JPS5816510B2 - counting device - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a counting device that identifies objects to be counted based on a combination of their external shape and surface color.

In the case of high-variety, low-volume production, due to the low-volume production,
Products consisting of multiple types of models are produced continuously on the same production line.

Moreover, in recent high-mix, low-volume production lines, the models change frequently, and each time, it is possible to grasp the output of each model at each process and supply parts to the next process at °C. The production line will be disrupted.

Therefore, in terms of production management, it is necessary to accurately and quickly count the output of each model on each production line.

Incidentally, conventionally, the output of each model is counted by an inspector who visually determines the external dimensions and surface color of the object to be inspected.

Although this method is simple, it requires a dedicated inspector for counting, and also does not reduce the possibility of miscounts, resulting in poor reliability of the counting results.

Another method is the barcode method, in which a barcode sheet is attached to each model, and the number is read and counted by a detection device.

Although this method improves the reliability of counting compared to the above-mentioned method that relies on manual labor, on the other hand, the work of pasting the barcode paper itself is time-consuming, and this method does not require much effort in the painting process or heating/furnace process. has the inconvenience of not being applicable.

Various other counting methods have been developed and put into practical use depending on the characteristics of the object being tested.

However, in any of the conventional counting methods, the more the number of models to be identified becomes, the more complicated the counting task becomes, so in practice, the number of models to be identified is quite limited.

The present invention has been made in view of the above-mentioned circumstances, and the external shape discriminator outputs the difference in external dimensions of the test object as different combinations of a plurality of electrical signals, and the brown color discriminator outputs the difference in the external dimensions of the test object as a different combination of a plurality of electrical signals. Outputs an electrical signal corresponding to the intensity of light in a specific wavelength range among the reflected light of the reflected light, and further inputs an electrical signal from the outer shape discrimination section and an electrical signal from the color discrimination section to the arithmetic control section. This system is designed to identify differences in the objects to be tested based on these electrical signals.
It is an object of the present invention to provide a counting device that accurately and quickly counts various types of test objects based on combinations of external shapes and surface colors.

Hereinafter, the present invention will be described in detail based on embodiments with reference to the drawings.

FIG. 1 shows the counting device of the present invention and objects around it.

A plurality of test objects IAX1, ..., IGX5 are placed at approximately equal intervals on a conveyor 3 that moves in the two directions of the arrows.

The test objects IAX1, .

In other words, as shown in Table 1, there are 7 types of height H (A-G).
, and 5 different types for each height H (X1
-X5) There are models with different surface colors.

As a result, the test object IAXI......IGX
It consists of 135 types of models in total.

Further, these models are placed on the conveyor 3 at random.

A counting device of the present invention is installed along this conveyor 3.

The main parts of this counting device are composed of an external shape discriminating section 4, a color discriminating section 5, and an arithmetic control section 6 consisting of, for example, a microcomputer.

The external shape determining section 4 includes a pair of mounting frames 7a, 7b and a plurality of paired photoelectric switches 8a, 58a'...
... Consists of 8g and 8g'.

The mounting frames 7a and 7b each have two supports 9a...
・-・“°°9d and these pillars 9a・・・・mountain 9
It consists of bases 10, 10 for holding the conveyor 3, and is erected on both sides of the conveyor 3, facing each other.

In addition, the pillars 9a of the mounting frames 7a and 7b...
-・9d, the photoelectric switches 8a, 8a'...
...8g and 8g' are arranged so as to be able to rise and fall at predetermined intervals, which will be described later.

By the way, FIG. 2 shows a photoelectric switch 8a. 8a'...
......This is an explanatory diagram to show the arrangement positional relationship of 8g and 8g', but the surface color is white for ease of understanding.
Test objects IAX1 with different heights H for 1
, I BXl , I CX1. IDX1.

IEXl, IFXl, and 1GXI are shown stacked in the order of dimensions when placed on the conveyor 3.

Here, the pair of photoelectric switches 8a and 8a' are connected to the object I to be tested.
AX1 is arranged and placed opposite to each other at a height where the light projected from the light transmitting section 8a of the photoelectric switch and received by the light receiving section 8a' of the photoelectric switch is blocked by the portion 11 having a height H higher than the test object IBX1. There is.

