CN101596556B - Design method based on machine vision inspection centring control device - Google Patents
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Abstract
The invention relates to a design method based on a machine vision inspection centring control device; a line scanning sensor senses wide long banding surfaces, and the result is output to an image acquisition module; LED linear light source generates convergent linear light which is irradiated on the object to be inspected, and surface condition is sent to the line scanning sensor; the image acquisition module carries out bottom layer treatment conversion on input signals of the line scanning sensor; a PCIe bus image transmission module provides point-to-point independent bandwidth bus channels for two routes of data of the image acquisition module; a machine vision margin automatically positioning software carries out positioning tracking on belting margin and calculates belt material centre deviation value; a digital controller determines parameters of the digital controller according to signals introduced by an interface module, and control signals are output to the interface module; the interface module inputs the signals of a system to the digital controller, and the result is output to a hydraulic servo system; the hydraulic servo system adjusts load moving speed according to the control signals output by the interface module; and a power unit supplies stressor.
Description
Technical field
The present invention relates to a kind of method for designing, belong to vision measurement and control technology field based on Machine Vision Detection centering control device.
Background technology
Band should be in certain horizontal margin of tolerance on the production line of operation alignment machine group switching centre line (or desired location), otherwise can cause the equipment of scratching, broken belt to stop production and influence consequence such as product quality.In order to guarantee that band safe operation on production line needs band is carried out centering control, the chief component of band automatic centering control device comprises: detection system, micro-processor control device, driver and hydraulic control (or machine driving) system.Several forms of centering correction at present are: photo-electric, inductance type, condenser type, CCD formula, and the checkout gear of employing CCD formula adopts the mode of front illuminated more, and light source and CCD camera are positioned at the band both sides; Use two CCD cameras to measure, two edges of band are aimed in the optical center of camera, and two cameras link to each other with leading screw, when strip width changes, by shaking leading screw, make the centre-to-centre spacing of two cameras consistent with strip width.In the testing process, with the calculating that subtracts of the measured value of two cameras, according to the numerical value and the symbol that calculate, the side-play amount of band and offset direction as can be known.This detection method can realize the centering needs produced, but its complex structure, the fault rate height, and need need configuration location and drive unit according to strip width manual adjustments detection position.Cause having influenced production efficiency under the quantity-produced situation, its chief reason is that the visual range of checkout gear is less, does not realize the automatic location of band limit portion.Such device processing platform lacks flexibility and can't realize complicated Intelligent Measurement and control algolithm based on hardware simultaneously.
Therefore, how to realize that fully-automatic intelligent Detection ﹠ Controling, the ease for operation and the reliability that improve device are technical problems that will solve.
Summary of the invention
The objective of the invention is to overcome the deficiency that prior art exists, a kind of method for designing based on Machine Vision Detection centering control device is provided.
Purpose of the present invention is achieved through the following technical solutions:
Method for designing based on Machine Vision Detection centering control device, characteristics are: described device comprises first line scan sensor, second line scan sensor, the linear light source of LED, image capture module, PCIe bus image transmission module, the automatic positioning software of machine vision limit portion, digitial controller, interface module, Hydrauservo System and hydraulic power unit, the linear light source of described LED is connected with second line scan sensor with first line scan sensor, described first line scan sensor and the second line scan sensor incoming image acquisition module, described image capture module connects PCIe bus image transmission module, described PCIe bus image transmission module communicates to connect by automatic positioning software of machine vision limit portion and digitial controller, described interface module inserts digitial controller, described interface module also is connected with Hydrauservo System, and described hydraulic power unit is connected with the Hydrauservo System oil circuit;
Described first line scan sensor, second line scan sensor are responded to wide cut long ribbon shape surface fast, and the result of induction exports to image capture module with the form of Line Chart picture;
The linear light source of described LED produces and converges linear light radiation to object to be detected, gives first line scan sensor, second line scan sensor by reflection with the surface appearance of object to be detected;
Described image capture module carries out bottom layer treatment and conversion to the input signal of first line scan sensor and second line scan sensor, and the signal of will going as required simultaneously is merged into the picture signal of suitable size;
Described PCIe bus image transmission module is for the two paths of data of image capture module provides point-to-point free band width bus passage;
The automatic positioning software of described machine vision limit portion positions and follows the tracks of band material limit portion by image processing algorithm, goes out band practical center position according to two limit portion calculated signals, relatively calculates current band centre deviation amount with rolling centerline;
Described digitial controller, wide and the digital quantity control signal of speed, tension force, coil diameter, the material of the machine row system of importing into according to interface module is determined the parameter of digitial controller, and calculates the controlled quentity controlled variable signal according to the band position of center line deviation signal of the automatic positioning software input of machine vision limit portion and controller parameter and export to interface module;
Described interface module, the wide and digital quantity control signal of speed, tension force, coil diameter, the material of reader row system is given digitial controller, simultaneously the result of calculation of digitial controller is exported to Hydrauservo System;
Described Hydrauservo System is according to the size and Orientation of the control signal regulating load movement velocity of interface module output;
Described hydraulic power unit is for hydraulic control system provides pressure source.
