 can move up, down, left, and right by each arm 67 and joint mechanism 68. The configuration of the arm device 62 is well known, so a detailed description will be omitted.

The drive device 63 (Figure 3) includes, for example, a drive motor and a drive mechanism that drives the arm device 62 with the driving force of the drive motor. The drive motor is connected to the control device 70 by a signal line 11. That is, the control device 70 can drive the arm device 62 by inputting a control signal to the drive motor. The arm device 62 is an example of a holder.

The mounting member 64 is attached to the tip of the arm device 62. The mounting member 64 is rod-shaped, and is moved in the conveying direction 9 or the opposite direction to the conveying direction 9 while being maintained in a position in which its longitudinal direction coincides with the width direction 8. In the following, the position in which the longitudinal direction of the mounting member 64 coincides with the width direction 8 will be described as the measurement position. The direction along the conveying direction 9 in which the mounting member 64 moves will be described as the scanning direction 7. The scanning direction 7 is a direction along the horizontal direction.

As shown in FIG. 6(B), the first sensor group 65 has a first distance measurement sensor 101 and a second distance measurement sensor 102. The first distance measurement sensor 101 and the second distance measurement sensor 102 are aligned along the longitudinal direction of the mounting member 64. The direction in which the first distance measurement sensor 101 and the second distance measurement sensor 102 are aligned is an example of a parallel direction. The parallel direction is along the width direction 8 in the measurement attitude, and is perpendicular to the up-down direction and the scanning direction 7.

The first distance measurement sensor 101 has a light emitting diode 105, a photodiode 106, and a control circuit (not shown). In the measurement position, the light emitting diode 105 is attached to the mounting member 64 in a direction that irradiates laser light downward. The photodiode 106 is attached to the mounting member 64 in a direction that receives laser light incident from below. In addition, in the measurement position, the light emitting diode 105 is located above the upper surface 38 of the left side wall 34 of the formwork 30. The laser light is an example of a measurement wave.

The control circuit of the first distance measuring sensor 101 is connected to the control device 70 by the signal line 11. The control circuit drives the light emitting diode 105 based on a control signal input from the control device 70, causing the light emitting diode 105 to irradiate laser light. The laser light irradiated by the light emitting diode 105 is reflected by the upper surface 38 of the left side wall 34 of the formwork 30 and received by the photodiode 106. The control circuit of the first distance measuring sensor 101 outputs a detection signal corresponding to the difference between the timing when the light emitting diode 105 irradiates the laser light and the timing when the photodiode 106 receives the reflected light. This detection signal indicates the distance between the first distance measuring sensor 101 and the upper surface 38 of the left side wall 34. In other words, the first distance measuring sensor 101 is a sensor that measures the distance to the upper surface 38 of the left side wall 34. In the following, the detection signal output by the first distance measuring sensor 101 will be described as the first measured distance. The first measurement distance output by the first distance measuring sensor 101 is input to the control device 70 via the signal line 11.

The second distance measurement sensor 102 has the same configuration as the first distance measurement sensor 101, and includes a light-emitting diode 107, a photodiode 108, and a control circuit. In the measurement position, the light-emitting diode 107 of the second distance measurement sensor 102 is located above the left end of the panel body 81.

The control circuit of the second distance measuring sensor 102 is connected to the control device 70 by a signal line 11. The control circuit drives the light emitting diode 107 based on a control signal input from the control device 70, causing the light emitting diode 107 to irradiate laser light. The laser light irradiated by the light emitting diode 107 is reflected by the upper surface of the panel body 81 and received by the photodiode 108. The control circuit of the second distance measuring sensor 102 outputs a detection signal corresponding to the difference between the timing when the light emitting diode 107 irradiates the laser light and the timing when the photodiode 108 receives the reflected light. This detection signal indicates the distance between the second distance measuring sensor 102 and the upper surface of the panel body 81. In other words, the second distance measuring sensor 102 is a sensor that measures the distance to the upper surface of the left end of the panel body 81. In the following, the detection signal output by the second distance measuring sensor 102 will be described as the second measured distance. The second measured distance output by the second distance measuring sensor 102 is input to the control device 70 through the signal line 11.

The second sensor group 66 includes a third distance measurement sensor 103 and a fourth distance measurement sensor 104. The third distance measurement sensor 103 has the same configuration as the first distance measurement sensor 101, and includes a light-emitting diode, a photodiode, and a control circuit. In the measurement position, the light-emitting diode of the third distance measurement sensor 103 is located above the top surface 38 of the right side wall 35 of the formwork 30. The control circuit of the third distance measurement sensor 103 is connected to the control device 70 by a signal line 11. The third distance measurement sensor 103 inputs a third measured distance indicating the distance to the top surface 38 of the right side wall 35 to the control device 70 via the signal line 11.

The fourth distance measurement sensor 104 has the same configuration as the second distance measurement sensor 102, and includes a light-emitting diode, a photodiode, and a control circuit. In the measurement position, the light-emitting diode of the fourth distance measurement sensor 104 is located above the right end of the panel body 81. The control circuit of the fourth distance measurement sensor 104 is connected to the control device 70 by a signal line 11. The fourth distance measurement sensor 104 inputs a fourth measured distance indicating the distance to the top surface of the right end of the panel body 81 to the control device 70 via the signal line 11.

The distance between the first sensor group 65 and the second sensor group 66 in the width direction 8 may be changed depending on the type of formwork 30. Specifically, the mounting member 64 is formed so that the sensor groups 65, 66 can be attached so that the distance can be changed. Alternatively, the distance can be changed by using various mounting members 64 with lengths according to the type of formwork 30.

In the following description, the first distance measurement sensor 101, the second distance measurement sensor 102, the third distance measurement sensor 103, and the fourth distance measurement sensor 104 will also be referred to as distance measurement sensors 101, 102, 103, 104 or the first distance measurement sensor 101, etc.

The display device 57 shown in FIG. 1 is a device that displays the results of the inspection performed by the measuring device 60. The display device 57 is connected to the control device 70 by a signal line 11.

The control device 70 shown in FIG. 3 is a personal computer, a tablet, or the like. The control device 70 includes a CPU 71, which is a central processing unit, a memory 72, a communication bus 73, a communication interface 74, an input interface 75, and a display 76. The CPU 71 is an example of a controller. Note that in FIG. 3, "interface" is abbreviated to "I/F."