Similarly, the photoelectric switches 8b and 8b' are also connected to the test object IBX1.
are disposed opposite to each other at a height where the light projected from the light transmitting section 8b of the photoelectric switch and received by the light receiving section 8b' of the photoelectric switch is blocked by a portion 12 having a height H higher than that of the test object ICX1.

Other photoelectric switch 8 Cy 8 c'-...
・8g and 8g' also correspond to models with different heights H, so test objects ICX1 are placed in order of height H...
When the IGX5s are lined up, they are disposed opposite to each other in positions that are blocked by portions with different heights H.

In addition, the light transmitting parts 8at8bt8cld, 8 of the charging switch
In order to prevent the light projected by et8f and et8g from being dispersed and entering a light receiving section other than the targeted light receiving section of the photoelectric switch, causing malfunction, the light transmitting section is set as shown in Fig. 1. 8a, 8b.

8C) 8d, 8e, 8f, 8g and light receiving section 8a'.

8b', 8c', 8ci', 8e', 8t"t
8g/ is installed alternately on the mounting frames γa and 7b, and on each support 9a and 7b.
-...They are arranged in a staggered manner on 9b.

That is, in the support 9a, the light transmitting parts 8a, 8c are arranged from above.
In the order of t8e and 8g, the light receiving portion 8b' of the pillar 9b is shown from above.

In the order of 8d' and 8f', from above in the pillar 9c, the light receiving parts 8a/, Bc/, 8e/, 8g
In the order of
, 8f.

Thus, the photoelectric switch 8a. 3 a/・・・・・
...8gt8g' is the test object IAX1...
---Signal level "1" when blocked by IGX5
When the signal is not blocked, a signal level of "0" is output.

On the other hand, the color discriminating section 5 is adjacent to the external shape discriminating section 4 on one side of the conveyor 30, and the object to be inspected IAX1...
・It is installed at a certain distance from the side surface 13 of IGX5.

As shown in FIG. 3, this color discrimination section 5 includes a light projecting device 14a,
14b and light receiving section 15 a 1.15 a 2.15
b 1.15 b 2, these are the first
They are each held on a mounting plate 17 attached to a base 16 shown in the figure.

The light projecting devices 14a and 14b are arranged parallel to each other and spaced apart by a predetermined distance so that their light projecting directions are perpendicular to the traveling direction of the conveyor 3.

Further, as shown in FIG. 3, cylindrical light receiving sections 15al and 15a2 sandwich the light projecting device 14a.
Test object IAX1・・・・・・・・・・IGX5 by a
The orientation is fixed so as to receive the diffusely reflected light from the light projecting portion.

Similarly, a cylindrical light receiving section 1 is placed across the light projecting device 14b.
5b1 and 15b2 are oriented and fixed so as to receive the diffusely reflected light from the portion of the light projecting device 14b projecting light onto the test object IAX1...IGX5.

Here, the light receiving portions 15aL15a2, 15bL15b
2 is the side surface 13 of the object to be inspected IAX1... IGX5 of the light projected from the light projectors 14a and 14b.
It is provided within the diffuse reflection area due to -...-.

In addition, the light receiving section 15aL 15a2, 15b1.15
A condenser lens 18 a 1.18 a is attached to one end of b2 on the side of the test object IAX1... IGX5.
2.18 b 1 t18b2 is installed,
At the other end, there are separate photoelectric converters 19aL 19a2, 19.
bl.

19b2 is attached.

Furthermore, the light receiving section 15 a 1.15 a 2.15
Inside the cylinder of b 1.15 b 2 are color selection filters 20a1, 20a2, 20b 1 + 20b2.
is built-in.

The color selection filter 20a1.20a2.20bl.

Among the filters 20b2, the color selection filters 20a1.20b1 have a characteristic of selectively transmitting only light in the wavelength range of 400nrrL to 500nm ((N) range) in FIG. 4.

