CN108896579B - Full view surface defect detection system based on integral cage illumination for component/material surface - Google Patents
Full view surface defect detection system based on integral cage illumination for component/material surface Download PDFInfo
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Abstract
The invention discloses a full view surface defect detection system based on an integral cage illumination component/material surface, which comprises: the integration cage lighting device comprises a diffusion lighting device and an integration cage, wherein a light source hole for installing the diffusion lighting device, a conveying inlet and a conveying outlet for conveying components/materials and at least six detection holes for installing an imaging assembly are formed in the cage wall of the integration cage; the imaging device comprises a plurality of imaging assemblies arranged outside the integration cage, and each detection hole is provided with at least one imaging assembly for imaging and scanning the component/material entering the integration cage through the detection holes so as to realize the full-view detection of the surface defects of the component/material; conveyor means for smooth passage of the component/material surface from within the integrating cage illuminator; the supporting device is used for installing the integrating cage lighting device and the imaging device; a controller connecting the diffuse lighting device and the imaging device; and the digital image processing device is in communication connection with the controller and the imaging device.
Description
Technical Field
The invention relates to the technical field of component/material surface defect detection, in particular to a component/material surface full-view surface defect detection system based on integral cage illumination.
Background
The existing defect detection system comprises a laser, a camera, a computer and an image processing device, wherein detected materials/components are placed on a carrying platform, the camera is located above the carrying platform, the camera is connected with the computer, and the image processing device is arranged in the computer. The laser is positioned at one side of the detected material, the light beam emitted by the laser is emitted through the glass in a certain light path, the computer controls the camera to shoot the front surface of the glass, and the shot image is collected by the computer and identified by the image processing device.
The defect detection system only can illuminate the detected material in a single direction because the laser is fixed on one side of the detected material and the position of the laser is fixed. When a defect image of the other side of the inspected material needs to be photographed, the inspected material needs to be turned over. In the detection process of the detection system, imaging shadows and visual angle blind spots are easy to appear due to directional illumination, defect hiding and escape phenomena are generated under the background, vibration of a detected material is often caused in the component overturning process, and interference is easy to be caused to a shot image, so that complexity and uncertainty of a detection result are caused.
Disclosure of Invention
The invention provides a full-view surface defect detection system based on an integral cage illumination component/material surface, which aims to solve the technical problems that imaging shadows and visual angle blind spots are easily caused by directional illumination and component overturning, and complexity and uncertainty of a detection result are caused by the directional illumination component/material surface.
The technical scheme adopted by the invention is as follows:
a total view surface defect detection system for a component/material surface based on integrating cage illumination, comprising: the integration cage lighting device comprises a diffusion lighting device and an integration cage, wherein a light source hole for installing the diffusion lighting device, a conveying inlet and a conveying outlet for conveying components/materials and at least six detection holes for installing an imaging assembly are formed in the cage wall of the integration cage; the imaging device comprises a plurality of imaging assemblies arranged outside the integration cage, and each detection hole is provided with at least one imaging assembly for imaging and scanning the component/material entering the integration cage through the detection holes so as to realize the full-view detection of the surface defects of the component/material; conveyor means for smooth passage of the component/material surface from within the integrating cage illuminator; the support device is used for installing the fixed integration cage lighting device and the imaging device; the controller is connected with the diffuse lighting device and the imaging device, and is used for controlling the diffuse lighting device to realize the conversion of lighting modes and the conversion of spectrums and controlling the imaging device to continuously scan the components/materials when the components/materials enter the integration cage and are illuminated so as to acquire image data of each view surface; and the digital image processing device is in communication connection with the controller and the imaging device and is used for generating control instructions to the controller and receiving image data generated by the imaging device, and recombining the image data of each channel according to the time-sharing switching sequence, so that the imaging device forms independent images for each illumination channel, and performs image analysis and identifies defects of the surfaces of the components/materials.
Further, the light source of the diffusion lighting device is a visible light source, and the spectrum range of the light source is in the sensitization range of the imaging device; the imaging device comprises imaging components of each detection hole, at least one imaging component is arranged in each detection hole, and the imaging components can be provided with a common lens or a microscope lens; the imaging component is any one of a CCD linear array imaging component, a CCD area array imaging component, a CMOS linear array imaging component and a CMOS area array imaging component.
Optionally, the integration cage is a vacuum integration cage or an atmospheric integration cage; the vacuum integration cage is internally provided with a vacuum cavity, and comprises an integration cage cavity, a cavity vacuum device, an inlet air lock and an outlet air lock, wherein the cavity vacuum device is used for pumping out air in the integration cage cavity, the inlet air lock and the outlet air lock are respectively positioned at a conveying inlet and a conveying outlet, the inlet air lock and the outlet air lock respectively comprise an upstream normal-pressure gate, a downstream vacuum gate, a gate chamber, a valve and a gate chamber vacuum device, the gate chamber is respectively separated from the integration cage cavity and the outside through the upstream normal-pressure gate and the downstream vacuum gate, the valve is used for allowing outside air to enter the gate chamber, and the gate chamber vacuum device is used for pumping out the air in the air lock; the normal pressure is adopted in the normal pressure integrating cage, the internal and external air pressures of the integrating cage are equal, and the conveying inlet and the conveying outlet are matched with no door, a manual door or an automatic door.
Optionally, the imaging device comprises imaging components of each detection hole, and at least one imaging component is disposed in each detection hole; at least a cage center vertical detection hole is respectively formed in the centers of six visual surfaces of an upper visual surface, a lower visual surface, a left visual surface, a right visual surface, a front visual surface and a rear visual surface of the integration cage, each detection hole is at least provided with one imaging component, and front view, rear view, upper view, lower view, left visual surface and right visual surface images of the detected component/material when the detected component/material passes through the cage center are respectively captured from the six detection surfaces of the front visual surface, the rear visual surface, the upper visual surface, the lower visual surface, the left visual surface and the right visual surface of the detected component/material, so that the full visual surface detection of the detected component/material is realized.