The communication interface 74 is connected to the multi-story warehouse 20, the conveyor device 40, the tag reader 51, the sensors 53, 54, 55, 56, the display device 57, and the measuring device 60 by the signal line 11. The communication interface 74 may be wirelessly connected to the multi-story warehouse 20, the conveyor device 40, the tag reader 51, the sensors 53, 54, 55, 56, the display device 57, and the measuring device 60. The wireless communication connection may be, for example, Wi-Fi (registered trademark) or Bluetooth (registered trademark).

The input interface 75 is an interface to which an input terminal such as a keyboard, mouse, microphone, or touch sensor is connected. For example, if the control device 70 is a personal computer, the input terminal is a keyboard or mouse. If the control device 70 is a tablet, the input terminal is a touch sensor superimposed on the display 76.

The CPU 71, memory 72, communication interface 74, input interface 75, and display 76 are connected to the communication bus 73. That is, the CPU 71 can read information from the memory 72, store information in the memory 72, send and receive information via the communication interface 74, obtain information via the input interface 75, input image data to the display device 57, and display an image on the display device 57.

The memory 72 stores an operating system (OS 77), a control program 78, a test value identification table, a correspondence table, format data for the test result table, and original test result image data.

The control program 78 is a program that executes the manufacturing process shown in Figures 9 to 11. The manufacturing process is a process that causes the manufacturing line 10 to manufacture the exterior wall panel 80.

The inspection value identification table shown in FIG. 8 (A) is a data table used in the manufacturing process. The inspection value identification table has multiple records (rows) and multiple columns. In the illustrated example, the inspection value identification table has four columns. Each column is assigned the items "form type," "initial position," "inspection interval," and "inspection distance." In other words, the inspection value identification table is a data table that associates "form type," "initial position," "inspection interval," and "total inspection distance."

Each field in the column of the item "Form type" stores a form type. Form type "AK01" indicates, for example, the largest size form 30. Form type "FK15" indicates, for example, the smallest size form 30. Form type "CL32" indicates, for example, a medium size form 30. Note that the form type indicates not only the size of the form 30 but also the type of pattern 37. In other words, form 30 of the same size but with different patterns are different types of form 30.

Each field in the column of the item "initial position" stores the initial position of the mounting member 64 at the start of measurement. To explain in detail, the appropriate initial position of the mounting member 64 differs depending on the type of formwork 30. Each field in the column of the item "initial position" stores the appropriate initial position of the mounting member 64 according to the type of formwork 30. The initial position is, for example, coordinates (x, y) in a coordinate system defined by the x-axis and y-axis along a horizontal plane. For example, the worker actually transports the formwork 30 on the conveyor device 40 and stops it at the inspection position, and then manually operates the arm device 62 so that the mounting member 64 is in an appropriate initial position. Then, the worker inputs an instruction to the control device 70 to register the coordinates of that position as the initial position in the inspection value identification table in association with the type of formwork 30. That is, the worker teaches the initial position for each type of formwork 30.

In the manufacturing process described below, the control program 78 identifies an "initial position" in the inspection value identification table that corresponds to the type of formwork 30 being transported, moves the mounting member 64, i.e., the first distance measuring sensor 101, etc., to the identified initial position, and causes the measuring device 60 to start measuring.

Each field in the column of the item "Inspection interval" stores the inspection interval shown in FIG. 7. In FIG. 7, the multiple dots (black circles) indicated by the first measurement group 111 indicate the positions on the upper surface 38 where the first distance measurement sensor 101 performed the measurement. The multiple dots indicated by the second measurement group 112 indicate the positions on the panel body 81 where the second distance measurement sensor 102 performed the measurement. The multiple dots indicated by the third measurement group 113 indicate the positions on the upper surface 38 where the third distance measurement sensor 103 performed the measurement. The multiple dots indicated by the fourth measurement group 114 indicate the positions on the panel body 81 where the fourth distance measurement sensor 104 performed the measurement. That is, the thickness of the panel body 81 is inspected at multiple measurement positions along the conveying direction 9. The separation distance (interval) between adjacent measurement positions in the scanning direction 7 is the inspection interval.

In the inspection value identification table shown in FIG. 8(A), "inspection interval" is associated with "formwork type." That is, the thickness of the panel body 81 is measured at an inspection interval according to the type of formwork 30. In the example shown in FIG. 8(A), the inspection interval for the largest size formwork 30 (AK01) is 20 mm, the inspection interval for the smallest size formwork 30 (FK15) is 10 mm, and the inspection interval for the medium size formwork 30 (CL32) is 15 mm.

By changing the inspection interval according to the type (size) of the formwork 30, the number of measurements can be kept constant regardless of the size of the formwork 30, and the measurement time can be kept constant. Note that inspections may be performed at the same interval regardless of the size of the formwork 30. In that case, the inspection value identification table does not need to have the item "Inspection interval."

Each field in the column of the item "Total inspection distance" stores a distance according to the type of formwork 30. Specifically, each field in the column of the item "Total inspection distance" stores a distance slightly shorter than the length of the formwork 30 in the transport direction 9. In the manufacturing process described below (Figures 9 to 11), the control program 78 inspects the panel body 81 for the distance stored in the field in the column of the item "Total inspection distance". In other words, regardless of the type of formwork 30, the thickness is measured from one end of the panel body 81 to the other.

As shown in FIG. 8(B), the correspondence table is a data table showing the correspondence between the type (product number) of the exterior wall panel 80 and the formwork type. In the manufacturing process (FIGS. 9 to 11) described below, the control program 78 uses the correspondence table to identify the formwork type that corresponds to the type of exterior wall panel 80 to be manufactured, and manufactures the exterior wall panel 80 using a formwork 30 of the identified formwork type.

The format data of the inspection results is data that the control program 78 uses to generate the inspection results table shown in FIG. 8(C). In the manufacturing process described below (FIGS. 9 to 11), the control program 78 generates the inspection results table by storing the inspection results obtained by the measuring device 60 and values calculated from the inspection results in each field of the format data.

