CN102305793A - Method and equipment for detecting appearance quality of product - Google Patents
Method and equipment for detecting appearance quality of product Download PDFInfo
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Abstract
The invention discloses a method and equipment for detecting the appearance quality of a product. The method can be used for comprehensively detecting the outer contour defect and surface defect of the product and the defect of the product in a working state. The equipment comprises an illumination light source, a speed detection device, an image acquisition device, a defect detection module, a not good (NG) product removing device, an NG product conveying belt, a defect alarm device, a fixing frame, an electric control box, an industrial personal computer, a display and the like. When the defect detection module detects products with unqualified appearance quality, the defect alarm device gives an acousto-optic alarm, and the NG product removing device is started to remove the unqualified products to the NG product conveying belt. By the method and the equipment, the appearance quality defect is comprehensively detected, the equipment is high in automation degree, the detection speed is high, the detection result is high in objectivity and consistency, and the production efficiency of the manufacturing industry can be effectively improved.
Description
Technical field
The present invention relates to a kind of method and apparatus of product appearance quality testing, particularly the optical profile type detection method and the equipment of product appearance defective.
Background technology
The product quantity of modern manufacturing industry is increasing, and product quality requires more and more higher.And for the appearance quality detection of product; Present most of manufacturer still adopts the mode of human eye detection; Human eye detection is divided into the naked modes such as detection, microscope human eye detection, CCD imaging human eye detection of looking several of human eye again; Though these several modes also have the branch of quality; But the qualification determination of product appearance quality all depends on the people and makes judgement.Human eye is very easily tired when long-time the observation on the one hand, and the influence of the examined personnel's individuality of testing result is very big, and testing result is not objective.On the other hand, along with the expansion of manufacturing industry scale, product quantity is increasing, and relying on manual work to detect far merely can not meet the needs of production, more and more stronger to the demand of automatic detection system.
In recent years; The product appearance quality detection apparatus of robotization constantly occurs; Such as Chinese patent number is 200810216939.6; Name is called the patent of " a kind of product appearance quality determining method, system and checkout equipment "; Disclose a kind of replacement human eye range estimation, realized the method and apparatus that robotization detects.But this patent only is based on the detection of product surface quality, and powerless for the open defect that the product outline exists, this patent can only solve the detection problem of off-line simultaneously, can't detect and reject product on the automatic production line.
The invention provides the method and apparatus that a kind of presentation quality detects automatically; Through this equipment; Defectives such as dirty, the burr on can full automatic detection streamline on the production product appearance, cut, unfilled corner, breakage; And can automatically the defectiveness product be rejected; And, be used to instruct or promote the improvement of production-line technique to the quality situation statistical study of product.
Summary of the invention
The invention provides a kind of detection method and equipment of product appearance quality, can be automatically the presentation quality defective of product on the production line be detected, and can substandard product be rejected automatically according to testing result.
One object of the present invention is to provide a kind of complete product appearance quality determining method, can carry out comprehensive appearance quality detection to defective under product outline defective, surface defects of products and the product duty.And for the electrical type features/components; Like liquid crystal module; Directly the off-line independent detection can only be found the presentation quality defective of part; Greatly the presentation quality defective often appears at module and works on power under the state, therefore the presentation quality defects detection under the product duty also is necessary.
Product outline defects detection is divided into two steps: edge contour extracts and the profile determining defects.Edge contour extracts the two kinds of situation that are divided into:
(1) for the product that possesses regular appearance profile, as square or circular, utilize known product attribute, near profile, product is carried out the edge search, confirm its edge contour;
(2), directly utilize edge extracting and track algorithm to obtain the external periphery outline of product for the product of irregular contour profile.
Near the zone that profile, has big light and shade difference can be adopted binary conversion treatment to reduce and disturbed, and then seeks the edge;
For the judgement of profile defective, can adopt following one or more modes to carry out:
(1) for the limit situation of seeking of edge search, judges as threshold value, can confirm whether profile exists defectives such as burr such as quantity, edge length and the fitting a straight line at the edge of seeking out or the error of fitting of circular fitting;
(2) for polygonal profile, the edge calculations summit that can adopt match to obtain, and then calculate the closed area, girth etc. of profile by the summit, judge as threshold value with this;
(3), can use error of fitting, radius and girth to judge as threshold value for circular arc or circle;
(4), can use error of fitting, girth and area etc. to do threshold decision with standard form for the profile of non-rule.