Optionally, the imaging assemblies of at least six detection holes are turned on or off under the control of the controller, and are combined into a plurality of detection modes: single view plane detection mode, face-to-face detection mode, adjacent plane detection mode, three adjacent plane detection mode, four adjacent plane detection mode, double-face detection mode, basin detection mode, and full view plane detection mode.
Further, the conveyor comprises at least one of a gravity conveyor and a magnetic levitation conveyor.
Optionally, the gravity conveying device comprises a feeding device, an inlet sliding device, an outlet receiving device and an outlet transferring device, wherein the feeding device is positioned above the conveying inlet, the inlet sliding device is arranged at the conveying inlet and is connected with the feeding device and the conveying inlet of the inlet, and the outlet receiving device is arranged at the conveying outlet and is connected with the conveying outlet and the outlet transferring device positioned below the integration cage.
Optionally, the magnetic suspension conveying device comprises an inlet placing device, a conveying belt type conveying mechanism, a suspension module and an outlet transferring device, wherein the conveying belt type conveying mechanism comprises a driving wheel, a driven wheel and a conveying belt which are arranged below the integration cage, the conveying belt is driven by the driving wheel and the driven wheel to horizontally move below the integration cage, the suspension module is connected with the conveying belt and is used for generating suspension force for the components/materials to float to the height of the conveying inlet, the suspension module horizontally moves along with the conveying belt, and the components/materials enter the integration cage from the conveying inlet along the horizontal direction along with the suspension module and are removed from the conveying outlet.
Further, the digital image processing apparatus includes at least one of: the super-resolution module is used for synthesizing the received continuous multi-frame images by utilizing an image fitting algorithm and a super-resolution algorithm of image reconstruction, breaking through the limitation of the resolution of an imaging assembly, obtaining a super-resolution image and obtaining the detail information of the full view surface of the component/material; the three-dimensional synthesis module is used for synthesizing the images of six view planes on the same time sequence, establishing a three-dimensional model of the tested part/material, and comparing the three-dimensional model with a three-dimensional standard model of the tested part/material so as to detect the shape variation defect of the tested part/material and detect the extreme value of length, width and height on the whole; and the defect identification module is used for carrying out image analysis on the acquired image and identifying all defects in the perception range.
Further, the digital image processing apparatus further includes at least one of: the quality grade classification module is used for counting the defect analysis results to classify the quality of the product to obtain quality grade information; the defect position analysis module is used for determining the length, width, area and three-dimensional relative position information of each defect according to the defect analysis result and generating a plane distribution map and/or a three-dimensional distribution map of the defects; and the storage module is used for receiving and storing the defect analysis result.
The invention relates to a full view surface defect detection system based on the surface of a component/material illuminated by an integrating cage, wherein the change of an illumination mode is controlled by a controller, a non-contact conveying device is adopted to realize that the component/material passes through the cavity of the integrating cage in a non-contact manner in the integrating cage, an imaging device captures full view surface images of the surface of the component/material in a one-stop manner under a 360-degree three-dimensional shadowless illumination environment provided by the integrating cage illuminating device, a digital image processing device simultaneously analyzes the full view surface images, all view surface images mutually evidence and complement each other, the defect detection efficiency, detection rate and recognition rate are improved, and the full view surface detection is realized for the component/material by arranging a plurality of detection holes on the integrating cage and correspondingly configuring an imaging assembly without turning over the component.
In addition to the objects, features and advantages described above, the present invention has other objects, features and advantages. The invention will be described in further detail with reference to the accompanying drawings.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the invention. In the drawings:
FIG. 1 is a schematic diagram of the configuration of a full view defect detection system for a component/material surface based on integrating cage illumination in accordance with a preferred embodiment of the present invention;
fig. 2 is a schematic structural view of another embodiment of the levitation transport device of the present invention.
Reference numerals illustrate:
1. an integrating cage; 2. a diffusion surface light source; 3. a top view detection hole; 4. looking down the detection hole; 5. a delivery outlet; 6. a transfer inlet; 7. a top view camera; 8. a left-view camera; 9. a down-looking camera; 10. a right-view camera; 11. a conveyor belt; 12. a suspension module; 13. the part/material to be tested; 14. a controller; 15. a digital image processing device; 16. a controller communication cable; 17. a camera data communication cable.
Detailed Description
It should be noted that, in the case of no conflict, the embodiments and features in the embodiments may be combined with each other. The invention will be described in detail below with reference to the drawings in connection with embodiments.
The invention provides a full view surface defect detection system based on an integral cage illumination component/material surface, which comprises the following components:
the integration cage lighting device comprises a diffusion lighting device and an integration cage, wherein a light source hole for installing the diffusion lighting device, a conveying inlet and a conveying outlet for conveying components/materials and at least six detection holes for installing an imaging assembly are formed in the cage wall of the integration cage;
the imaging device comprises a plurality of imaging assemblies arranged outside the integration cage, and each detection hole is provided with at least one imaging assembly for imaging and scanning the component/material entering the integration cage through the detection holes so as to realize the full-view detection of the surface defects of the component/material;
conveyor means for smooth passage of the component/material surface from within the integrating cage illuminator;
the support device is used for installing the fixed integration cage lighting device and the imaging device;
the controller is connected with the diffuse lighting device and the imaging device, and is used for controlling the diffuse lighting device to realize the lighting mode and the spectrum conversion and controlling the imaging device to continuously scan the components/materials when the components/materials enter the integration cage and are illuminated so as to acquire image data of each view surface;
And the digital image processing device is in communication connection with the controller and the imaging device and is used for generating control instructions to the controller and receiving image data generated by the imaging device, and recombining the image data of each channel according to the time-sharing switching sequence, so that the imaging device forms independent images for each illumination channel, and performs image analysis and identifies defects of the surfaces of the components/materials.
Further, the integrating cage lighting device comprises a diffuse lighting device and an integrating cage. The diffusion lighting device is used for providing a diffusion light source for the integration cage, and the integration cage is a cavity cage with the inner wall coated with a diffuse reflection material. The diffuse lighting device comprises a plurality of light sources which are combined into a round shape, a rectangular shape or other shapes suitable for detection, a transparent material with a rough surface is arranged in front of the light sources, and light emitted by the light sources is irregularly reflected in all directions through the rough surface of the transparent material and diffusely emitted to different directions so as to form diffuse reflection light sources. The controller is connected with each light source of the diffusion lighting device and is used for controlling different combinations of the light sources to switch the lighting in time so as to provide a plurality of different lighting modes and simultaneously perform a plurality of spectrum transformations.