The format data has multiple records (rows) and multiple columns. In the illustrated example, the format data has 10 columns. Each column is assigned the items "inspection order," "inspection distance," "first measurement value," "second measurement value," "first thickness corresponding value," "first average value," "third measurement value," "fourth measurement value," "second thickness corresponding value," and "second average value."

Each field in the column of the item "Test Order" prestores the order of measurements on the panel body 81. For example, measurement order "1" indicates the first measurement shown in FIG. 7, and measurement order "10" indicates the tenth measurement shown in FIG. 7.

Each field in the "Inspection distance" column stores in advance the distance (such as "5", "25", or "45") from the edge of the panel body 81 (the right edge in FIG. 7) to each measurement position. When the formwork type is "AK01" and the inspection interval is "20", the inspection distance increases by "20" for every "1" increase in the inspection order. Note that the "25", "45", or the like in each field of the "Inspection distance" column may be calculated and stored by the control program 78. The control program 78 calculates "20" by dividing the total inspection distance of 2000 (FIG. 8(A)) by the number of inspection orders of 100, and adds (20 x (inspection order - 1)) to the distance of "5" to calculate the inspection distance, and stores the calculated value in each field of the "Inspection distance" column.

In each field of the column of the item "First measurement value", the first measurement distance input from the first distance sensor 101 is stored by the control program 78.In each field of the column of the item "Second measurement value", the second measurement distance input from the second distance sensor 102 is stored by the control program 78.In each field of the column of the item "Third measurement value", the third measurement distance input from the third distance sensor 103 is stored by the control program 78.In each field of the column of the item "Fourth measurement value", the fourth measurement distance input from the fourth distance sensor 104 is stored by the control program 78.

In each field of the column of the item "First thickness corresponding value", the control program 78 stores the value obtained by subtracting the first measured distance and a predetermined value "B" (FIG. 6B) from the second measured distance. In the manufacturing process (FIGS. 9 to 11) described below, the control program 78 calculates the first thickness corresponding value based on the first measured distance and the second measured distance input from the measuring device 60, and registers the calculated first thickness corresponding value in the measurement data (described below) generated from the format data.

The predetermined value "B" is a value at which the first thickness corresponding value is "0" when the thickness of the panel body 81 is the standard value in the specifications. In other words, when the thickness of the panel body 81 is the standard value in the specifications, the first thickness corresponding value is "0". When the thickness of the panel body 81 is thicker than the standard value in the specifications, the first thickness corresponding value is a negative value. When the thickness of the panel body 81 is thinner than the standard value in the specifications, the first thickness corresponding value is a positive value. In other words, the first thickness corresponding value is a value indicating the thickness of the left end portion of the panel body 81. The predetermined value "B" is, for example, 5 (mm).

In each field in the column of the item "First average value", the average value of the three first thickness corresponding values is stored by the control program 78. In the manufacturing process described below (FIGS. 9 to 11), the control program 78 calculates the first average value based on the calculated first thickness corresponding values, and registers the calculated first average value in the measurement data generated from the format data.

In each field of the column of the item "Second thickness corresponding value", the control program 78 stores a value obtained by subtracting the third measured distance and a predetermined value "B" from the fourth measured distance. The second thickness corresponding value is a value indicating the thickness of the right end portion of the panel body 81. In the manufacturing process described below (FIGS. 9 to 11), the control program 78 calculates the second thickness corresponding value based on the third measured distance and the fourth measured distance input from the measuring device 60, and registers the calculated second thickness corresponding value in the measurement data generated from the format data.

In each field of the column of the item "Second average value", the average value of the three second thickness corresponding values is stored by the control program 78. In the manufacturing process described below (FIGS. 9 to 11), the control program 78 calculates the second average value based on the calculated second thickness corresponding values, and registers the calculated second average value in the measurement data generated from the format data.

The inspection result image original data is data for generating an inspection result image (FIG. 12) to be displayed on the display device 57. As shown in FIG. 12, the inspection result image has a frame object 121 indicating the outline of the panel main body 81, a first thickness corresponding value, a second thickness corresponding value, and a warning object 122. In the example shown in FIG. 12, the warning object 122 is the character "NG." In the manufacturing process described below (FIGS. 9 to 11), the control program 78 generates inspection result image data by inputting data indicating the first average value, the second average value, and the position at which the warning object 122 is to be displayed into the inspection result image original data.

The manufacturing process executed by the control program 78 will be described below with reference to Figures 9 to 11. Note that the process executed by the control program 78 is the process executed by the CPU 71, which is the controller.

The operator inputs production schedule information into the control device 70 using an input terminal such as a keyboard or mouse. The production schedule information includes, for example, the production date, the type of exterior wall panel 80 to be produced on that production date, and the number of exterior wall panels 80 to be produced. As shown in FIG. 9, the control program 78 accepts the input of the production schedule information (S11) and stores the accepted production schedule information in the memory 72 (S12). The control program 78 then waits until a "start command" instructing the start of the production line 10 is input through the input interface 75 (S13: No).

When the control program 78 determines that a "start command" has been input (S13: Yes), it reads the production schedule information from the memory 72 and identifies the formwork type (S14). To explain in more detail, the control program 78 identifies the type (product number) of the exterior wall panel 80 to be manufactured today from the read production schedule information and today's date. The control program 78 identifies the formwork type that corresponds to the identified type of exterior wall panel 80 in the correspondence table (Figure 8 (B)).

Next, the control program 78 generates a measurement folder in association with today's date (S15). For example, the control program 78 generates a measurement folder whose folder name includes today's date.

The control program 78 also stores the measurement order "1" in the memory 72 as the initial value (S16). The measurement order stored in the memory 72 is used to generate the test result table. This will be described in more detail later.

The control program 78 inputs a control signal to the multi-story warehouse 20 via the communication interface 74, which indicates that the specified type of formwork 30 is to be transported to the conveyor device 40 and installed there (S17). The process of installing the formwork 30 on the conveyor device 40 is an example of a formwork installation process.

Next, the control program 78 inputs control signals to the transport device 43, tag reader 51, and sensors 53, 54, 55, and 56 of the conveyor device 40 through the communication interface 74 to drive them (S18). The driven transport device 43 transports the formwork 30. The driven tag reader 51 reads formwork information from the IC tag 92 affixed to the transported formwork 30 or pallet 90, and inputs the read formwork information to the control device 70. The control program 78 acquires the formwork information input from the tag reader 51 (S19).