Further, above-mentioned method for designing based on Machine Vision Detection centering control device, wherein, described first line scan sensor, second line scan sensor all comprise machine vision camera lens, linear CCD photo-sensitive cell, analog-to-digital conversion circuit, bottom layer signal treatment circuit, power module and interface circuit; The linear light source of described LED comprises cooling system, power module, power distribution plate, LED particle, concentration module and preposition astigmatism plate; Described image capture module comprises CameraLink input interface module, camera control clock, ROI zone collection and trigger control unit, general serial control module, exterior I O expansion interface, triggers control connection device, real-time sync cap unit and bus interface controller; Described PCIe bus image transmission module comprises the PCIe EBI; The automatic positioning software of described machine vision limit portion comprises image denoising processing unit, image correction process module, image enhancing unit, image difference unit, statistical moment adaptive threshold rim detection module, edge link unit, morphology processing unit, image calibration system, band picture centre position and world coordinates modular converter, rolling centerline deviation computing unit and NI Labview and Vision development environment; Described digitial controller comprises the pid parameter self adaptation and calculates module and PID controller module; Described interface module comprises machine row control figure input module, transmission analog signal input module, caution data signal output module, DP fieldbus module, serial communication interface and point-to-point physical interface; Described Hydrauservo System comprises servo controller and servo valve; Described hydraulic power unit comprises hydraulic pump motor, hydraulic pressure electric control system and pressure control section.
Further, above-mentioned method for designing based on Machine Vision Detection centering control device, wherein, described linear CCD photo-sensitive cell or be area array CCD or cmos sensor; The interface circuit type is CameraLink or is 1394 interfaces or for the GIGE interface or for USB interface; The fieldbus type is a TS61158 fieldbus or for ControlNet and Ethernet/IP fieldbus or for the Profibus fieldbus or for the P-NET fieldbus or for FF HSE fieldbus or for the SwiftNet fieldbus or for World FIP fieldbus or for the Interbus fieldbus or for FF H1 fieldbus or for the ROFInet fieldbus or be EPA.
Substantive distinguishing features and obvious improvement that technical solution of the present invention is outstanding are mainly reflected in:
Whole device is based on the PCIe bus embedded type, and is point-to-point independent mode, and hardware configuration is more flexible, freely selects all types bus capture card and input/output board, and sensor is selected also more flexible, supports the total interface sensor.By software camera is demarcated, the picture that the camera collection is come carries out preliminary treatment then, as figure image intensifying, denoising, filtering, field condition according to reality adds needed interference protection measure, carries out interesting areas ROI and selects, and finds edge on the pixel by these measures, be identification of band limit portion and location, again this location of pixels is corresponded on the actual physical position,, rectify a deviation by real-time closed-loop control again by calculating position of center line and side-play amount.This device volume is little, and is easy for installation, and precision height, response speed are fast, not only can be used as independently vision-based detection and control device and uses, and also can be used as under the substation simultaneously to hang on the main equipment, seamlessly is integrated in the Auto-Test System and uses.
Description of drawings
Below in conjunction with accompanying drawing technical solution of the present invention is described further:
Fig. 1: the block configuration schematic diagram of apparatus of the present invention;
Fig. 2: the gray value demonstration figure that scanning obtains;
Fig. 3: the denoising gradation effect shows figure;
Fig. 4: the denoising image effect shows figure;
Fig. 5: the edge-detected image effect shows figure.