Further, the light source of the diffuse lighting device may be various types of visible light sources. The spectral range of the light source is unlimited, but needs to be within the photosensitive range of the imaging device. The light source can be an incandescent lamp, an energy-saving lamp, an LED lamp and the like, preferably the LED lamp has long service life and can obtain higher brightness. The light source of the diffuse lighting device can also be designed as a coherent light source, and the light sources provide light with the same frequency and the same vibration direction so as to adapt to the detection requirement of the tiny defects on the surface of the precise component/material.
In the present invention, the cage body of the integration cage may be spherical, cylindrical, drum-shaped, barrel-shaped, olive-shaped, and other shapes. The cage wall is provided with a plurality of window holes which are round, square or other shapes suitable for detection. The apertures include a light source aperture for mounting a diffuse illumination device, a transfer inlet and a transfer outlet for transferring components/materials, and at least six detection apertures for imaging scanning of the components/materials into the integrating cage by the imaging device. The inner wall of the cage is coated with an ideal diffuse reflection material, i.e. a material with a diffuse reflection coefficient close to 1. The diffuse light emitted by the light source in the diffuse lighting device is continuously reflected by the coating on the inner wall of the integration cage for countless times, uniform illuminance is formed at any position of the inner wall, and uniform illuminance is formed at any position of the inner cavity. When the transparent part to be tested is placed in the cavity, the integration cage provides 360-degree stereoscopic shadowless illumination for the transparent part to be tested, the defects in the transparent part to be tested also obtain 360-degree stereoscopic shadowless illumination, and simultaneously 360-degree stereoscopic reflection is carried out, so that the imaging device can capture reflected light rays from all defects in the transparent part to be tested in one step from any detection hole, and all defects in the perception range of the imaging device are identified.
The integration cage is divided into a vacuum integration cage and an atmospheric integration cage according to whether the inner cavity of the integration cage is provided with gas or not.
The vacuum integration cage is internally provided with a vacuum cavity, and comprises an integration cage cavity, a cavity vacuum device, an inlet air gate and an outlet air gate. The inlet air lock is arranged at the conveying inlet, and the outlet air lock is arranged at the conveying outlet. The inlet air gate and the outlet air gate respectively comprise an upstream normal pressure gate, a downstream vacuum gate, a gate chamber, a valve and a gate chamber vacuum device. The cavity vacuum device is used for pumping out air in the integral pet cavity to form a vacuum cavity, so that the problem that imaging is affected due to variation of a running track caused by air resistance when components/materials pass through the integral cage is avoided. The two air gates are respectively positioned at the conveying outlet and the conveying inlet. Each air lock comprises a lock chamber, a valve, an upstream normal-pressure gate and a downstream vacuum gate, and the two gates are used for separating the lock chamber from the integrating cage cavity and the outside to form an independent space, so that the tested part/material enters or leaves the cavity through the air pressure drop. The upstream atmospheric gate is close to the outer side of the cavity to be connected with an external atmospheric region, and the downstream vacuum gate is close to the inner side of the cavity to be connected with an intracavity vacuum region. The valve is used for allowing outside air to enter the lock chamber. When the tested part/material needs to enter the vacuum integration cage, the gate chamber valve of the inlet air gate at the conveying inlet is firstly opened, when the air pressure in the gate chamber is the same as the external air pressure, the upstream normal pressure gate is opened, the tested part/material needs to enter the gate chamber, the upstream normal pressure gate and the valve are closed immediately, the gate chamber vacuum device is opened, when the air pressure in the gate chamber is the same as the air pressure in the cavity, the downstream vacuum gate is opened, and when the tested part or material leaves the gate chamber and enters the cavity of the vacuum integration cage, the air pressure is just opposite. The terms "upstream" and "downstream" as used herein refer to air flowing in directions, and the air pressure of "upstream" is greater than the air pressure of "downstream".
The inside of the normal pressure integration cage is normal pressure, and the internal pressure and the external pressure are equal. The conveying inlet and the conveying outlet can be provided with no door, and a manual door or an automatic door can also be arranged. The automatic door is in communication with a controller for controlling the automatic door on the transfer entrance and/or transfer exit to open when the part/material being tested is approaching and to close after the part/material being tested enters or leaves the integrating cage. To minimize the effect of the openings on the uniform illumination within the cage, the present invention preferably provides for the installation of manual or automatic doors for the transfer entrance and transfer exit. Of course, in other embodiments, the transfer inlet and transfer outlet may be configured as gateless.
The detection holes can be multiple so as to detect defects from multiple visual surfaces of the tested component/material and acquire image information of different visual surfaces. The angle of the imaging assembly at the detection hole for acquiring the image can be divided into an oblique angle detection hole, a vertical detection hole and a cage core vertical detection hole. The oblique angle detection hole refers to a required included angle between a focusing center line of the imaging component deployed in the detection hole and a conveying direction or a conveying surface, and the imaging component is coplanar with the conveying direction, so that the imaging component captures an image of the transparent component to be detected passing through the cavity from an oblique angle. The vertical detection hole refers to that the focusing center line of the imaging component arranged in the detection hole is perpendicular to the conveying direction or the conveying surface and coplanar with the conveying direction, so that the imaging component just captures the image of the transparent component to be detected passing through the cavity from the front surface. The vertical detection hole of the cage core means that a focusing central line of an imaging component arranged in the detection hole passes through the cage core, is perpendicular to or 0 degree with the conveying direction or the conveying surface, and is coplanar with the conveying direction, and the imaging component just captures an image with high illumination uniformity of the transparent component passing through the cage core from the front.