The control program 78 generates measurement data using the acquired formwork information and the format data stored in the memory 72 (S20). Specifically, the control program 78 generates measurement data by storing format data in a measurement folder as measurement data, with the format data having a file name including the formwork type and formwork number indicated by the acquired formwork information. The measurement result table shown in FIG. 8 (C) is completed by storing the first measurement distance, etc. in each field of the measurement data. Note that the measurement result table shown in FIG. 8 (C) has a file name including the formwork type "AK01" and formwork number "032".

Next, the control program 78 acquires the detection information output by the first sensor 53 (S21). Based on the acquired detection information, the control program 78 determines whether the formwork 30 being transported has reached the hopper position (FIG. 1) (S22). The control program 78 repeatedly executes the processes of steps S21 and S22 until the formwork 30 reaches the hopper position. The control program 78 repeatedly acquires the detection information output by the first sensor 53 at time intervals of, for example, several milliseconds to several tens of milliseconds.

When the control program 78 determines that the formwork 30 has reached the hopper position (S22: Yes), it inputs a control signal to the conveyor device 40 through the communication interface 74 to stop the transport of the formwork 30 (S23). In other words, the transported formwork 30 is stopped at the hopper position.

The worker operates the hopper 52 to pour ready-mixed concrete into the formwork 30 located below the hopper 52 (Figure 5 (A)). The ready-mixed concrete poured into the formwork 30 forms a rectangular plate-shaped panel body 81. The process in which the worker operates the hopper 52 to pour ready-mixed concrete into the formwork 30 is an example of a casting process.

After pouring the ready-mix concrete into the formwork 30, the worker inputs a movement command to the control device 70 to indicate that the work is complete. For example, the worker inputs the movement command to the control device 70 by pressing an operation button attached to the conveyor device 40.

The control program 78 waits until a movement command is input (S24: No). Based on the input of a movement command (S24: Yes), the control program 78 inputs a control signal to the transport device 43 of the conveyor device 40 and instructs the conveyor device 40 to transport the formwork 30 (S25).

The control program 78 acquires detection information input from the second sensor 54 (S26). Based on the acquired detection information, the control program 78 determines whether the transported formwork 30 has reached the inspection position (S27). The control program 78 repeatedly executes the processes of steps S26 and S27 until the formwork 30 reaches the inspection position. The control program 78 repeatedly acquires the detection information output by the second sensor 54 at time intervals of, for example, several milliseconds to several tens of milliseconds.

When the control program 78 determines that the formwork 30 has reached the inspection position (S27: Yes), as shown in FIG. 10, it inputs a control signal to the conveyor device 40 via the communication interface 74 to stop the transport of the formwork 30 (S28).

Next, the control program 78 acquires the initial position, the inspection interval, and the total inspection distance (S29). To explain in more detail, the control program 78 identifies the initial position, the inspection interval, and the total inspection distance associated with the formwork type indicated by the formwork information acquired in step S19 in the inspection value identification table (Figure 8 (A)), and acquires the identified initial position, the inspection interval, and the total inspection distance.

The control program 78 inputs a control signal indicating the initial position to the measurement device 60 through the communication interface 74. The measurement device 60, which has received the control signal, drives the arm device 62 so that the attachment member 64 is positioned at the initial position indicated by the control signal. That is, the control program 78 moves the attachment member 64 to the initial position (S30).

The control program 78 inputs a control signal to the measurement device 60 via the communication interface 74 to drive the distance measuring sensors 101, 102, 103, and 104 and start measurement (inspection) (S31). The process of step S31 is an example of the first process.

When driven, the first distance measuring sensor 101 outputs a first measured distance, which is the distance to the top surface 38 of the left side wall 34 of the formwork 30. When driven, the second distance measuring sensor 102 outputs a second measured distance, which is the distance to the top surface of the left end of the panel body 81. When driven, the third distance measuring sensor 103 outputs a third measured distance, which is the distance to the top surface 38 of the right side wall 35 of the formwork 30. When driven, the fourth distance measuring sensor 104 outputs a fourth measured distance, which is the distance to the top surface of the right end of the panel body 81.

The control program 78 acquires the first measured distance, the second measured distance, the third measured distance, and the fourth measured distance output by the distance measuring sensors 101, 102, 103, and 104 through the communication interface 74 (S32). The processing of step S32 is an example of the second processing. The processing of steps S31 and S32 is an example of the measurement processing.

The control program 78 calculates a first thickness corresponding value by subtracting the first measurement distance and a predetermined value "B" (FIG. 6B) from the acquired second measurement distance, and calculates a second thickness corresponding value by subtracting the third measurement distance and a predetermined value "B" from the acquired fourth measurement distance (S33). The process of step S33 is an example of a calculation process.

The control program 78 registers the first measurement distance, the second measurement distance, the third measurement distance, and the fourth measurement distance acquired in step S31, and the first thickness corresponding value and the second thickness corresponding value calculated in step S32 in a field of the measurement data generated in step S20 that corresponds to the measurement order "1" stored in the memory 72 in step S16 (S34). That is, the measurement order "1" stored in the memory 72 identifies one record (the top record) in the measurement data, and the first measurement distance, etc. are registered in the identified record. The processing of step S34 is an example of a storage process.

Next, the control program 78 determines whether the "test order," which is set to an initial value of "1" in step S16 and is counted up each time the distance measuring sensor 101, etc. is moved in step S37 described below, has reached a predetermined value (S35). In the example shown in FIG. 8(C), the predetermined value is "100." That is, in step S35, it is determined whether the first distance measuring sensor 101, etc. has reached the edge of the panel body 81 (the left edge in FIG. 7).

When the control program 78 determines that the inspection order stored in the memory 72 has not reached the predetermined value (S35: No), it inputs a control signal to the measurement device 60 via the communication interface 74 to move the first distance measuring sensor 101, etc. along the scanning direction 7 by the inspection interval acquired in step S29. That is, the control program 78 moves the first distance measuring sensor 101 to the next measurement position (S36). The inspection interval is an example of a predetermined distance. Step S36 is an example of a movement process. The processes of steps S31, S32, and S36 are examples of a scanning process.

After moving the first distance measuring sensor 101 etc. by the inspection interval, the control program 78 counts up the inspection order stored in the memory 72 by "1" (S37).