Further, the color selection filters 20a2 and 20b2 have a characteristic of selectively transmitting only light in a wavelength range of 60011 m to 700 nm (H range) in FIG. 4.

Furthermore, the test object IA of the light projecting device 14a+14b
X 1-----I GXS side end 21a
, 21b includes a photoelectric converter 22 that detects the amount of light emitted.
a t 22 b is attached.

The photoelectric converter 19 a 1.19 a 2.19 b
1.

19b2, 22a, and 22b are each connected to an amplifier 23, as shown in FIG.

This amplifier 23 is connected to a test object I whose surface color X is white X1.
A.

The output voltage at the photoelectric converter 19a1219a2, 19b1 t19b2 that receives the reflected light when the light is projected from 14b is the reference voltage V.

Amplify by 1.

Further, the output voltage when the photoelectric converters 22 a and 22 b receive light from the respective light projecting devices 14 a and 14 b is amplified by the amplifier 23 to a reference voltage vL.

Furthermore, the amplifier 23 is electrically connected to the arithmetic control section 6 via an analog-to-digital converter 24 that performs digital conversion one channel at a time.

Further, as shown in FIG. 3, a test object detector 26 such as a limit switch is installed at the end 25 of the mounting plate 17, and a detection signal is output from the test object detector 26. When the external shape discriminating section 4 and the color discriminating section 5
is located at a position facing the side surface 13 of the object to be inspected.

This object detector 26 is connected to the arithmetic control section 6 as shown in FIG.

Similarly, the external shape discrimination section 4 also has a photoelectric switch 8a' on the light receiving section side.
, 8b'+ 8c', 8d'+ 8e', 8f'
.

Each unit 8a is connected to the arithmetic control unit 6.

The arithmetic control unit 6 includes a plurality of registers for separately storing arithmetic processing results.

It is also connected to the display section 27 of the arithmetic control section 6 .

The display section 27 includes a count display section 28, a discrimination section abnormality display section 29, and a printer section 30.

The display unit 27 includes an LED display 31 that shows the total number calculated by the calculation control unit 6, an LED display 32 that shows the type of model currently counted, and an LED display 3 that shows the amount of production.
3, a digital switch 34 for specifying the model, and an LED display 35 for indicating the output of the specified model.

Further, the discrimination section abnormality display section 29 is for displaying and warning whether the discrimination section is normal or abnormal, and includes an LED lamp 36 that lights up when each discrimination section is normal, and an LED lamp that lights up when the external shape discrimination section 4 is abnormal. 37, an LFD lamp 38 that lights up when the color discrimination section 5 is abnormal, and a buzzer 39 that issues an alarm when there is an abnormality.

Further, the printer section 30 prints the volume and total number of each model stored in the arithmetic control section 6.

Furthermore, the arithmetic control section 6 is electrically connected to an operation section 40 that operates or stops the device and operates the printer section 30.

Note that the amplifier 23 and the analog-digital converter 2
4. The display 27 is provided in the casing shown as the arithmetic control section 6 in FIG.

Next, the operation and operation of the counting device of the present invention will be explained with reference to FIGS. 6 to 9.

A test object IAX1...-IGX5 is conveyed on the conveyor 3, and the side surface 13 is the test object detector 2.
6, the test object detection signal WA is sent to the calculation control unit 6.
and add 1 to the total number already stored as shown at the beginning of the flowchart in Figure 6.
The addition result is stored in register RT as the current total number.

Next, the signals from each discrimination section are input to the arithmetic control section 6 to perform model discrimination.

To identify the model, first, the height detection signal Ha......Hg (see Fig. 5) is output from each photoelectric switch 8a...8a of the external shape discrimination section 4. ) are sequentially input into the register R1 as shown in FIG.

Then, this detection signal is set to the signal level "0" shown in Table 2.
The height is identified by comparing it with a detection signal model consisting of a combination of the signal level "1" and the signal level "1".

For example, when the height H is C, the detection signal Ha and the detection signal Hb are at the signal level "0", and the other detection signals Hc, Ha, He, Hf, and Hg are all at the signal level "1". Become.