The imaging device comprises imaging components of each detection hole, and at least one imaging component is arranged in each detection hole. The imaging assembly may be configured with a conventional lens or a microscope lens. The number of the imaging components is reasonably configured according to the number of the detection holes, one detection hole is configured, a plurality of detection holes can be configured, and one detection hole is preferably configured. The imaging component is embedded on the wall of the integration cage or outside the integration cage and is dead against the inside of the integration cage for scanning imaging. The imaging component is increased, so that the transparent component is subjected to multiple detection, the scanning frequency of the defects is increased by multiple, the information quantity of the defects is increased by multiple, imaging information of the defects is more complete, the indication information form, size, three-dimensional position and the like of the defects are more accurate, and the detection rate and the identification rate of the defects in the transparent material are greatly improved. The full-view surface detection system is characterized in that at least a cage center vertical detection hole is formed in the center of six surfaces of an upper surface, a lower surface, a left surface, a right surface, a front surface and a rear surface of an integrating cage, at least one imaging component is deployed in each detection hole, and front view, rear view, upper surface, lower surface, left surface and right surface images of the detected component/material when the detected component/material passes through the cage center are captured from the six detection surfaces of the detected component/material respectively, so that one-stop type acquisition of image data of all surfaces of the detected component/material is realized, and all-view surface image data of all surfaces of the detected component/material are mutually complemented and mutually evidence. The imaging components of each detection hole are opened or closed under the control of the controller, and are combined into a plurality of detection modes: single view face detection mode (1 view face), face-to-face detection mode (2 view faces), adjacent face detection mode (2 view faces), three adjacent face detection mode (3 view faces), four adjacent face detection mode (4 view faces), double face detection mode (4 view faces), basin-shaped detection mode (5 view faces), full view face detection mode (6 view faces), and is suitable for detection needs of components/materials with different geometric shapes, such as spherical components, mobile phone glass preferably face-to-face detection mode, and hexahedral components preferably full view face detection mode. Besides the standard six-view-surface cage center vertical detection holes, the integration cage can be provided with various holes in other directions, detection of other surfaces is added, and beneficial supplement and evidence are carried out on the full-view-surface detection so as to adapt to the detection needs of components/materials with complex geometric shapes.
The contactless conveyor of the present invention allows any shape of component/material to translate or move relative to the integrating cage illuminator, the component/material being suspended in the air without any extraneous mechanical contact, substantially eliminating the interference of the conveyor with imaging.
The transfer device of the present invention can be divided into a gravity transfer device and a magnetic levitation transfer device according to the composition.
The gravity conveying device comprises a feeding device, an inlet sliding device, an outlet catching device and an outlet transferring device. The feeding device is positioned above the conveying inlet of the normal-pressure integration cage, the inlet sliding device is arranged at the conveying inlet and is connected with the feeding device and the conveying inlet of the inlet, and the outlet receiving device is arranged at the conveying outlet and is connected with the conveying outlet and the outlet transferring device positioned below the integration cage. The parts/materials are conveyed to the inlet sliding device through the feeding device, continuously move downwards under the gravity and inertia of the parts/materials, enter the integration cage in the vertical direction when the inlet sliding device is changed into a rail, freely fall through the normal-pressure integration cage by means of the gravity of the parts/materials, fall into the opposite outlet receiving device and slide to the outlet transferring device by means of the gravity of the parts/materials. The components/materials pass all the way through the integrating cage without any contact, substantially eliminating the interference of the conveyor with imaging, such as vibrations.
Further, if the measured member itself is light in weight and is affected by air resistance, a variation in track may occur during free falling, and a vacuum integrator cage is preferable.
The magnetic suspension conveying device is only suitable for metal parts/materials, so that the metal parts/materials relatively pass through the integration cage in a suspended manner, the structure of the magnetic suspension conveying device is easier to realize relative to the gravity conveying device, and the control degree is relatively better.
The magnetic suspension conveying device comprises an inlet placing device, a conveying belt type conveying mechanism, a suspension module and an outlet transferring device, wherein the conveying belt type conveying mechanism comprises a driving wheel, a driven wheel and a conveying belt which are arranged below an integration cage, the conveying belt is driven by the driving wheel and the driven wheel to horizontally move below the integration cage, the suspension module is connected with the conveying belt and is used for generating suspension force for a part/material to be tested to enable the part/material to float to the height of the conveying inlet, the suspension module horizontally moves along with the conveying belt, and the part/material enters the integration cage from the conveying inlet along the horizontal direction along with the suspension module and moves out from the conveying outlet. The inlet placement device is used for taking the tested components/materials from the storage device of the components/materials to be tested, placing the tested components/materials on the suspension module, triggering the suspension module to float, placing the suspension module on the conveyor belt, enabling the suspension module to enter the integration cage from the conveying inlet along with the movement of the conveyor belt, enabling the suspension module to pass through the integration cage at a constant speed or stop at the cage center position, sending the suspension from the conveying outlet, stopping the floatation, and enabling the outlet transfer device to obtain the tested components/materials from the floatation module and placing the tested components/materials on the storage device of the tested components/materials. In the conveying process, the tested part/material is stable and has no vibration or contact, and the interference of the conveying device on imaging is basically eliminated. The magnetic suspension conveying device is suitable for detecting metal parts with high stability requirements, and in order to avoid the shielding effect of the integration cage on the magnetic field generated by the suspension module, the integration cage is made of nonmetallic materials.
The levitation module is a magnetic levitation module or other levitation modules, the magnetic levitation module can be realized through a plurality of electromagnetic blocks, the electromagnetic blocks acquire power from a power supply and generate high-frequency electromagnetic fields, and eddy currents are generated on the surfaces of the parts/materials made of metal by utilizing the high-frequency electromagnetic fields to realize levitation of the parts/materials. The inlet placement device and the outlet transfer device can adopt an automatic mechanical arm, and can also adopt a conveyor belt structure correspondingly matched with the position of the suspension module. In other embodiments, the component to be tested may be placed on the levitation module or the tested component may be grasped from the levitation module and placed in the storage device by manual grasping.