After executing the process of step S37, the control program 78 executes the processes of steps S31 to S35 again. That is, the first distance measuring sensor 101, etc. alternates between measuring the distance and moving the first distance measuring sensor 101, etc. until the measurement order reaches the predetermined value "100". In addition, the measured distance, etc. is registered in the measurement data, and the measurement result table is completed.

When the control program 78 determines in step S35 that the inspection order has reached a predetermined value (S35: Yes), it calculates a first average value from the three first thickness corresponding values registered in the measurement data, calculates a second average value from the three second average values, and stores the calculated first average value and second average value in the measurement data field (S38). The first average value and the second average value are examples of values corresponding to the thickness corresponding values. The number of first thickness corresponding values and second thickness corresponding values for calculating the average value, "3", is an example of a predetermined number. Note that the average value of two or four or more first thickness corresponding values may be set as the first average value, and the average value of two or four or more second thickness corresponding values may be set as the second average value.

The control program 78 judges whether each of the calculated first average values exceeds a threshold range, and whether each of the calculated second average values exceeds a threshold range (S39). The threshold range is a range determined by a lower limit value and an upper limit value. The lower limit value is, for example, "-3", and the upper limit value is, for example, "+3". The threshold range is stored in advance in the memory 72. When the first average value or the second average value is below the lower limit value of the threshold range, it indicates that the thickness of the panel body 81 is thicker than the standard range. When the first average value or the second average value is above the upper limit value of the threshold range, it indicates that the thickness of the panel body 81 is thiner than the standard range. That is, in step S38, it is judged whether the thickness at each measurement position of the panel body 81 is within the standard range. The lower limit value and the upper limit value of the threshold range are examples of thresholds. Step S39 is an example of a judgment process.

When the control program 78 determines that the calculated first average value or second average value exceeds the threshold range (S39: Yes), it decides to display a warning for the first average value or second average value that exceeds the threshold range (S40). For example, the control program 78 identifies the first average value or second average value for which a warning is to be displayed by storing an "ON" warning display flag in the memory 72 in association with the first average value or second average value that exceeds the threshold range. On the other hand, when the control program 78 determines that the first average value or second average value does not exceed the threshold range (S39: No), it skips the processing of step S40. That is, in steps S39 and S40, the first average value and second average value for which a warning is to be displayed are identified.

Next, the control program 78 generates the inspection result image data based on the measurement result table, which is the completed measurement data, the warning display flag stored in the memory 72 in steps S39 and S40, and the inspection result image original data stored in the memory 72 (S41). Specifically, the control program 78 inputs the first average value and the second average value registered in the inspection result table, and data generated from the warning display flag and indicating the position at which the warning object 122 is to be displayed, into the inspection result image original data to generate the inspection result image data.

The control program 78 inputs the generated test result image data to the display device 57 via the communication interface 74, and causes the display device 57 to display the test result image (FIG. 12) indicated by the test result image data (S42). In the example shown in FIG. 12, the first average value and the second average value associated with the warning object 122, which is the character "NG", are displayed in red in the test result image, and are more emphasized than the other first average values and second average values displayed in black. The processing of steps S40 to S42, in which the control program 78 causes the display device 57 to display the test result image including the warning object 122, is an example of an error notification process.

The worker visually checks the inspection result image displayed on the display device 57, and based on the "NG" character displayed in the inspection result image and the first and second average values, confirms which areas of the panel body 81 are thinner than the standard value and which areas are thicker than the standard value, and how thin or thick they are. The worker adds an amount of ready-mixed concrete corresponding to the first average value to areas where the thickness is thinner than the standard value. The worker also removes an amount of ready-mixed concrete corresponding to the second average value from areas where the thickness is thicker than the standard value. Alternatively, the worker smoothes the top surface of the panel body 81 so that ready-mixed concrete moves from the thick areas to the thin areas.

After the worker adds or removes fresh concrete from the panel body 81 or smoothes the top surface of the panel body 81, the worker presses the remeasurement button attached to the conveyor device 40 to input a remeasurement instruction to the control device 70. Alternatively, the worker presses the end button attached to the conveyor device 40 to input an end instruction to the control device 70. Note that the remeasurement instruction or end instruction may be input to the control device 70 by a means other than the remeasurement button or end button. In that case, the remeasurement instruction or end instruction is input to the control device 70 through, for example, the input interface 75. The process in which the worker adds or removes fresh concrete from the panel body 81 or smoothes the top surface of the panel body 81 is an example of a correction process.

The control program 78 waits until a remeasurement instruction or an end instruction is input (S43: No and S44: No). When the control program 78 determines that a remeasurement instruction has been input (S43: Yes), it executes the processing from step S30 onwards again. Note that the first measurement distance measured by the processing from step S30 onwards that is executed again and the calculated first thickness corresponding value may be overwritten and stored in each field of the measurement data, which is, for example, a completed measurement result table, or new measurement data may be generated and stored in each field of the generated new measurement data.

The process in which the exterior wall panel 80 is inspected by processing steps S29 to S42 is an example of an inspection process.

When the control program 78 determines that an end command has been input (S44: Yes), it inputs a control signal to the transport device 43 of the conveyor device 40 through the communication interface 74, and causes the conveyor device 40 to transport the formwork 30, as shown in FIG. 11 (S45).

Next, the control program 78 acquires detection information input from the third sensor 55 (S46). Based on the acquired detection information, the control program 78 determines whether the transported formwork 30 has reached the burial position (S47). The control program 78 repeatedly executes the processes of steps S46 and S47 until the formwork 30 reaches the burial position. The control program 78 repeatedly acquires the detection information input from the third sensor 55 at time intervals of, for example, several milliseconds to several tens of milliseconds.

When the control program 78 determines that the formwork 30 has reached the embedding position (S47: Yes), it inputs a control signal to the transport device 43 of the conveyor device 40 via the communication interface 74 to stop the transport of the formwork 30 (S48). In other words, the formwork 30 is stopped at the embedding position. Note that the formwork 30 is transported to the embedding position before the ready-mix concrete that forms the panel body 81 hardens.