Surface defects of products detects and generally also is divided into two steps:
(1) defective edge search: at the edge of definite inner search for defects of product outline of a last step, and pixel, the fitting a straight line error at calculating defective edge, FRET diameter etc.
(2) determining defects: do threshold decision with standard value for the moulding amount of pixels at defective edge, fitting a straight line error, FRET diameter etc.
The operator in some cases, also need on the image of gathering, add edge labelling, so that can do further artificial judgment when needing with particular color (color that does not have in the image imaging) to detected defective.
Defects detection under the product duty: on this equipment, be reserved with general interface, software also provides expansion interface, but product adds electro-detection on the pipeline.Such as, can power up liquid crystal module, detect in the liquid crystal module rear surface that powers on whether display defect is arranged, and send shows signal, whether the image of the generation of the defects detection module comparison liquid crystal module in the software detects liquid crystal module and shows normal.
Another object of the present invention is to provide a kind of product appearance mass defect checkout equipment; This equipment can directly be installed on the existing streamline; The product that passes through on the pipeline carries out appearance quality detection; According to testing result, can exist the substandard product of mass defect to reject to outward appearance.
Defects detection equipment of the present invention comprises: lighting source, speed detector, image capture module, defects detection module, NG product device for eliminating, NG product travelling belt, defective warning device, fixed mount, electric cabinet, industrial computer and display.
Lighting source provides even, consistent illumination to examined product, and it is clear, sharp keen to guarantee that product forms images in image capture module, and the illuminating effect of different brightness and different angles can be provided for Different products.
Image capture module comprises imaging lens, line array CCD and image pick-up card; Camera lens arrives the line array CCD imaging surface with the product image projection; Line array CCD is once gathered the product image of a sweep trace; The sweep trace series arrangement that difference is gathered constantly; Be merged into a complete image; And the electric signal that collects is converted into vision signal, image pick-up card is then accomplished the digitizing conversion of vision signal.
The defects detection module adopts above-mentioned product appearance quality determining method testing product outward appearance from view data whether to have defective, and sends the detection decision signal according to testing result.
The signal that the defective warning device provides according to the defects detection module sends preset sound and light alarm, and there is defective substandard product in prompting, notifies the staff to do necessary further processing.
NG product device for eliminating is rejected substandard product on the NG product travelling belt according to the signal that the defects detection module provides, and NG product travelling belt sends it to assigned address.
Fixed mount is used for supporting light sources, image capture module, NG product device for eliminating etc.
Industrial computer and display are formed computer system, are used to realize the software function of defects detection module.
The invention has the advantages that defects detection in the presentation quality is comprehensive, automation degree of equipment is high, detection speed is fast, testing result objectivity and high conformity, it is little influenced by human factor, can effectively improve existing manufacturing industry production efficiency, significantly improves production capacity.
Description of drawings
Fig. 1 is the schematic flow sheet of product appearance quality determining method of the present invention.
Fig. 2 is a product appearance quality detection apparatus one-piece construction synoptic diagram of the present invention.
Fig. 3 is that light source in the embodiment of the invention, camera lens, line array CCD install and fix the mode synoptic diagram.
Primary structure is among the figure: 11-speed detection module, 12-light source, 13-defects detection module, 14-image capture module, 15-product travelling belt, 16-NG product travelling belt, 17-defective warning device, 18-NG product device for eliminating, 21-NG product travelling belt, 23-warning device, 24-fixed mount, 25-NG product device for eliminating, 26-product travelling belt, 31-product to be detected, 32-line array CCD, 33-camera lens.
Embodiment
Fig. 1 has provided the schematic flow sheet of automatic production appearance quality detection method of the present invention, and this method relates to: light source 12, speed detection module 11, image capture module 14, defects detection module 13, defective warning device 17, NG product device for eliminating 18, product travelling belt 15, NG product travelling belt 16.Wherein, image capture module 14 is in product travelling belt 15 upper fixed, and is connected with defects detection module 13; Defective warning device 17 is connected with defects detection module 13; NG product device for eliminating 18 is connected with defects detection module 13, and is connected with product travelling belt 15; NG product travelling belt 16 is connected with product travelling belt 15; Light source 12 and product travelling belt 15 relative fixed; Speed detection module 11 is connected with product travelling belt 15.