Furthermore, the invention utilizes the imaging environment formed by the integral cage shadowless high-brightness uniform illumination environment and the contactless transmission device, and each imaging component continuously scans at high frequency at the angle to obtain continuous multi-frame images. The digital image processing device comprises a super-resolution module, wherein the super-resolution module synthesizes the received continuous multi-frame images by utilizing an image fitting algorithm and an image reconstruction super-resolution algorithm, breaks through the limitation of the resolution of an imaging assembly, obtains super-resolution images, and obtains more abundant detail information of the whole visual surface of the component/material surface. The digital image processing device then analyzes the defects of the synthesized images, greatly improves the accuracy of defect detection, is suitable for detecting the surface defects of related precision parts, and has the detection accuracy at least reaching the micron level and the submicron level. The invention uses the imaging environment formed by the illumination environment with uniform integral cage shadowless high brightness and the contactless transmission device, each imaging component is provided with a microscope lens to carry out imaging scanning on the tiny surface defects of the precise component/material to obtain the amplified continuous multi-frame images of the detected precise component/material, the super-resolution module of the digital image processing device obtains the super-resolution images of the received continuous multi-frame images, and the defect detection precision can at least reach the micron level or even the nano level by combining an image analysis algorithm.
The full view surface defect detection system based on the integral cage illumination component/material surface can capture six view surface images of the detected component/material passing through the cage core from six view surfaces simultaneously, the digital image processing device comprises a three-dimensional synthesis module, the three-dimensional synthesis module is used for synthesizing the images of the six view surfaces on the same time sequence, a three-dimensional model of the detected component/material is established, and the three-dimensional model is compared with a three-dimensional standard model of the detected component/material, so that the shape variation of the detected component/material, such as abnormal angle, edge warping and the like, is detected on the whole. Meanwhile, according to the established three-dimensional model of the tested part/material, the extreme value of the length, width and height of the tested part/material can be obtained and compared with the standard length, width and height of the tested part/material, so that the length, width and height specification of the tested part/material can be detected.
The digital image processing device also comprises a defect identification module which is used for carrying out image analysis on the acquired image and identifying all defects in the perception range. The digital image processing device also comprises a quality grade dividing module which is used for counting the defect analysis result so as to grade the quality of the product to obtain quality grade information. The digital image processing device also comprises a defect position analysis module which is used for determining the length, width, area and three-dimensional relative position information of each defect according to the defect analysis result and generating a plane distribution map and/or a three-dimensional distribution map of the defects. The digital image processing device further comprises a storage module for receiving and storing the defect analysis result.
The full-view surface defect detection system based on the integral cage illumination component/material surface can capture images of the detected component/material passing through the cage core from six view surfaces simultaneously, realize 360-degree detection of the detected component/material, acquire all images of the full-view surface of the detected component/material surface with any geometric shape in one step by an imaging device, and continuously carry out multi-frame, wherein the images complement each other, mutually prove that the defect detection efficiency, the defect detection rate and the defect identification rate are improved, and the complexity, the uncertainty and the defect repeatability caused by multi-angle illumination, multi-angle detection and component overturning are avoided, and the phenomena of shadow imaging, visual angle blind spots and complexity under the background and defect hiding and escaping under the background are avoided. In the full view surface defect detection system based on the integral cage illumination component/material surface, a non-contact conveying device is creatively used, interference of component conveying on imaging is basically eliminated, particularly, a suspension conveying device is used, the whole detection process is non-contact and vibration-free, the conveying efficiency is high, and complexity and uncertainty caused by component overturning in directional detection are avoided.
According to the full view surface defect detection system of the component/material surface developed by the invention, real image information about defects of the detected surface of the detected component/material can be obtained by any view surface detection, edge defects such as concave and convex parts at the edge of the component, unfilled corners and the like, light distortion points, concave parts, convex parts, scratches and the like of the surface can be detected, and in addition, the digital image processing device determines three-dimensional characteristics such as the size, the shape, the area and the like of a defect kernel through digital image analysis. In addition, the imaging assembly is added, so that the multi-face detection is carried out on the component, the scanning frequency of the defect is increased in a multiplied manner, the information quantity of the defect is increased in a multiplied manner, the multi-face image data of the defect are mutually supplemented, mutually evidence and mutually checked, the imaging information of the defect is more complete, the indication information form, size, three-dimensional position and the like of the defect are more accurate, and the detection rate and the identification rate of the full-view surface defect on the surface of the component/material are greatly improved.
Furthermore, the detection result according to the invention can be used for carrying out big data analysis, so that the defect types of the parts, such as edge defects, surface defect scratches and the like, can be accurately classified, products are sequentially classified in quality, and quality grade information is sent to carry out intelligent sorting in cooperation with corresponding manipulators; the analysis result of the component grade can be used for evaluating the relevant suppliers, and the relevant suppliers can evaluate the quality stability of the component production line according to the analysis result and optimize, reform and the like the relevant production process according to the analysis result; and the three-dimensional relative position information such as the size, the longitudinal position, the column direction position and the like of the defect can be accurately calculated by utilizing the obtained defect data information, and a three-dimensional distribution diagram, a defect probability diagram and the like of the defect in the component are drawn by importing a three-dimensional modeling diagram of the component.
Fig. 1 shows a full view defect detection system for a component/material surface based on integrating cage illumination in accordance with the present invention. It comprises the following steps: support means (not shown in fig. 1) for mounting the stationary integrator cage illuminator, the imaging device, etc.; a part under test 13; integrating cage lighting device: the integration cage 1, the diffusion surface light source 2, the upper view detection hole 3, the lower view detection hole 4, the transfer inlet 6, the transfer outlet 5, the front view detection hole and the rear view detection hole are not shown; an image forming apparatus: an upper view camera 7, a left view camera 8, a lower view camera 9, a right view camera 10, a front view camera and a rear view camera are not shown; contactless transfer device: conveyor 11, levitation module 12, entrance placement device, exit transfer device, etc. are not shown; a controller 14; a digital image processing device 15. The controller 14 is communicatively connected to the diffusion surface light source 2, each camera, and the digital image processing device 15, respectively, via a controller communication cable 16. The digital image processing device 15 is communicatively connected to each camera via a camera data communication cable 17. In the conveyor of fig. 1, the conveyor belt circulates in a vertical plane. In fig. 2 the conveyor belt is circulating in a horizontal plane.
In the invention, the measured component can be a metal component or a nonmetal component, and can be a flat plate, a column or any other geometric shape, such as a watch component, an automobile component, a mobile phone panel component, a television panel and the like. In this example, the transfer device is a magnetic levitation transfer device, so the part under test 13 is correspondingly a metal-based part.
The conveying device is used for enabling the tested part 13 to move relatively relative to the integration cage 1. For example, as shown in fig. 1, the above-described relative movement is generated by moving the measured member 13 relative to the integrating cage 1. As shown in fig. 1 and 2, the conveying device in this example is a magnetic suspension conveying device, and includes components such as a conveying belt, an inlet placement device, an outlet transfer device, a suspension module, a support frame, and the like, after the tested component 13 floats through the suspension module 12, the tested component is conveyed by the conveying belt 11, enters the inner cavity of the integration cage 1 through the conveying inlet 6, is driven by the conveying belt 11 to pass at a uniform speed, or stays at the position of the cage center, and leaves from the conveying outlet 5. The measured component 13 passes through the integration cage 1 without any contact in the whole course, and the interference of shaking, shielding and the like of the conveying device on imaging is basically eliminated. For purposes of illustration and not limitation, it will be assumed hereinafter that the integrating cage 1 remains stationary while the parts under test 13 are moved relative to them. In other embodiments, the above-mentioned relative movement can also be obtained by moving the integrating cage 1 and the camera relative to the measured part 13. For example, when the detected part is large in mass, large in size, special in shape, and not requiring a contact-free transfer, it is easier to move the integrating cage 1 and the camera than to move the detected part 13.
Fig. 1 shows an integrating cage 1, a diffuse surface light source 2, an upper view detection hole 3, a lower view detection hole 4, a transfer outlet 5, a transfer inlet 6, an upper view camera 7, a left view camera 8, a lower view camera 9, a right view camera 10, a transfer belt 11, a levitation module 12, a measured part 13, a controller 14, and a digital image processing device 15 in a total view defect detection system based on an element/material surface illuminated by the integrating cage, and a relative positional relationship therebetween. In this inspection system, as shown in fig. 1, the part 13 to be inspected is in a flat plate shape, which moves leftward in the horizontal direction at a uniform velocity V. The imaging device is constituted by 6 cameras, employing a full-view detection mode in which front-view cameras and rear-view cameras are not shown, one camera being disposed for each detection hole being exemplified. The number of the detection holes in practical application and the number of the imaging components configured for each detection hole can be reasonably configured according to detection requirements. The upper view camera 7, the left view camera 8, the lower view camera 9, the right view camera 10, the front view camera and the rear view camera are responsible for collecting light and imaging the collected light onto their photosurfaces and converting the electrical signals. In this example, the camera may employ a CCD linear array imaging assembly, a CCD area array imaging assembly, a CMOS linear array imaging assembly, a CMOS area array imaging assembly, or other imaging assemblies, and may generally integrate corresponding image processing functions, output relevant defect data information, and the like. In this example, six cameras are disposed in the vertical holes of the cage core of the six vision surfaces to form a full vision surface detection mode, the respective focusing central lines are perpendicular to the conveying direction or form 0 degree, are coplanar and pass through the cage core, so that when the measured component 13 passes through the integration cage, the illumination of the inner cavity of the integration cage 1 is most uniform, the bright cage core is right passed through, and the cameras just acquire the optimal image of the measured component 13 passing through the cage core. Other types of detection holes can be formed in the six-view surface of the integration cage 1 or various types of detection holes can be formed in the other-view surface so as to acquire images of other angles.
As shown in fig. 1, in the example of the present invention, the integrating cage 1 is spherical. In practical application, the device can be designed into a cylindrical shape, a waist drum shape, a barrel shape, an olive shape and other suitable shapes according to detection requirements. The inner wall of the integration cage 1 is coated with ideal diffuse reflection materials such as magnesium oxide and barium sulfate. The diffuse light emitted by the diffuse surface light source 2 is continuously reflected for a plurality of times through the coating on the inner wall of the integration cage, uniform illuminance is formed at any position of the inner wall, uniform illuminance is formed at any angle of any position on the inner cavity, the tested part/material is placed in the cavity, a 360-degree three-dimensional shadowless illumination environment is provided for the tested part/material, the defects in the tested part/material also obtain 360-degree three-dimensional shadowless illumination, and meanwhile, 360-degree three-dimensional reflection is carried out, so that a camera can capture reflected light rays from the tested surface of the tested part 13 from a detection hole, and all defects in the perception range of the tested part/material are identified.
As shown in fig. 1, in the example of the present invention, the diffuse lighting device employs a diffuse surface light source 2 mounted on the inner wall of an integrating cage 1. The inner wall of the integration cage 1 is provided with 2 diffusion area light sources 2, and the center line of the diffusion area light sources passes through the center of the integration cage. The diffusion surface light source 2 is formed by combining a plurality of diffusion light sources into a circle, the diffusion surface light source 2 is provided with a rough surface element, light emitted by the light sources is irregularly reflected to all directions by the rough surface and diffusely emitted to different directions, and therefore a diffuse reflection light source is formed. After being reflected by the rough surface, the diffusion surface light source 2 emits the formed diffusion light to the inner wall of the integration cage 1 along all directions, the diffusion light is reflected by the inner wall of the integration cage 1 for numerous times, and 360-degree stereoscopic shadowless illumination with uniform illumination and high brightness is formed in the inner cavity of the integration cage 1. The controller 14 provides a plurality of different illumination modes by controlling different combinations of the light sources to switch illumination, meets the sensitivity of different defects in the tested part 13 to different brightness, provides various different brightness selections for the tested part 13, and the camera acquires defect images under different brightness. In addition, the diffusion area light source 2 can also perform multiple spectrum transformation under the control of the controller, so that the sensitivity of different types of defects in the tested part 13 to different spectrums is met, various different spectrum selections are provided for the tested part 13, and the camera acquires defect images under different spectrums. For the component with high precision, a coherent light source can be designed, the coherent light source provided by the tested component 13 is selected, and the camera acquires the defect image under the coherent light source. In the diffuse illumination field environment of the integration cage 1, distortion and uneven refraction of the surface of the measured component 13 are very sensitive, and defects such as pits, bumps, deformation, scratches and the like on the surface of the measured component 13 can be detected by a camera. Unless otherwise indicated, what is referred to herein as turning on one or several of a combined light source, the other light sources are turned off.
In this example, the transfer outlet 5 and the transfer inlet 6 serve as detection holes at the same time, and a left-view camera 8 and a right-view camera 10 are correspondingly arranged outside the two to reduce the number of openings in the cage wall of the integration cage 1.
The process of defect detection using the total view surface detection system of the present invention based on integrating cage illumination of the component/material surface is generally as follows:
referring to fig. 1, the diffusion area light source 2 is turned on, light is emitted and then irradiates into the integration cage 1 along the arrow direction, and after being reflected by the inner wall for numerous times, a 360-degree stereoscopic shadowless illumination environment with uniform illumination and high brightness is formed in the inner cavity of the integration cage 1.
The conveyor is opened and the conveyor belt 11 moves the measured part 13, which is floated by the levitation module 12, into the integrating cage 1 via the conveyor inlet 6 at a speed V through the integrating cage 1. When the measured part 13 enters the inner cavity of the integration cage 1 and passes through the position of the cage center, the upper view camera 7, the left view camera 8, the lower view camera 9, the right view camera 10, the front view camera and the rear view camera scan and image from the upper view surface, the lower view surface, the left road view surface, the front view surface and the rear view surface of the measured part 13 at the same time. The measured part 13 passes through the integrating cage 1, leaves the integrating cage 1 through the conveying outlet 5, and floats to stop. The outlet transfer device transfers the measured component 13 and places it on the measured component storage device.
Specifically, the light source in the present invention may be a semiconductor light source or a general light source; the spectrum range is unlimited, but needs to be within the photosensitive range of the imaging device; the light source can be selected to be monochromatic light or white light. In this example, the light sources of the diffusing surface light source 2 are not turned on at the same time, spectrum conversion is performed, but the controller 14 performs time-sharing switching on the combined light sources to realize illumination on the tested component 13, and the camera 9 continuously scans in real time to alternately obtain defect data information under each illumination mode. In order to control the operation timing of the camera and the diffusion surface light source 2, a controller 14 is provided in the component detection system of fig. 1. The controller 14 serves as an external trigger source for controlling the trigger timing of each of the diffusion surface light source 2 and the 6 cameras. The controller 14 may include any type of pulse trigger such as, but not limited to, an encoder. During the detection process, the controller 14 senses the displacement of the detected part 13 and controls the operation of the light sources and the camera so that at least one round of detection is completed in one lighting cycle.
Experiments prove that the full view surface defect detection system based on the integral cage illumination can accurately identify and classify various defects such as part edge cutting defects, surface defect scratches, deformation, bulges, pits and the like, and can provide various different illumination modes, spectrum conversion and coherent light sources as the 360-degree stereoscopic shadowless illumination is provided, the defects of the full view surface of the measured part/material surface can escape, and an imaging device captures reflected light rays from all defects in the measured part/material to identify all defects in the perception range. Compared with the traditional detection system, the imaging system eliminates the interference of the transmission device on imaging, eliminates imaging shadows and visual angle blind spots under a directional illumination background, eliminates defect hiding and escaping phenomena under the background, eliminates complexity and uncertainty caused by multi-angle illumination and multi-angle imaging and component overturning and increases cost, and can carry out multi-face detection to obtain a defect image under various detection modes, wherein multi-face data are mutually supplemented, mutually evidence and mutually verify, so that imaging information of the defect is more complete, and the indication information form, size, three-dimensional position and the like of the defect are more accurate, thereby greatly improving the detection rate and the recognition rate of the full-view surface defect on the surface of the component/material.
It is to be understood that the foregoing examples of the invention have been presented for the purpose of illustration and description only, and are not intended to limit the invention to the particular forms disclosed. Modifications and alterations will occur to others upon a reading of this specification. For example, in the defect detection system of the present invention, the imaging component is not limited to one, and may be disposed in a plurality of, multiple angles.
The above description is only of the preferred embodiments of the present invention and is not intended to limit the present invention, but various modifications and variations can be made to the present invention by those skilled in the art. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (8)
1. A total view surface defect detection system for a component/material surface based on integrating cage illumination, comprising:
the integration cage lighting device comprises a diffusion lighting device and an integration cage, wherein a light source hole for installing the diffusion lighting device, a conveying inlet and a conveying outlet for conveying components/materials and at least six detection holes for installing an imaging assembly are formed in the cage wall of the integration cage;
The imaging device comprises a plurality of imaging assemblies arranged outside the integration cage, and each detection hole is provided with at least one imaging assembly for carrying out imaging scanning on the parts/materials entering the integration cage through the detection holes so as to realize full-view detection on the surface defects of the parts/materials;
conveyor means for smooth passage of the component/material surface from within said integrating cage illuminator;
the support device is used for installing the fixed integration cage lighting device and the imaging device;
the controller is connected with the diffusion lighting device and the imaging device and is used for controlling the diffusion lighting device to realize the conversion of lighting modes and the conversion of spectrums and controlling the imaging device to continuously scan the components/materials when the components/materials enter the integration cage and are illuminated so as to acquire image data of each view;
the digital image processing device is in communication connection with the controller and the imaging device and is used for generating control instructions to the controller, receiving image data generated by the imaging device, reorganizing image data of each channel according to a time-sharing switching sequence, enabling the imaging device to form independent images for each illumination channel, analyzing the images and identifying defects of the surfaces of the components/materials;
The imaging components of the at least six detection holes are opened or closed under the control of the controller, and are combined into a plurality of detection modes: single view plane detection mode, face-to-face detection mode, adjacent plane detection mode, three-adjacent plane detection mode, four-adjacent plane detection mode, double-face detection mode, basin-shaped detection mode, and full view plane detection mode;
the imaging device comprises imaging components of detection holes, and at least one imaging component is arranged in each detection hole;
at least a cage center vertical detection hole is respectively formed in the centers of six visual surfaces of an upper visual surface, a lower visual surface, a left visual surface, a right visual surface, a front visual surface and a rear visual surface of the integration cage, each detection hole is at least provided with one imaging component, and front view, rear view, upper view, lower view, left visual surface and right visual surface images of the detected component/material when the detected component/material passes through the cage center are respectively captured from the six detection surfaces of the front visual surface, the rear visual surface, the upper visual surface, the lower visual surface, the left visual surface and the right visual surface of the detected component/material, so that the full visual surface detection of the detected component/material is realized.
