Resin component appearance inspection device and resin component appearance inspection method

A resin component appearance inspection method using a component retention mechanism which retains a resin component which is an inspection target, a camera which takes an image of the resin component, an illumination which irradiates the resin component, and an image processing device which performs calculation processing on the image taken by the camera,

• wherein
• an angle formed by the illumination and the defective part of the resin component is defined as an incidence angle, and an angle formed by the camera and the defective part of the resin components is defined as a detection angle,
• when the illumination emits illumination light to the resin component that is lustrous, reflection with the incidence angle and a reflection angle equal to each other is defined as specular reflection light, and a part where an appearance of the illumination appears reflected on the surface of the resin component is defined as regular reflection,
• a part where reflection occurs also at angles different from the incidence angle due to a fact that surfaces of the resin component are not perfect mirror surfaces is defined as irregular reflection,
• the detection angle is provided with an angle difference relative to the incidence angle,
• so that a regular reflection light part of the specular reflection light is removed by trimming and an irregular reflection light part is extracted,
• the method comprising:
• an image acquisition step of acquiring the image taken by the camera, into the image processing device;
• a trimming step of trimming a defective part of a surface of the resin component;
• a smoothing step of smoothing an image generated in the trimming step;
• a difference image generation step of generating an image representing a difference between the image generated in the trimming step and an image generated in the smoothing step;
• a binarization step of binarizing the image generated in the difference image generation step;
• a contour extraction step of extracting a contour of the defective part;
• and
• a quantitative value calculation step of calculating a pixel ratio of the defective part to perform quantification.

A resin component appearance inspection method in which, using an injection molding device for performing injection molding of a resin component which is an inspection target, appearance quality inspection for the resin component is performed,

• in a state in which a camera which takes an image of the resin component and an illumination which irradiates the resin component are placed at a mold or a platen to be used for resin molding of the resin component, the method being performed using an image processing device which performs calculation processing on the image taken by the camera, a movable blackout screen, and a taking-out machine which takes the resin component out of the mold and moves the resin component,
• the method comprising:
• a position adjustment step of adjusting positions of the camera and the illumination;
• a consecutive molding start step of starting consecutive molding of the resin component;
• a resin loading step of loading resin into the mold;
• a first blackout screen movement step of moving the blackout screen close to the mold;
• a mold opening step of opening the mold after loading of the resin in the resin loading step is completed;
• an imaging step of emitting illumination light to the resin component by the illumination and taking an image of the resin component by the camera;
• a second blackout screen movement step of moving the blackout screen to outside of the mold;
• a chucking step of moving the taking-out machine close to the resin component and chucking the resin component;
• an image acquisition step of acquiring the image of the resin component taken by the camera, into the image processing device;
• an image processing step of performing image processing on the acquired image and calculating a quantitative value of an appearance quality of the resin component;
• a quantitative value output step of outputting the quantitative value of the appearance quality of the resin component calculated in the image processing step;
• a quality determination step of comparing the appearance quality of the resin component outputted in the quantitative value output step with a predetermined required quality, and determining whether or not the required quality is satisfied;
• a proper product processing step of, in a case where it is determined that the required quality is satisfied in the quality determination step, moving the resin component to a proper product place by the taking-out machine and returning to the resin loading step;
• a defective product processing step of, in a case where it is determined that the required quality is not satisfied in the quality determination step, moving the resin component to a defective product place by the taking-out machine;
• a defect frequency determination step of determining whether or not a defective product has been produced consecutively a predetermined threshold number of times or more, and in a case where a defective product has not been produced consecutively the predetermined threshold number of times or more, returning to the resin loading step, and in a case where a defective product has been produced consecutively the predetermined threshold number of times or more, proceeding to an alert output step;
• and
• the alert output step of outputting a consecutive defect alert and stopping a consecutive molding process.