The implication of each Reference numeral sees the following form among the figure:
| Reference numeral | Implication | Reference numeral | Implication | Reference numeral | Implication |
| 1 | First line scan sensor | 2 | Second line scan sensor | 3 | The linear light source of LED |
| 4 | Image capture module | 5 | PCIe bus image transmission module | 6 | The automatic positioning software of machine vision limit portion |
| 7 | Digitial controller | 8 | Interface module | 9 | Hydrauservo System |
| 10 | Hydraulic power unit | 11 | Load |
The specific embodiment
According to technology, the band position measurement is divided into two processes, and the one, by dual-side portion is carried out synchronous line acquisition, overcome the video acquisition mode and have the tubular problem of dtmf distortion DTMF; The 2nd, by the statistical nature of background gray scale and the limit portion self adaptation recognition and tracking of intelligent algorithm realization band; In addition owing to adopted first scanning technique to make that the longitudinal extent of one-time detection can be self-defined, so promptly overcome simple line scanning because the detection signal instability that may cause is split on the limit, having overcome traditional video signal mode again, to gather image size fixing, the problem that the refresh cycle is low.On implementation, adopt the virtual instrument software technology, adopt flexible, powerful computer software to replace some hardware of traditional instrument, make the Intelligent Measurement algorithm in application, be achieved, particularly appliance computer is participated in the generation of test signal and the parsing of measuring feature directly in the device, makes exploitation become very flexible.The software function of centering control device that the present invention is based on machine vision is powerful, and hardware configuration is flexible, and response speed is exceedingly fast, and the detection speed height is installed, easy and simple to handle.
As shown in Figure 1, centering control device based on machine vision, comprise first line scan sensor 1, second line scan sensor 2, the linear light source 3 of LED, image capture module 4, PCIe bus image transmission module 5, the automatic positioning software 6 of machine vision limit portion, digitial controller 7, interface module 8, Hydrauservo System 9 and hydraulic power unit 10, the linear light source 3 of LED is connected with second line scan sensor 2 with first line scan sensor 1, first line scan sensor 1 and second line scan sensor, 2 incoming image acquisition modules 4, image capture module 4 connects PCIe bus image transmission module 5, PCIe bus image transmission module 5 communicates to connect with digitial controller 7 by the automatic positioning software 6 of machine vision limit portion, interface module 8 inserts digitial controller 7, interface module 8 also is connected with Hydrauservo System 9, hydraulic power unit 10 is connected with Hydrauservo System 9 communications, and hydraulic power unit 10 drives with load 11 and is connected; First line scan sensor 1, second line scan sensor 2 are responded to wide cut long ribbon shape surface fast, and the result of induction exports to image capture module 4 with the form of Line Chart picture; The linear light source 3 of LED produces and converges linear light radiation to object to be detected, gives first line scan sensor 1, second line scan sensor 2 by reflection with the surface appearance of object to be detected; Image capture module 4 carries out bottom layer treatment and conversion to the input signal of first line scan sensor 1 and second line scan sensor 2, and the signal of will going as required simultaneously is merged into the picture signal of suitable size; PCIe bus image transmission module 5 is for the two paths of data of image capture module 4 provides point-to-point free band width bus passage; The automatic positioning software 6 of machine vision limit portion positions and follows the tracks of band material limit portion by image processing algorithm, goes out band practical center position according to two limit portion calculated signals, relatively calculates current band centre deviation amount with rolling centerline; Digitial controller 7, wide and the digital quantity control signal of speed, tension force, coil diameter, the material of the machine row system of importing into according to interface module 8 is determined the parameter of digitial controller 7, and calculates the controlled quentity controlled variable signal according to the band position of center line deviation signal of automatic positioning software 6 inputs of machine vision limit portion and controller parameter and export to interface module 8; Interface module 8, the wide and digital quantity control signal of speed, tension force, coil diameter, the material of reader row system is given digitial controller 7, simultaneously the result of calculation of digitial controller 7 is exported to Hydrauservo System 9; Hydrauservo System 9 is according to the size and Orientation of the control signal regulating load movement velocity of interface module 8 output; Hydraulic power unit 10 drives Hydrauservo System 9.
Wherein, first line scan sensor 1, second line scan sensor 2 all comprise machine vision camera lens, linear CCD photo-sensitive cell, analog-to-digital conversion circuit, bottom layer signal treatment circuit, power module and interface circuit; The linear light source 3 of LED comprises cooling system, power module, power distribution plate, LED particle, concentration module and preposition astigmatism plate; Image capture module 4 comprises CameraLink input interface module, camera control clock, ROI zone collection and trigger control unit, general serial control module, exterior I O expansion interface, triggers control connection device, real-time sync cap unit and bus interface controller; PCIe bus image transmission module 5 comprises the PCIe EBI; The automatic positioning software 6 of machine vision limit portion comprises image denoising processing unit, image correction process module, image enhancing unit, image difference unit, statistical moment adaptive threshold rim detection module, edge link unit, morphology processing unit, image calibration system, band picture centre position and world coordinates modular converter, rolling centerline deviation computing unit and NI Labview and Vision development environment; Digitial controller 7 comprises the pid parameter self adaptation and calculates module and PID controller module; Interface module 8 comprises machine row control figure input module, transmission analog signal input module, caution data signal output module, DP fieldbus module, serial communication interface and point-to-point physical interface; Hydrauservo System 9 comprises servo controller and servo valve; Hydraulic power unit 10 comprises hydraulic pump motor, hydraulic pressure electric control system and pressure control section.