2. The total view surface defect detection system of a component/material surface based on integrating cage illumination of claim 1, wherein,
The light source of the diffusion lighting device is a visible light source, and the spectrum range of the light source is in the photosensitive range of the imaging device;
the imaging device comprises imaging components of each detection hole, at least one imaging component is arranged in each detection hole, and the imaging components can be configured with a common lens or a microscope lens;
the imaging component is any one of a CCD linear array imaging component, a CCD area array imaging component, a CMOS linear array imaging component and a CMOS area array imaging component.
3. The total view surface defect detection system of a component/material surface based on integrating cage illumination of claim 1, wherein,
the integration cage is a vacuum integration cage or an atmospheric integration cage;
the vacuum integration cage is internally provided with a vacuum cavity and comprises an integration cage cavity, a cavity vacuum device, an inlet air lock and an outlet air lock, wherein the cavity vacuum device is used for pumping out air in the integration cage cavity, the inlet air lock and the outlet air lock are respectively positioned at a conveying inlet and a conveying outlet, the inlet air lock and the outlet air lock respectively comprise an upstream normal pressure gate, a downstream vacuum gate, a gate chamber, a valve and a gate chamber vacuum device, the gate chamber is respectively separated from the integration cage cavity and the outside through the upstream normal pressure gate and the downstream vacuum gate, the valve is used for allowing outside air to enter the gate chamber, and the gate chamber vacuum device is used for pumping out air in the air lock;
The inside of the normal pressure integration cage is normal pressure, the air pressure inside and outside the integration cage is equal, and the conveying inlet and the conveying outlet are matched with no door, a manual door or an automatic door.
4. The total view surface defect detection system of a component/material surface based on integrating cage illumination of claim 1, wherein,
the conveying device comprises at least one of a gravity conveying device and a magnetic suspension conveying device.
5. The total view surface defect detection system of a component/material surface based on integrating cage illumination of claim 4, wherein,
the gravity conveying device comprises a feeding device, an inlet sliding device, an outlet catching device and an outlet transferring device, wherein the feeding device is positioned above the conveying inlet, the inlet sliding device is arranged at the conveying inlet and is connected with the feeding device and the conveying inlet of the inlet, and the outlet catching device is arranged at the conveying outlet and is connected with the conveying outlet and the outlet transferring device positioned below the integration cage.
6. The total view surface defect detection system of a component/material surface based on integrating cage illumination of claim 4, wherein,
the magnetic suspension conveying device comprises an inlet placing device, a conveying belt type conveying mechanism, a suspension module and an outlet transferring device,
The conveyor belt type conveying mechanism comprises a driving wheel, a driven wheel and a conveying belt, wherein the driving wheel, the driven wheel and the conveying belt are arranged below the integration cage, the conveying belt is driven by the driving wheel and the driven wheel to horizontally move below the integration cage, the suspension module is connected with the conveying belt and is used for generating suspension force for the components/materials to float to the height of the conveying inlet, the suspension module horizontally moves along with the conveying belt, and the components/materials enter the integration cage from the conveying inlet along with the suspension module along with the horizontal direction and are removed from the conveying outlet.
7. The total view surface defect detection system of a component/material surface based on integrating cage illumination of claim 1, wherein,
the digital image processing apparatus includes at least one of:
the super-resolution module is used for synthesizing the received continuous multi-frame images by utilizing an image fitting algorithm and a super-resolution algorithm of image reconstruction, breaking through the limitation of the resolution of an imaging assembly, obtaining a super-resolution image and obtaining the detail information of the full view surface of the component/material;
the three-dimensional synthesis module is used for synthesizing the images of six view planes on the same time sequence, establishing a three-dimensional model of the tested part/material, and comparing the three-dimensional model with a three-dimensional standard model of the tested part/material so as to detect the shape variation defect of the tested part/material and detect the extreme value of length, width and height on the whole;
And the defect identification module is used for carrying out image analysis on the acquired image and identifying all defects in the perception range.
8. The total view surface defect detection system of a component/material surface based on integrating cage illumination of claim 7, wherein,
the digital image processing apparatus further includes at least one of:
the quality grade classification module is used for counting the defect analysis results to classify the quality of the product to obtain quality grade information;
the defect position analysis module is used for determining the length, width, area and three-dimensional relative position information of each defect according to the defect analysis result and generating a plane distribution map and/or a three-dimensional distribution map of the defects;
and the storage module is used for receiving and storing the defect analysis result.
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| CN104819405A (en) * | 2014-02-03 | 2015-08-05 | 三星电机株式会社 | Luminous module and visual inspection system using the same |
| CN103852429A (en) * | 2014-03-13 | 2014-06-11 | 武汉虹之彩包装印刷有限公司 | Extinction detection device for continuously identifying hue of laser-printed product |
| CN103901040A (en) * | 2014-03-27 | 2014-07-02 | 华中科技大学 | Three-dimensional online network defect detection system based on machine vision |
| KR101584767B1 (en) * | 2015-06-16 | 2016-01-12 | 주식회사 미래컴퍼니 | Method and apparatus for inspecting display panel |
| CN106018413A (en) * | 2016-05-12 | 2016-10-12 | 西安欣维视觉科技有限公司 | Product appearance detection device and method |
| CN106770307A (en) * | 2016-09-27 | 2017-05-31 | 西京学院 | A kind of electronic product appearance surfaces defect detecting device and its detection method |
| CN106248694A (en) * | 2016-11-02 | 2016-12-21 | 苏州鼎纳自动化技术有限公司 | A kind of articulated cross shaft defect detecting device and detection method thereof |
| CN107957425A (en) * | 2017-12-08 | 2018-04-24 | 湖南科创信息技术股份有限公司 | Transparent material defect detecting system and method |
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