The worker operates the embedding device 25 to embed the reinforcing bar member 82 and the rail member 83 in the panel body 81. After embedding the reinforcing bar member 82 and the rail member 83 in the panel body 81, the worker presses an operation button attached to the conveyor device 40 to input a movement command to the control device 70. The process in which the worker operates the embedding device 25 to embed the reinforcing bar member 82 and the rail member 83 in the panel body 81 is an example of an embedding process.

After stopping the transportation of the formwork 30 (S48), the control program 78 waits until a movement command is input (S49: No). When the control program 78 determines that a movement command has been input (S49: Yes), it inputs a control signal to the transport device 43 of the conveyor device 40 to transport the formwork 30 and the exterior wall panel 80 (S50).

After the exterior wall panel 80 has been cured (hardened), it is transported by the conveyor device 40. The process of curing the exterior wall panel 80 is an example of a curing process.

Next, the control program 78 acquires the detection information output by the fourth sensor 56 (S51), and determines whether or not the formwork 30 has reached the demolding position based on the acquired detection information (S52). The control program 78 repeatedly executes the processes of steps S51 and S52 until the formwork 30 reaches the demolding position (S52: No). The control program 78 repeatedly acquires the detection information input from the fourth sensor 56 at time intervals of, for example, several milliseconds to several tens of milliseconds.

When the control program 78 determines that the formwork 30 has reached the demolding position (S52: Yes), it inputs a control signal to the transport device 43 of the conveyor device 40 via the communication interface 74, stops the transport of the formwork 30 (S53), and ends the manufacturing process.

The worker operates the demolding device 26 to pull the exterior wall panel 80 upward from the formwork 30, and demolds the exterior wall panel 80.

[Effects of the embodiment]
It is difficult to measure the thickness of the panel body 81 formed by the ready-mixed concrete poured into the formwork 30 before the panel body 81 hardens (cures), that is, while the panel body 81 is in the formwork 30. In this embodiment, a value corresponding to the difference between the distance to the upper surface 38 of the side walls 34, 35 of the formwork 30 and the distance to the upper surface of the panel body 81 is acquired as a value corresponding to the thickness of the panel body 81. Therefore, the thickness of the panel body 81 can be inspected while the panel body 81 is in the formwork 30. Therefore, the number of exterior wall panels 80 that do not meet the specifications can be reduced by an operator adding or removing ready-mixed concrete to the panel body 81 or smoothing the upper surface of the panel body 81. As a result, the yield in the manufacture of the exterior wall panels 80 can be improved.

In this embodiment, the first average value and the second average value are displayed superimposed on the frame object 121, allowing the worker to easily identify thick and thin areas of the panel body 81.

In this embodiment, if the first average value or the second average value is not within the threshold range, a warning object 122 with the letters "NG" is displayed on the inspection result image. Therefore, the worker can easily recognize that work such as adding or removing fresh concrete from the panel body 81 or smoothing the top surface of the panel body 81 is required.

In this embodiment, the average value of the three first thickness corresponding values and the average value of the three second thickness corresponding values are displayed in the inspection result image. Therefore, compared to the case where all the first thickness corresponding values and second thickness corresponding values calculated by measurement are displayed in the inspection result image, it is possible for the worker to easily check the thickness of the panel main body 81.

In this embodiment, the measuring device 60 is provided with two sensor groups 65, 66: a first sensor group 65 that inspects the left end of the panel body 81, and a second sensor group 66 that inspects the right end of the panel body 81. Therefore, both ends of the panel body 81 can be inspected with a single scan. As a result, the time required to inspect the exterior wall panel 80 can be shortened.

[Modification 1]
In the above embodiment, an example has been described in which the first sensor group 65 includes two distance measurement sensors 101 and 102, and the second sensor group 66 includes two distance measurement sensors 103 and 104. However, the first sensor group 65 and the second sensor group 66 may each include three or more distance measurement sensors. FIG. 13A shows an example in which the first sensor group 65 includes a first distance measurement sensor 101, a second distance measurement sensor 102, and a fifth distance measurement sensor 109, and the second sensor group 66 includes a third distance measurement sensor 103, a fourth distance measurement sensor 104, and a sixth distance measurement sensor 110. The fifth distance measurement sensor 109 is located above the panel body 81 in the measurement posture. In addition, in the measurement posture, the fifth distance measurement sensor 109 and the second distance measurement sensor 102 are aligned in the width direction 8. On the other hand, the sixth distance measurement sensor 110 is located above the panel body 81 in the measurement posture. In the measurement attitude, the sixth distance measuring sensor 110 and the fourth distance measuring sensor 104 are aligned in the width direction 8 .

In step S32 (FIG. 10), the control program 78 further acquires the fifth measurement distance output by the fifth distance sensor 109 and the sixth measurement distance output by the sixth distance sensor 110. In step S33, the control program 78 calculates the third thickness corresponding value by subtracting the fifth measurement distance and a predetermined value "B" from the second measurement distance, and calculates the fourth thickness corresponding value by subtracting the sixth measurement distance and a predetermined value "B" from the fourth measurement distance. The control program 78 registers the acquired fifth measurement distance and sixth measurement distance in the measurement data. In this modified example, the format data (FIG. 8(C)) further has columns with the items "fifth measurement distance", "sixth measurement distance", "third average value", and "fourth average value".

In step S38, the control program 78 calculates the average of the three third thickness corresponding values as the third average value, and also calculates the average of the three fourth thickness corresponding values as the fourth average value. Then, in step S39, the control program 78 further determines whether the third average value and the fourth average value exceed the threshold range, and if it determines that they do exceed the threshold range (S39: Yes), it decides to display a warning (S40).

The control program 78 generates test result image data (S41) and displays the generated test result image data on the display device 57 (S42). FIG. 14 shows the test result image displayed on the display device 57. The test result image in this modified example has a third average value and a fourth average value in addition to the first average value and the second average value.

[Effects of Modification 1]
In this modified example, the number of measurement positions can be increased without increasing the time required for measurement (inspection).

[Modification 2]
In this modified example, an example will be described in which the measuring device 60 further includes a third sensor group 123 in addition to the first sensor group 65 and the second sensor group 66. The second sensor group 66 is a sensor group that inspects the thickness of the right end of the large-sized panel body 81. The third sensor group 123 is a sensor group that inspects the right end of the small-sized panel body 81. The first sensor group 65 is a sensor group that inspects the thickness of the left end of the small-sized panel body 81 and the left end of the large-sized panel body 81. In other words, the first sensor group 65 is used in common for inspecting the large-sized panel body 81 and the small-sized panel body 81.