Line speed detection module 11 adopts scrambler realization speed to detect; Be installed on the product travelling belt 15; Detect the translational speed of product to be detected on the travelling belt 15 in real time, and, guarantee that the image that collects is steady, undistorted with the picking rate that this speed is come synchronous images acquisition module 14.
NG product device for eliminating 18 directly links to each other with defects detection module 13; Accept 13 controls of defects detection module; The defective signal of detection according to 13 outputs of defects detection module; Send synchronously and reject action; Defective substandard product is rejected on the NG product travelling belt 16, and NG product travelling belt 16 is sent to substandard product and specifies in the receiving trap.Rejecting mechanism wherein adopts cylinder control pressure gas to realize operation.
The image that 13 pairs of image capture modules 14 of defects detection module obtain carries out pre-service, and carries out defects detection, and whether the testing product outward appearance exists defective, and provides the decision signal whether defective exists:
(1) the defects detection module is obtained view data from image capture module;
(2) the defects detection module uses the Gauss filter operator that view data is carried out smothing filtering, the influence of disturbing factors such as filtering noise to detecting;
(3) the defects detection module uses the Canny edge detection algorithm that filtered image is carried out rim detection; The high threshold parameter of Canny rim detection adopts the method for maximum between-cluster variance to obtain, and low threshold value is used half of high threshold; The Canny rim detection obtains edge point set data;
(4) the defects detection module at first adopts corrosion and expansion algorithm that detected edge point set data are handled, and utilizes the connection district algorithm of 8 neighborhoods to carry out the outline detection again;
(5) the defects detection module adopts the different detection method to different edge situation, to judge the product outline whether defectives such as burr, distortion, unfilled corner, breakage is arranged:
A) judge as threshold value according to the amount of edge, edge length and the fitting a straight line that seek or the error of fitting of circular fitting, can confirm whether profile exists defectives such as burr;
B) for polygonal profile, adopt match edge calculations summit, and then calculate the closed area, girth etc. of profile by the summit, judge as threshold value with this;
C), use error of fitting, radius and girth to judge as threshold value for circular arc or circle;
D), use error of fitting, girth and area etc. to do threshold decision with standard form for the profile of non-rule;
(6) if detecting outline exists defective, belong to unacceptable product, the defects detection module provides defective judgement, clearly indicates the defective region, and sends the corresponding judgment signal;
(7) qualified at the product outline, do not exist under the situation of defective, the defects detection module extracts the surf zone of examined product according to detected product outline of (4) step, adopts following four kinds of modes to judge whether the surf zone quality is qualified:
A) gradation of image in the surf zone is done mean value, compare, do threshold decision with standard value;
B) gray variance to image in the surf zone calculates, and does threshold decision;
C) image in the surf zone and standard items image are done pattern match;
D) carry out the search of defective edge in surf zone inside, and calculate pixel, the fitting a straight line error at defective edge, FRET diameter etc.; Do threshold decision for the moulding amount of pixels at defective edge, fitting a straight line error, FRET diameter etc. with standard value;
If detecting surf zone exists defective, belong to unacceptable product, the defects detection module directly provides defective judgement, clearly indicates defect type and region, and sends the corresponding judgment signal;
(8) the defects detection module is up-to-standard at surf zone, does not exist the liquid crystal display class module of defective to work on power and detects under the state: power on but do not have test electric signal input state down detection liquid crystal module outward appearance whether have defective; Whether liquid crystal module is being sent under the test signal condition, it is normal to detect the liquid crystal module display image; For there being surface quality defect under the duty, send the corresponding judgment signal equally;
(9) for the product that does not have surface quality defect, the defects detection module is not sent any signal;
(10) total quantity, specification product quantity, the substandard product quantity of testing product of defects detection module real-time statistics.
Fig. 2 has provided the structural representation of an embodiment of this automatic defect checkout equipment.This equipment comprises light source 12, camera lens 33, line array CCD 32, warning device 23, fixed mount 24, NG product device for eliminating 25, product travelling belt 26, NG product travelling belt 21.Wherein, camera lens is connected with line array CCD and is one, and is installed in product travelling belt 26 tops through fixed mount 24 together with light source 12, warning device 23.NG product device for eliminating 25 is fixed on product travelling belt 26 sides, the substandard product on the product travelling belt 26 can be rejected on the NG product travelling belt 21.NG product travelling belt 21 is sent to predeterminated position with substandard product.
Fig. 3 has provided light source 12 in the present embodiment, camera lens 33, line array CCD 32 and installed and fixed the mode synoptic diagram: camera lens 33 links together with line array CCD 32; And with barcode LED light source 12 positions of measurement product 31 to be detected before product travelling belt 26 is taken in jointly, can be that the imaging of line array CCD 32 provides appropriate illumination to guarantee to adjust led light source 12.
At industrial computer image pick-up card is installed; The image transitions that it obtains line array CCD 32 is a digital picture; And use defects detection module 13 to carry out defects detection according to above-mentioned defect inspection method; If detect defective substandard product; Then driving N G product device for eliminating 18, and substandard product is rejected on the NG product travelling belt 16.NG product device for eliminating 18 adopts the pressure gas of solenoid control to realize removing function.
Claims (12)
1. a product appearance quality determining method is characterized in that, said method comprising the steps of:
Image capture module [14] is gathered product image to be detected;
Defects detection module [13] is carried out The disposal of gentle filter to the image of gathering;
Defects detection module [13] is carried out rim detection to image after the Filtering Processing, obtains edge point set data;
Defects detection module [13] is carried out the product outline to detected edge point set data and is detected;
Defects detection module [13] is carried out defects detection to the presentation quality of product;
NG product device for eliminating [18] is rejected the surface quality substandard product on the driving-belt according to the detection signal of defects detection module [13];
Defects detection module [13] real-time statistics is testing product total quantity, specification product quantity, substandard product quantity.
2. defects detection module as claimed in claim 1 is characterized in that, said defects detection module [13] comprises defects detection module three parts under product outline defects detection module, surface defects of products detection module, the product duty.
3. outline defects detection module as claimed in claim 2; It is characterized in that; Outline defects detection module is carried out filtering, rim detection, profile detection to the product image; Again the outline data that obtains is carried out amount of edge, length, error of fitting, closed area, girth and carry out the qualification inspection, judge whether outline exists open defect.
4. surface defects of products detection module as claimed in claim 2; It is characterized in that; The surface defects of products detection module is to gradation of image mean value, gray variance value in the product image calculation surf zone; And do the qualification inspection in the threshold range with standard value, judge whether product surface exists open defect.
5. defects detection module under the product duty as claimed in claim 2; It is characterized in that the defects detection module can work on power under the state to liquid crystal display class module and detect under the product duty: power on but do not have test electric signal state down detection liquid crystal module outward appearance whether have defective; Whether liquid crystal module is being sent under the test signal condition, it is normal to detect the liquid crystal module display image.
6. product appearance quality detection apparatus, it is characterized in that: equipment is made up of light source [12], image capture module [14], speed detection module [11], NG product travelling belt [21], NG product device for eliminating [25], defective warning device [17], fixed mount [24], industrial computer and display.
7. light source as claimed in claim 6 is characterized in that, light source [12] is a strip green LED light source, and wavelength 520nm, LED adopt constant current source to drive.
8. image capture module as claimed in claim 6 is characterized in that, image capture module [14] comprises camera lens, line array CCD and image pick-up card.
9. speed detection module as claimed in claim 6 is characterized in that, the transfer rate on the real-time testing product travelling belt of speed detection module [11] is with the picking rate of line array CCD in this speed control image capture module [14].
10. industrial computer as claimed in claim 6 is characterized in that, industrial computer comprises defects detection module [13].
11. NG product device for eliminating as claimed in claim 6 is characterized in that, NG product device for eliminating [25] is rejected the product on the product travelling belt [26] on the NG product travelling belt [21] according to the defective signal of detection of defects detection module [13] output.
12. defective warning device as claimed in claim 6 [17] is characterized in that, defective warning device [17] sends sound and light alarm according to the defective signal of detection of defects detection module [13] output.
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