Whole device is based on the PCIe bus embedded type, and PCIe bus data acquisition bandwidth is 125M, and is point-to-point independent mode, hardware configuration is more flexible, freely select all types bus capture card and input/output board, sensor is selected also more flexible, supports the total interface sensor.By software camera is demarcated, the picture that the camera collection is come carries out preliminary treatment then, as figure image intensifying, denoising, filtering, field condition according to reality adds needed interference protection measure, carries out interesting areas ROI then and selects, and finds edge on the pixel by these measures, be identification of band limit portion and location, again this location of pixels is corresponded on the actual physical position,, rectify a deviation by real-time closed-loop control again by calculating position of center line and side-play amount.
The concrete installation when using, sensor and light source are installed in the both sides of band, adopt and face radiation modality directly.The line array CCD industrial camera constantly carries out line scanning to band, and capture card is delivered to data (gray value of the band that scans as shown in Figure 2) on the industrial computer and carried out the image processing by Labview software.At first carry out some pictures and strengthen, the preliminary treatment of denoising, filtering and so on, when carrying out wavelet decomposition and reconstruct, the selection of wavelet basis all has very big influence to computational complexity and figure image intensifying effect.Following three factors are considered in selection for wavelet basis usually: orthogonality, support width and regularity.Orthogonality is that the correlation of the wavelet coefficient after the conversion is considered.If orthogonal wavelet, the wavelet coefficient after the conversion is uncorrelated, and filter effect is better like this.But. for the orthogonal wavelet except that the Haar small echo, be contradiction between character such as linear phase and tight support, therefore select biorthogonal wavelet generally speaking, secondly biorthogonal wavelet also is easy to realize.Support width is to consider from time complexity.Wavelet transformation essence is a convolution process, if the oversize meeting of convolution kernel has a strong impact on operation time.Regularity is to consider from the smooth degree of wavelet basis, if the wavelet basis regularity is too poor, the effect of filtering might extremely worsen; And regularity is very good, then might filter a lot of details of image.In view of to the taking all factors into consideration of above factor, chosen the Db04 small echo.If the number of plies of wavelet decomposition is too much, the image after the filtering reconstruct might produce distortion phenomenon, and operand increases the program runtime growth.With the small echo denoising time, three layers of general decomposition, when picture breakdown to three layer. noise has been decayed more than 90%, so level=3, three yardstick wavelet decomposition have been adopted, Fig. 3 from the gray value angle with filtering before and filtering after compare, Fig. 4 shows denoising effect intuitively by image.The signal later to denoising carries out rim detection, and Fig. 5 is that the rim detection effect is showed.Calculate the position of disalignment, give the PID controller with deviation and carry out the PID adjusting, PID regulates the back and passes to controller by the PCIe bus, controller drives hydraulic system and adjusts the position, reach the purpose of correction, depart from the control hydraulic system, drive adjusting deviation device according to the band center by controller, band is positioned on the unit center line all the time.
In sum, the whole device of the present invention is based on PCIe bus embedded type industrial computer platform, comprise hardware components and software section, hardware components is made up of ccd sensor, vision lens, the linear light source of LED, capture card, image processor and input/output board, after will carrying out processing calculating such as binaryzation, edge detection through software section by the image that the capture card collection comes, judge whether band has disalignment, and calculate the distance of skew; Software section carries out image by Labview software and handles and control.This device volume is little, and is easy for installation, and two paths of data is supported the multinuclear issue by developing software, and parallel processing fully, substitutes former hardware processing method of habitually practising with software measure, and hardware configuration is flexible, precision is high, response speed is fast.Adopt linear light sorurce, make stronger for the environment interference of coloured processing site.Have industrial gigabit ethernet interface, serial ports and digital I interface, this device not only can be used as independently vision-based detection and control device use, also can be used as under the substation simultaneously to hang on the main equipment, seamlessly is integrated in the Auto-Test System and uses.
What need understand is: above-mentioned explanation is not to be limitation of the present invention, and in the present invention conceived scope, the interpolation of being carried out, conversion, replacement etc. also should belong to protection scope of the present invention.
Claims (3)
1. based on Machine Vision Detection centering control device, it is characterized in that: described device comprises first line scan sensor (1), second line scan sensor (2), the linear light source of LED (3), image capture module (4), PCIe bus image transmission module (5), the automatic positioning software of machine vision limit portion (6), digitial controller (7), interface module (8), Hydrauservo System (9) and hydraulic power unit (10), the linear light source of described LED (3) is connected with second line scan sensor (2) with first line scan sensor (1), described first line scan sensor (1) and second line scan sensor (2) incoming image acquisition module (4), described image capture module (4) connects PCIe bus image transmission module (5), described PCIe bus image transmission module (5) communicates to connect by automatic positioning software of machine vision limit portion (6) and digitial controller (7), described interface module (8) inserts digitial controller (7), described interface module (8) also is connected with Hydrauservo System (9), and described hydraulic power unit (10) is connected with Hydrauservo System (9) oil circuit;
Described first line scan sensor (1), second line scan sensor (2) are responded to wide cut long ribbon shape surface fast, and the result of induction exports to image capture module (4) with the form of Line Chart picture;
The linear light source of described LED (3) produces and converges linear light radiation to object to be detected, gives first line scan sensor (1) and second line scan sensor (2) by reflection with the surface appearance of object to be detected;
Described image capture module (4) carries out bottom layer treatment and conversion to the input signal of first line scan sensor (1) and second line scan sensor (2), and the signal of will going as required simultaneously is merged into the picture signal of suitable size;
Described PCIe bus image transmission module (5) is for the two paths of data of image capture module (4) provides point-to-point free band width bus passage;
The automatic positioning software of described machine vision limit portion (6) positions and follows the tracks of band material limit portion by image processing algorithm, goes out band practical center position according to two limit portion calculated signals, relatively calculates current band centre deviation amount with rolling centerline;
Described digitial controller (7), wide and the digital quantity control signal of speed, tension force, coil diameter, the material of the machine row system of importing into according to interface module (8) is determined the parameter of digitial controller (7), and calculates the controlled quentity controlled variable signal according to the band position of center line deviation signal of the automatic positioning software of machine vision limit portion (6) input and controller parameter and export to interface module (8);
Described interface module (8), the wide and digital quantity control signal of speed, tension force, coil diameter, the material of reader row system is given digitial controller (7), simultaneously the result of calculation of digitial controller (7) is exported to Hydrauservo System (9);
Described Hydrauservo System (9) is according to the size and Orientation of the control signal regulating load movement velocity of interface module (8) output;
Described hydraulic power unit (10) is for Hydrauservo System (9) provides pressure source.
2. according to claim 1 based on Machine Vision Detection centering control device, it is characterized in that: described first line scan sensor (1), second line scan sensor (2) all comprise machine vision camera lens, linear CCD photo-sensitive cell, analog-to-digital conversion circuit, bottom layer signal treatment circuit, power module and interface circuit; The linear light source of described LED (3) comprises cooling system, power module, power distribution plate, LED particle, concentration module and preposition astigmatism plate; Described image capture module (4) comprises CameraLink input interface module, camera control clock, ROI zone collection and trigger control unit, general serial control module, exterior I O expansion interface, triggers control connection device, real-time sync cap unit and bus interface controller; Described PCIe bus image transmission module (5) comprises the PCIe EBI; The automatic positioning software of described machine vision limit portion (6) comprises image denoising processing unit, image correction process module, image enhancing unit, image difference unit, statistical moment adaptive threshold rim detection module, edge link unit, morphology processing unit, image calibration system, band picture centre position and world coordinates modular converter, rolling centerline deviation computing unit and NILabview and Vision development environment; Described digitial controller (7) comprises the pid parameter self adaptation and calculates module and PID controller module; Described interface module (8) comprises machine row control figure input module, transmission analog signal input module, caution data signal output module, fieldbus module, serial communication interface and point-to-point physical interface; Described Hydrauservo System (9) comprises servo controller and servo valve; Described hydraulic power unit (10) comprises hydraulic pump motor, hydraulic pressure electric control system and pressure control section.
3. according to claim 2 based on Machine Vision Detection centering control device, it is characterized in that: described linear CCD photo-sensitive cell is a cmos sensor; The interface circuit type is CameraLink or is 1394 interfaces or for the GIGE interface or for USB interface.
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