The third sensor group 123 has the same configuration as the second sensor group 66, and includes a seventh distance measurement sensor 124, an eighth distance measurement sensor 125, and a control circuit. In the measurement position, the seventh distance measurement sensor 124 is located above the upper surface 38 of the right side wall 35 of the small-sized formwork 30. In the measurement position, the eighth distance measurement sensor 125 is located above the right end portion of the small-sized panel body 81.

The control program 78 identifies the sensor group to be activated based on the formwork type included in the formwork information acquired in step S19. For example, if the identified formwork type is a small-sized formwork 30, the control program 78 identifies the first sensor group 65 and the third sensor group 123 as the sensor groups to be activated. The control program 78 then executes the processing from step S28 to S42 using the identified sensor groups.

[Effects of Modification 2]
In this modified example, it is possible to inspect the thicknesses of both the left and right ends of panel main bodies 81 of various sizes without replacing the mounting member 64 or changing the mounting position of the second sensor group 66. As a result, it is possible to save the worker the trouble of replacing the mounting member 64 or changing the mounting position of the second sensor group 66.

The measuring device 60 may have four or more sensor groups.

[Modification 3]
15, an example will be described in which the measuring device 60 (FIG. 6A) includes only one sensor group (first sensor group 65), and the first sensor group 65 moves back and forth along the scanning direction. The first sensor group 65 inspects the thickness of the left end of the panel body 81 on the outward path, and inspects the thickness of the right end of the panel body 81 on the return path.

In the correspondence table shown in FIG. 8 (B), "form type" and "slide distance" are further associated with each other. The control program 78 uses the form type included in the form information acquired in step S19 (FIG. 9) and the correspondence table to identify the slide distance (S29). The control program 78 repeats the processing of steps S30 to S37 to inspect the left end of the panel body 81 on the outbound path, then moves the first sensor group 65 along the width direction 8 by the identified slide distance, and repeats the processing of steps S31 to S37 to inspect the right end of the panel body 81 on the return path.

In this modified example, both the left and right ends of the panel body 81 can be inspected using only the first sensor group 65, so the number of distance measuring sensors used can be reduced compared to the embodiment.

In addition, in this modified example, it is possible to inspect the thicknesses of both the left and right ends of the panel body 81 of various sizes without replacing the mounting member 64 or changing the mounting position of the second sensor group 66 as in the embodiment. As a result, it is possible to save the worker the trouble of replacing the mounting member 64 and changing the mounting position of the second sensor group 66.

[Other Modifications]
In the above embodiment, an example has been described in which the arm device 62 moves the distance measuring sensors 101, 102, 103, and 104 along the scanning direction 7. However, instead of the arm device 62, a slide device may be used. The slide device includes, for example, a guide rail that holds the mounting member 64 movably along the scanning direction, a motor, and a drive mechanism. The drive mechanism includes, for example, a rack gear provided on the mounting member 64, and a drive gear that meshes with the rack gear and is rotated by the motor. The rack gear is rod-shaped along the scanning direction. When the motor is driven by a control signal input from the control device 70, the drive gear rotates, and the rack gear that meshes with the drive gear moves along the scanning direction together with the mounting member 64. The motor is an example of a drive device. The slide device is an example of a holder.

In the above embodiment, an example has been described in which the measurement device 60 includes distance measurement sensors 101, 102, 103, and 104 that emit laser light as a measurement wave. However, instead of the distance measurement sensors 101, 102, 103, and 104, the measurement device 60 may include a radio wave sensor or a sound wave sensor that emits radio waves or sound waves as a measurement wave as a distance measurement sensor.

In the above embodiment, an example has been described in which an IC tag 92 is affixed to the formwork 30 or the pallet 90, and the production line 10 is equipped with a tag reader 51. However, a QR code (registered trademark) may be affixed to the formwork 30 or the pallet 90 instead of the IC tag 92, and the production line 10 may be equipped with a camera having an image sensor instead of the tag reader 51. The camera inputs QR code image data generated by capturing an image of the QR code (registered trademark) to the control device 70. The control device 70 obtains information such as a URL and a file path from the QR code image data, and obtains formwork information from the information.

In the above embodiment, as shown in FIG. 8(A), an example has been described in which the inspection interval is set according to the type of formwork 30, and the panel body 81 is inspected at a fixed number (100) of measurement positions regardless of the type (size) of the formwork 30. However, the inspection interval may be fixed regardless of the type of formwork 30, and the number of measurement positions may be changed depending on the type of formwork 30. In that case, format data is stored in the memory 72 in the number corresponding to the number of types of formwork 30. The control program 78 generates measurement data using the format and data corresponding to the formwork type indicated by the formwork information acquired in step S19 (S20).

In the above embodiment, an example has been described in which the character "NG" is displayed on the test result image when the first average value or the second average value exceeds the threshold range. However, it is also possible to simply display the first average value or the second average value superimposed on the frame object 121 without determining whether or not the first average value or the second average value exceeds the threshold range.

In the above embodiment, the first average value and the second average value are displayed superimposed on the frame object 121 to allow the worker to recognize thick and thin areas of the panel body 81. However, other methods may be used to allow the worker to recognize thick and thin areas of the panel body 81. For example, instead of the frame object 121, the distance from the edge of the panel body 81 may be displayed in the inspection result image. In that case, the distance from the edge of the panel body 81 and the first and second average values are displayed in correspondence with each other. The worker recognizes thick and thin areas of the panel body 81 based on the associated distances.

In the above embodiment, an example has been described in which the first average value and the second average value are calculated and displayed in the inspection result image. However, the first thickness corresponding value and the second thickness corresponding value may be displayed directly in the inspection result image.

In the above embodiment, an example has been described in which the first thickness correspondence value is calculated by subtracting the first measurement distance and the predetermined value "B" from the second measurement distance. However, the first thickness correspondence value may also be calculated by subtracting the first measurement distance from the second measurement distance. In that case, the first thickness correspondence value is based on the predetermined value "B". In other words, a first thickness correspondence value that is greater than the predetermined value "B" indicates that the thickness of the panel body 81 is thinner than the standard value, and a first thickness correspondence value that is smaller than the predetermined value "B" indicates that the thickness of the panel body 81 is thicker than the standard value. The same is true for the second thickness correspondence value.