According to the flowchart in FIG. 6, the combinations of the detection signals are sequentially checked from the combinations of height H and A in Table 2, and it is found that the combination of the detection signals corresponds to the combination of height H and C. The identification result is stored in the register RH.

When other combinations of detection signals are input, the same procedure is followed.

However, if the height H in Table 2 does not correspond to any of the heights A to H'b''-G, this is determined to be abnormal, and the LED lamp 37 lights up and the buzzer 39 sounds.

1. Next, after the signal processing from the external shape determination unit 4 is completed, the test object to be measured IAXI......IG
Light projecting devices 14 a , 14 projected onto the side surface 13 of X5
506 photoelectric converters 19a1, 19a2, 19b1°' 19 b
The output signals from 2 + 22 a and 22 b are each amplified by an amplifier 23 to obtain a photodetection signal voltage v1°v2.
V4. v5. V3. V6 data is output to the analog-to-digital converter 24.

The photodetection signal voltage v1. which is digitized by this analog-digital converter 24. v2. V4. v5. V3
．． Registers R2, R3, R4, R of V6c calculation control unit 6
5.

Input to R6 and R7.

As mentioned above, the photoelectric converters 22a and 22b are for detecting the amount of light projected from the light projecting devices 14a and 14b.

□The photodetection signal voltage V3. output from these photoelectric converters 22a, 22b. Although v6 is set to be the reference voltage vL, it changes over time due to various causes.

Along with this, photoelectric converters 19aL 19a2t 19b
The output voltage from L 19b2 also changes accordingly, causing an erroneous determination.

Therefore, photoelectric converters 22a and 22b for detecting the amount of light are used.
The correction coefficients (α) and (β) are calculated by dividing the reference voltage vL by the photodetection signal voltage 3°V6.

Thus, the above correction coefficient (α) is set to the photodetection signal voltage v1.
V2, and the above correction coefficient (β) is the photodetection signal voltage V4
．． The photodetection signal voltage V, , V2°V4.V5 is multiplied by the newly corrected photodetection signal voltage V, , V2°V4. Obtained V5,
These are converted to the original registers R2, R3, R5, R6 separately.
to update the memory contents.

Next, calculations for color discrimination are performed. The principle of color discrimination,
This will be explained based on FIG. 4, which shows the relationship between the wavelength of reflected light converted into an electrical signal by a photoelectric converter and its output voltage.

In region M, level L1, level L2, and level L3 are set in descending order of output voltage.

In addition, in the region N, levels L4, L4,
Set level L5, level L6, and level L7.

Therefore, the reflected light exhibiting the curve S in FIG. 4 is between the level L1 and the level L2 in the area M, and
is between level L4 and level L5.

Therefore, if the output voltage level of the color to be determined is set in advance, the color can be determined from the output voltage level.

This is utilized in the color discrimination section 5 of the counting device of this embodiment.
・・・・“・−・The output voltage of surface color X of IGX5 is the first
It will look like Figure 0.

In other words, if the surface color is brown X5, area M is at level L.
It is below 7.

Furthermore, when the surface color X is green X4, the area M is at the level L
The KIJj range N is between levels L6 and L7.

In addition, when the surface color X is yellow X3, the area M is at level L
1 and level L2, and region N is between level L6 and level L7.

Furthermore, when the surface color X is almond color X2, the area M is between levels L1 and L2, and the area N is at level L5.
and level L6.

In addition, when the surface color X is white X1, the area M is level/L
/Ll and level L2, and region N is between level L4 and level L5.

The level relationship of the output voltages corresponding to the surface color X described above is set in advance in the arithmetic control section 6.

The calculation control unit 6 then proceeds with the calculation according to the procedure shown in the flowchart shown in FIG.

For example, test object IAX1......IGX
When the surface color X of No. 5 is green X4, it is compared whether the photodetection signal voltage ■1 stored in the register R2 is higher than the level L1.

In this case, since it is not larger than the level L1, next a comparison is made to see if the detection signal voltage V1 is higher than the level L2.

In this case as well, since it is not higher than level L2, a comparison is made to see if the photodetection signal voltage v1 is higher than level L3.

