Ceramic body defect inspecting apparatus and defect inspecting method

1. A defect inspecting apparatus configured to inspect existence of a defect on an end face of a sealed honeycomb structural body, the apparatus comprising:

a table on which a sealed honeycomb structural body as an inspection target is to be placed;

an image capturing part configured to capture an image of an inspection target region as at least part of said end face which is an inspection target surface of said sealed honeycomb structural body placed on said table in a normal direction of said inspection target region;

one or more illumination parts including four or more illumination elements configured to irradiate said inspection target region with illumination light obliquely at an identical irradiation angle in respective irradiation directions different from each other and equiangularly spaced from each other around said image capturing part;

a determination image generation part configured to generate determination image data for determining existence of a defect in said inspection target region based on captured image data acquired by said image capturing part; and

a defect determination part configured to determine existence of a defect in said inspection target region based on said determination image data, wherein

said plurality of illumination elements are sequentially turned on and off,

said image capturing part generates a plurality of pieces of captured image data by capturing an image of said inspection target region when each of said plurality of illumination elements is turned on, and

said determination image generation part generates minimum luminance image data in which a minimum value among luminance values of said plurality of pieces of captured image data at an identical pixel position is set as a luminance value at the pixel position and then generates said determination image data as binarized data based on said minimum luminance image data; and

said defect determination part determines that a defect exists in said inspection target region when a dark part exists in an area equal to or larger than a predetermined second dark part threshold in said determination image data in which a dark part corresponding to an opening in said inspection target region is excluded and a bright part corresponding to any joining part and a dark part corresponding to outside of said sealed honeycomb structural body, if any, are additionally excluded.

2. The defect inspecting apparatus according to claim 1 , wherein said determination image generation part

further includes a luminance correction processing part configured to correct the luminance values of said plurality of pieces of captured image data so that the levels of luminance at a reference part previously defined in each of said plurality of pieces of captured image data are equivalent among said plurality of pieces of captured image data, and

generates said minimum luminance image data based on said plurality of pieces of captured image data the luminance values of which are corrected by said luminance correction processing part.

3. The defect inspecting apparatus according to claim 2 , wherein said one or more illumination parts include:

a low-angle illumination part including, as said plurality of illumination elements, a plurality of low-angle illumination elements each configured to irradiate said inspection target region with illumination light at an irradiation angle of 5° to 30° inclusive;

an intermediate-angle illumination part including, as said plurality of illumination elements, a plurality of intermediate-angle illumination elements each configured to irradiate said inspection target region with illumination light at an irradiation angle of 30° to 60° inclusive; and

a high-angle illumination part including, as said plurality of illumination elements, a plurality of high-angle illumination elements each configured to irradiate said inspection target region with illumination light at an irradiation angle of 60° to 85° inclusive.

4. The defect inspecting apparatus according to claim 3 , wherein

said image capturing part generates a plurality of pieces of low-angle captured image data by performing, for all of said plurality of low-angle illumination elements, image capturing of said inspection target region when each of said plurality of low-angle illumination elements is turned on, generates a plurality of pieces of intermediate-angle captured image data by performing, for all of said plurality of intermediate-angle illumination elements, image capturing of said inspection target region when each of said plurality of intermediate-angle illumination elements is turned on, and generates a plurality of pieces of high-angle captured image data by performing, for all of said plurality of high-angle illumination elements, image capturing of said inspection target region when each of said plurality of high-angle illumination elements is turned on,

said plurality of pieces of low-angle captured image data, said plurality of pieces of intermediate-angle captured image data, said plurality of pieces of high-angle captured image data are said plurality of pieces of captured image data different from each other,

said determination image generation part generates, as said minimum luminance image data, low-angle minimum luminance image data in which a minimum value among luminance values of said plurality of pieces of low-angle captured image data at an identical pixel position is set as a luminance value at the pixel position, intermediate-angle minimum luminance image data in which a minimum value among luminance values of said plurality of pieces of intermediate-angle captured image data at an identical pixel position is set as a luminance value at the pixel position, and high-angle minimum luminance image data in which a minimum value among luminance values of said plurality of pieces of high-angle captured image data at an identical pixel position is set as a luminance value at the pixel position, and generates said determination image data by generating low-angle determination image data based on said low-angle minimum luminance image data, generating intermediate-angle determination image data based on said intermediate-angle minimum luminance image data, and generating high-angle determination image data based on said high-angle minimum luminance image data; and

said defect determination part determines existence of a defect in said inspection target region based on all of said low-angle determination image data, said intermediate-angle determination image data, and said high-angle determination image data.