The first thickness correspondence value may also be calculated by subtracting the second measurement distance from a value obtained by adding a predetermined value "B" to the first measurement distance. That is, the positive and negative signs of the first thickness correspondence value may be reversed from those in the embodiment. In that case, a positive first thickness correspondence value or a positive first average value indicates that the panel body 81 is thick, and a negative first thickness correspondence value or a negative first average value indicates that the panel body 81 is thin. This allows the worker to more easily recognize whether each point of the panel body 81 is thick or thin.

The measurement data (inspection result table) generated in step S20 may be generated with a file name that includes the serial number in addition to the formwork type and formwork number. The serial number or information indicating the serial number may be written on the manufactured exterior wall panel 80. In this case, the inspection results for the manufactured exterior wall panel 80 can be identified by the serial number.

In the above embodiment, an example has been described in which a worker adds fresh concrete to the panel body 81, removes fresh concrete from the panel body 81, and smooths the top surface of the panel body 81 based on the inspection results. However, a device for adding fresh concrete to the panel body 81, removing fresh concrete from the panel body 81, and smoothing the top surface of the panel body 81 may be provided in the production line 10. In other words, the correction process of adding fresh concrete to the panel body 81, removing fresh concrete from the panel body 81, and smoothing the top surface of the panel body 81 may be performed automatically.

7: Scanning direction 8: Width direction 9: Conveying direction 10: Manufacturing line 11: Signal line 20: Multi-storey warehouse 25: Embedding device 26: Demolding device 30: Formwork 31: Bottom plate 32, 33, 34, 35: Side wall 38: Top surface (top surface of formwork)
40: Conveyor device 41: Base 42: Table 43: Transport device 51: Tag reader 52: Hopper 53, 54, 55, 56: Sensor 57: Display device 60: Measuring device 61: Device main body 62: Arm device (holding body)
63: Drive device 64: Mounting member 65: First sensor group 66: Second sensor group 70: Control device 71: CPU (controller)
72: Memory 74: Communication interface 75: Input interface 78: Control program 80: Exterior wall panel 81: Panel body 82: Reinforcing bar member 83: Rail member (attachment member)
90: Pallet 92: IC tag 101: First distance measuring sensor 102: Second distance measuring sensor 103: Third distance measuring sensor 104: Fourth distance measuring sensor 121: Frame object 122: Warning display object 123: Third sensor group

Claims (7)

A method for manufacturing a wall member using a conveyor device having a table on which a form is placed and a base that supports the table so as to be movable in a conveying direction, a measuring device fixed to the base, and a control device,
The measuring device is
a sensor group including a first distance measuring sensor and a second distance measuring sensor arranged in a parallel direction and spaced from each other and emitting measurement waves in the same direction;
a holder that holds the group of sensors so as to be movable in a scanning direction that intersects the parallel direction and is aligned along a horizontal direction;
A drive device that drives the holder,
The control device includes:
A controller for controlling the driving of the conveyor device and the measuring device;
A memory,
The above controller is
performing a scanning process that alternately performs a measurement process for driving the sensor group to perform a measurement and a movement process for driving the drive device to move the sensor group in the scanning direction by a predetermined distance stored in the memory;
The above measurement process is
a first process for causing the first distance measuring sensor to emit a measurement wave toward a top surface of the formwork extending in the scanning direction and along a horizontal direction, and causing the second distance measuring sensor to emit a measurement wave toward an end portion in the parallel direction of an upper wall surface of a wall member made of concrete within the formwork, the end portion being adjacent to the top surface of the formwork ;
a second process of acquiring a first measured distance output by the first distance measuring sensor and a second measured distance output by the second distance measuring sensor,
The above controller is
a calculation process of calculating a value corresponding to a difference between the first measured distance and the second measured distance measured at the same time as a thickness corresponding value corresponding to a thickness of the end portion of the wall member;
A storage process for storing the thickness corresponding value in the memory is executed;
a form setting process of setting the form on the table;
A pouring process of pouring fresh concrete into the formwork;
an inspection step of causing the measuring device to measure only the end portion of the wall member after the casting step ;
a correction step of correcting unevenness in thickness of the end portion by adding fresh concrete to the wall member in the formwork , removing fresh concrete from the wall member, or leveling an upper surface of the wall member based on the inspection result in the inspection step;
A method for manufacturing a wall member comprising: a curing step of curing the wall member. The apparatus further includes a display device for displaying an image represented by the image data input from the controller,
The above controller is
The method for manufacturing a wall member as described in claim 1, further comprising a result display process for displaying on the display device an inspection result image showing the thickness correspondence value or a value corresponding to the thickness correspondence value and the position on the top surface of the wall member where the thickness correspondence value was measured. The above controller is
a determination process for determining whether the thickness corresponding value or a value corresponding to the thickness corresponding value exceeds a threshold value stored in the memory;
The method for manufacturing a wall member as described in claim 2, further comprising: based on a determination that the thickness corresponding value or a value corresponding to the thickness corresponding value exceeds the threshold, executing an error notification process to indicate in the inspection result image that the thickness corresponding value or a value corresponding to the thickness corresponding value exceeds the threshold. The above test result image is
a rectangular frame object representing the formwork or the wall member;
The method for manufacturing a wall member according to claim 2 or 3, further comprising: the thickness corresponding values or values corresponding to the thickness corresponding values, which are respectively superimposed on the corresponding measurement positions in the frame object. The value corresponding to the thickness corresponding value is an average value of a predetermined number of the thickness corresponding values measured continuously,
The method for manufacturing a wall member according to claim 2 , wherein in the result display process, a value corresponding to the thickness corresponding value is displayed on the display device. The sensor device includes two sensor groups, a first sensor group and a second sensor group,
The method for manufacturing a wall member according to claim 1 , wherein the holding body holds the first sensor group and the second sensor group spaced apart from each other in the parallel direction. 7. The method for manufacturing a wall member according to claim 1, further comprising an embedding step, which is carried out after the correction step and before the curing step, of embedding an attachment member in the wall member from the upper wall surface.

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