In this case, since it is higher than level L3, it is determined at this point that photodetection signal voltage V1 is between level L2 and level L3.

Next, a comparison is made to see if the photodetection signal voltage v2 stored in the register R3 is higher than the level L6.

In this case, since it is not higher than the level L6, next a comparison is made to see if the photodetection signal voltage v2 is higher than the level L7.

In this case, since the level is higher than the level L7, it is determined that the photodetection signal voltage v2 is between the level L6 and the level L7.

Therefore, it is identified that the surface color X is green X4,
This result is input to register RC and stored.

The calculations for the other surface colors X are performed in the same manner as in the case of the green color X4, and are input to the register RC.

However, if the photodetection signal voltage Vl5V2 deviates from the area occupied by each surface color in FIG.
It is determined that there is an abnormality in itself, and the LED lamp 38 lights up and the buzzer 39 sounds.

By the way, FIG. 8 shows the photodetection signal voltage v1. Although the flowchart is shown only for v2, the calculation is actually performed in exactly the same procedure for the photodetection signal voltage V4>V5.

Then, the photodetection signal voltage V1. Identification result by V2 and photodetection signal voltage V4. The identification results from V5 are compared, and if the identification results are different, it is determined that one of them is abnormal, and the LED lamp 38 and buzzer 39 are activated.

Next, the contents of the register RH for storing the result of external shape determination and the contents of the register RC for storing the result of external shape determination are combined and stored in register RR.

Then, the contents of this register RR are successively compared with the combination of height H and surface color
l) ---... Count up the count contents of R (CX5).

For example, if the combination of discrimination results is that the height H is C and the surface color X is X4, then CX4 is stored in register RR, and
As shown in the flowchart shown in the figure, the reference combinations are sequentially compared, and as a result, the model is identified as CX4, and the count content of register R (CX4) is incremented by 1.

The identification information of the model thus obtained is displayed on the LED display 32, and the counting result, that is, the production amount is displayed on the LED display 33.

In addition, by operating the operation unit 40, the printer unit 3
0 on the recording paper.

Furthermore, if you want to know the trading volume of a particular model at any time, simply set the digital switch 34 to that model and the desired trading volume will be displayed on the LED display 35.

When the test object 1AXI...-...ICX5 passes through and the test object detector 26 outputs the test object detection signal to the WN car calculation control unit 6, the external shape discriminator 4 outputs a high The detection signal Ha...Hg is sent to register R1.
Enter.

At that time, if the signal level of each signal is "0", the external shape determining section 4 is normal, and the LED lamp 36 is lit.

On the other hand, if even one signal has a signal level of "1", the external shape discriminator 4 determines that there is an abnormality, for example, the optical axis is off or there is a failure, and the LED rung 38 and buzzer 39 are activated to issue an alarm.

Next, the photodetection signal voltages v3°V6 from the photoelectric converters 22a and 22b of the color discriminator 5 are input to the register R4, and these values are compared with a preset minimum reference voltage VLM. If the color is thicker than the value, the color discrimination section 5 determines that the color is normal, and the LED lamp 36 lights up.

On the other hand, if the voltage is lower than the minimum reference voltage vLM, it is determined that there is an abnormality, that is, the illumination lamp is at the end of its life or has run out, and the LED lamp 38 and buzzer 39 are activated to issue an alarm.

As described above, the counting device of the present invention outputs the difference in external dimensions of the object to be inspected as different combinations of a plurality of electrical signals by the outer shape discriminating section, and outputs the difference in the external dimensions of the object to be inspected as different combinations of a plurality of electrical signals, and outputs the difference in the external dimensions of the object to be inspected as different combinations of a plurality of electrical signals, and outputs the difference in the external dimensions of the object to be inspected. Outputs an electrical signal corresponding to the intensity of only light in a specific wavelength range among the reflected light of the reflected light, and further inputs an electrical signal from the external shape discrimination section and an electrical signal from the color discrimination section to the arithmetic control section. The system is designed to identify differences between objects to be inspected by comparing these electrical signals with preset reference values, allowing accurate and quick detection of objects with different external shapes and surface colors. Can be identified.