5. The defect inspecting apparatus according to claim 3 , wherein said plurality of low-angle illumination elements each include at least two dimming units individually dimmable.

6. The defect inspecting apparatus according to claim 5 ,

wherein said plurality of low-angle illumination elements, said plurality of intermediate-angle illumination elements, and said plurality of high-angle illumination elements are supported by one support body, and

said plurality of low-angle illumination elements, said plurality of intermediate-angle illumination elements, and said plurality of high-angle illumination elements are disposed in respective planes different from each other.

7. The defect inspecting apparatus according to claim 1 , wherein said one or more illumination parts include:

a first illumination part including, as said plurality of illumination elements, a plurality of first illumination elements each configured to irradiate said inspection target region with illumination light at a first irradiation angle of 30° to 60° inclusive; and

a second illumination part including, as said plurality of illumination elements, a plurality of second illumination elements each configured to irradiate said inspection target region with illumination light at a second irradiation angle of 60° to 85° inclusive.

8. The defect inspecting apparatus according to claim 7 , wherein

said image capturing part generates a plurality of pieces of first captured image data by performing, for all of said plurality of first illumination elements, image capturing of said inspection target region when each of said plurality of first illumination elements is turned on, and generates a plurality of pieces of second captured image data by performing, for all of said plurality of second illumination elements, image capturing of said inspection target region when each of said plurality of second illumination elements is turned on,

said plurality of pieces of first captured image data and said plurality of pieces of second captured image data are said plurality of pieces of captured image data different from each other,

said determination image generation part generates, as said minimum luminance image data, first minimum luminance image data in which a minimum value among luminance values of said plurality of pieces of first captured image data at an identical pixel position is set as a luminance value at the pixel position and second minimum luminance image data in which a minimum value among luminance values of said plurality of pieces of second captured image data at an identical pixel position is set as a luminance value at the pixel position, and generates said determination image data by generating first determination image data based on said first minimum luminance image data and generating second determination image data based on said second minimum luminance image data; and

said defect determination part determines existence of a defect in said inspection target region based on both of said first determination image data and said second determination image data.

9. The defect inspecting apparatus according to claim 7 ,

wherein the number of said plurality of first illumination elements is equal to the number of said plurality of second illumination elements and the first and second illumination elements are arranged so that a vertical plane including an irradiation direction of each of said first illumination elements always includes an irradiation direction of one of said second illumination elements,

said plurality of first illumination elements emit illumination light belonging to a first wavelength band, and said plurality of second illumination elements emit illumination light belonging to a second wavelength band different from said first wavelength band,

each pair of said first and said second illumination elements having irradiation directions included in an identical vertical plane is simultaneously turned on and off,

said image capturing part generates said plurality of pieces of captured image data by capturing an image of said inspection target region when each pair of said first and second illumination elements is turned on,

the defect inspecting apparatus further includes a separation image generation part configured to generate a plurality of pieces of first separation image data and a plurality of pieces of second separation image data by performing color separation of each of said plurality of pieces of captured image data based on said first wavelength band and said second wavelength band,

said determination image generation part generates, as said minimum luminance image data, first minimum luminance image data in which a minimum value among luminance values of said plurality of pieces of first separation image data at an identical pixel position is set as a luminance value at the pixel position and second minimum luminance image data in which a minimum value among luminance values of said plurality of pieces of second separation image data at an identical pixel position is set as a luminance value at the pixel position, and generates said determination image data by generating first determination image data based on said first minimum luminance image data and generating second determination image data based on said second minimum luminance image data; and

said defect determination part determines existence of a defect in said inspection target region based on both of said first determination image data and said second determination image data.

10. The defect inspecting apparatus according to claim 7 ,

wherein said plurality of first illumination elements and said plurality of second illumination elements are supported by one support body, and

said plurality of first illumination elements are arranged in one plane, and said plurality of second illumination elements are arranged in another plane.

11. The defect inspecting apparatus according to claim 1 , wherein said plurality of illumination elements included in each of said one or more illumination parts are eight illumination elements.

12. A method of inspecting existence of a defect on an end face of a sealed honeycomb structural body, the method comprising:

a placement step of placing a sealed honeycomb structural body as an inspection target on a predetermined table;

an image capturing step of generating a plurality of pieces of captured image data by capturing, through predetermined image capturing means, an image of an inspection target region as at least part of said end face which is an inspection target surface of said sealed honeycomb structural body placed on said table in a normal direction of said inspection target region;

a determination image generation step of generating determination image data for determining existence of a defect in said inspection target region based on said plurality of pieces of captured image data; and

a defect determination step of determining existence of a defect in said inspection target region based on said determination image data, wherein

in said image capturing step, said plurality of pieces of captured image data are generated by sequentially turning on and off four or more illumination elements that are provided to one or more illumination parts, are configured to emit illumination light obliquely at an identical irradiation angle in respective irradiation directions different from each other, and are equiangularly spaced from each other around said image capturing means, and capturing an image of said inspection target region when each of said plurality of illumination elements is turned on, and

in said determination image generation step, minimum luminance image data in which a minimum value among luminance values of said plurality of pieces of captured image data at an identical pixel position is set as a luminance value at the pixel position is generated, and then said determination image data is generated as binarized data based on said minimum luminance image data; and

in said defect determination step, it is determined that a defect exists in said inspection target region when a dark part exists in an area equal to or larger than a predetermined second dark part threshold in said determination image data in which a dark part corresponding to an opening in said inspection target region is excluded and a bright part corresponding to any joining part and a dark part corresponding to outside of said sealed honeycomb structural body, if any, are additionally excluded.

13. The defect inspecting method according to claim 12 , wherein said determination image generation step further includes a luminance correction processing step of correcting luminance values of said plurality of pieces of captured image data so that the levels of luminance at a reference part previously defined in each of said plurality of pieces of captured image data are equivalent in said plurality of pieces of captured image data; and

in said determination image generation step, said minimum luminance image data is generated based on said plurality of pieces of captured image data the luminance values of which are corrected through said luminance correction processing step.

14. The defect inspecting method according to claim 13 , wherein said one or more illumination parts include:

a low-angle illumination part including, as said plurality of illumination elements, a plurality of low-angle illumination elements each configured to irradiate said inspection target region with illumination light at an irradiation angle of 5° to 30° inclusive;

an intermediate-angle illumination part including, as said plurality of illumination elements, a plurality of intermediate-angle illumination elements each configured to irradiate said inspection target region with illumination light at an irradiation angle of 30° to 60° inclusive; and

a high-angle illumination part including, as said plurality of illumination elements, a plurality of high-angle illumination elements each configured to irradiate said inspection target region with illumination light at an irradiation angle of 60° to 85° inclusive.

15. The defect inspecting method according to claim 14 ,

wherein in said image capturing step, a plurality of pieces of low-angle captured image data is generated by performing, for all of said plurality of low-angle illumination elements, image capturing of said inspection target region when each of said plurality of low-angle illumination elements is turned on, a plurality of pieces of intermediate-angle captured image data is generated by performing, for all of said plurality of intermediate-angle illumination elements, image capturing of said inspection target region when each of said plurality of intermediate-angle illumination elements is turned on, and a plurality of pieces of high-angle captured image data is generated by performing, for all of said plurality of high-angle illumination elements, image capturing of said inspection target region when each of said plurality of high-angle illumination elements is turned on,

said plurality of pieces of low-angle captured image data, said plurality of pieces of intermediate-angle captured image data, said plurality of pieces of high-angle captured image data are said plurality of pieces of captured image data different from each other,

in said determination image generation step, low-angle minimum luminance image data in which a minimum value among luminance values of said plurality of pieces of low-angle captured image data at an identical pixel position is set as a luminance value at the pixel position, intermediate-angle minimum luminance image data in which a minimum value among luminance values of said plurality of pieces of intermediate-angle captured image data at an identical pixel position is set as a luminance value at the pixel position, and high-angle minimum luminance image data in which a minimum value among luminance values of said plurality of pieces of high-angle captured image data at an identical pixel position is set as a luminance value at the pixel position are generated as said minimum luminance image data, said determination image data is generated by generating low-angle determination image data based on said low-angle minimum luminance image data, generating intermediate-angle determination image data based on said intermediate-angle minimum luminance image data, and generating high-angle determination image data based on said high-angle minimum luminance image data; and

in said defect determination step, existence of a defect in said inspection target region is determined based on all of said low-angle determination image data, said intermediate-angle determination image data, and said high-angle determination image data.

16. The defect inspecting method according to claim 14 , wherein

said plurality of low-angle illumination elements each include at least two dimming units individually dimmable, and

luminance difference in accordance with difference between distances from said plurality of low-angle illumination elements in a capturing range of said predetermined image capturing means is reduced by individually dimming said at least two dimming units in advance before image capturing by said predetermined image capturing means in said image capturing step.

17. The defect inspecting method according to claim 12 , wherein said one or more illumination parts include:

a first illumination part including, as said plurality of illumination elements, a plurality of first illumination elements each configured to irradiate said inspection target region with illumination light at a first irradiation angle of 30° to 60° inclusive; and

a second illumination part including, as said plurality of illumination elements, a plurality of second illumination elements each configured to irradiate said inspection target region with illumination light at a second irradiation angle of 60° to 85° inclusive.

18. The defect inspecting method according to claim 17 , wherein

in said image capturing step, a plurality of pieces of first captured image data is generated by performing, for all of said plurality of first illumination elements, image capturing of said inspection target region when each of said plurality of first illumination elements is turned on, and a plurality of pieces of second captured image data is generated by performing, for all of said plurality of second illumination elements, image capturing of said inspection target region when each of said plurality of second illumination elements is turned on,

said plurality of pieces of first captured image data and said plurality of pieces of second captured image data are said plurality of pieces of captured image data different from each other,

in said determination image generation step, first minimum luminance image data in which a minimum value among luminance values of said plurality of pieces of first captured image data at an identical pixel position is set as a luminance value at the pixel position and second minimum luminance image data in which a minimum value among luminance values of said plurality of pieces of second captured image data at an identical pixel position is set as a luminance value at the pixel position are generated as said minimum luminance image data, and said determination image data is generated by generating first determination image data based on said first minimum luminance image data and generating second determination image data based on said second minimum luminance image data; and

in said defect determination step, existence of a defect in said inspection target region is determined based on both of said first determination image data and said second determination image data.

19. The defect inspecting method according to claim 17 , wherein

the number of said plurality of first illumination elements is equal to the number of said plurality of second illumination elements and the first and second illumination elements are arranged so that a vertical plane including an irradiation direction of each of said first illumination elements always includes an irradiation direction of one of said second illumination elements, and then said plurality of first illumination elements emit illumination light belonging to a first wavelength band and said plurality of second illumination elements emit illumination light belonging to a second wavelength band different from said first wavelength band,

each pair of said first and said second illumination elements having irradiation directions included in an identical vertical plane is simultaneously turned on and off,

in said image capturing step, said plurality of pieces of captured image data is generated by capturing an image of said inspection target region when each pair of said first and second illumination elements is turned on,

the defect inspecting method further includes a separation image generation step of generating a plurality of pieces of first separation image data and a plurality of pieces of second separation image data by performing color separation of each of said plurality of pieces of captured image data based on said first wavelength band and said second wavelength band,

in said determination image generation step, first minimum luminance image data in which a minimum value among luminance values of said plurality of pieces of first separation image data at an identical pixel position is set as a luminance value at the pixel position and second minimum luminance image data in which a minimum value among luminance values of said plurality of pieces of second separation image data at an identical pixel position is set as a luminance value at the pixel position are generated as said minimum luminance image data, and said determination image data is generated by generating first determination image data based on said first minimum luminance image data and generating second determination image data based on said second minimum luminance image data; and

in said defect determination step, existence of a defect in said inspection target region is determined based on both of said first determination image data and said second determination image data.

20. The defect inspecting method according to claim 12 , wherein said plurality of illumination elements provided to each of said one or more illumination parts are eight illumination elements.