Therefore, when applied to a high-mix, low-volume production line, even if the number of models exceeds the limit of visual recognition, the output of each model can be easily and accurately counted.

In addition, even if the model changes frequently, it can be quickly adapted by simply changing the arrangement of the photoelectric switches or correcting various reference values in the arithmetic control section, thereby preventing unnecessary confusion on the production line.

Furthermore, there is no need to provide a dedicated inspector, which results in a significant labor saving effect.

Further, the counting device of the present invention can also be applied to painting processes and heating furnace processes, unlike the method of pasting barcode paper onto a test object.

Furthermore, the arithmetic control unit is equipped with a function to self-diagnose abnormalities in the external shape discrimination unit and color discrimination unit, so if an abnormality occurs in the equipment, it can immediately alert the operator and prevent errors in model discrimination. It can be eliminated.

Furthermore, since a test object detector is installed, the total production volume can be counted at the same time as the production volume for each model.

In the above embodiment, the external shape determining section detects the height of the object to be examined, but the external size may be determined based on the width, depth, etc.

Further, in the above embodiment, a photoelectric switch is used as the external shape discriminator, but without being limited to this, a detector using ultrasonic waves or the like may be used.

In addition, in the above embodiment, the photoelectric switches are provided corresponding to the height of the object to be tested, but even if they are arranged continuously at a certain interval, it is possible to change the calculation content in the calculation control unit. The same effects as in the above embodiment can be obtained.

Furthermore, in the above embodiment, the number of models to be identified is 35.
The number of types of models that can be identified can be increased to any extent by changing the number of light receiving sections in the color discrimination section and the color discrimination filter, and by increasing the number of photoelectric switches in the shape discrimination section.

It goes without saying that various other changes can be made without departing from the gist of the present invention.

[Brief explanation of drawings]

FIG. 1 is a perspective view showing an outline of the counting device of the present invention, FIG. 2 is a diagram illustrating the arrangement relationship of the photoelectric switch to the mounting frame,
Figure 3 is a plan view of the main part showing the color discrimination section of the counting device shown in Figure 1, and Figure 4 shows the relationship between the wavelength and output voltage of the light converted into an electrical signal by the photoelectric converter and transmitted by the color selection filter. 5 is a diagram showing the connection relationship of the counting device shown in FIG. 1, and FIGS. 6 to 9 are flowcharts and registers used to explain the operation of the counting device of the present invention. FIG. 10 is an identification diagram based on the output voltage from each photoelectric converter for color discrimination. IAXl・・・・・・・・・-IGX5: Test object, 3:
Conveyance path, 4: External shape discrimination section, 5: Color discrimination section, 6: Arithmetic control section, 19al, 19a2, 19bL 19b2: Photoelectric converter, 20al, 20a2, 20bl. 20b2: Color selection filter.

Claims (1)

[Claims] 1 Installed along a conveyance path that transports multiple test objects identified by combinations of external shapes and surface colors, and outputs differences in specific external dimensions of the test objects as different combinations of multiple electrical signals. It has an external shape discrimination section, a color selection filter that transmits light in a specific wavelength range, and a photoelectric converter that receives the light that has passed through the color selection filter, and is installed along the conveyance path to detect the surface of the object to be inspected. A color discrimination unit receives the reflected light and outputs an electrical signal corresponding to the intensity of the light transmitted through the color selection filter, and a combination of a plurality of electrical signals from the external shape discrimination unit is determined based on the external dimensions of the object to be inspected. The external dimensions of the object to be inspected are identified by comparing them with a combination of reference signals set in advance in accordance with ℃ and ℃, and this identification result is stored as a 10th memory value, and the electrical signal from the color discrimination section is Identifying the surface color of the object to be tested by comparing it with a plurality of preset reference levels corresponding to the surface color of the object to be tested, storing this identification result as a second memory value, and storing the identification result in the first memory. an arithmetic control unit that combines the value and the second stored value and compares the result of this combination with a preset reference combination of external dimensions and surface color of the object to be tested to identify differences in the object to be tested; A counting device characterized by comprising: