CN102621156B - Image-processing-based automatic micro part sorting system - Google Patents
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Abstract
The invention provides an image-processing-based automatic micro part sorting system. The system comprises a workpiece screening module, a detection module, a software control system and a detection postprocessing module, wherein the detection module is positioned on the two sides of a rail of the workpiece screening module and connected with the software control system on a computer through a data line; and the detection postprocessing module is directly connected with the detection module and controlled by the software control system of the computer. By the system, the problems of low part surface quality detection efficiency, a high omission factor and high labor cost in the conventional micro part production process are mainly solved; and micro cylinder parts can be detected and sorted on line, particularly defects such as bumps, scratches, cracks and pits on the surfaces of the parts can be accurately distinguished and removed, the yield of the sorted products is ensured, and high sorting speed is achieved.
Description
Technical field
The present invention relates to rapid sorting system, be specifically related to a kind of micro parts Automated Sorting System based on image processing.
Background technology
Micro parts refers to that External Shape physical dimension is less than the part of 5mm.Due to micro parts being widely used in military products, civilian goods and industrial goods, its piece surface Defect Detection is an important content for part quality detection and precision control during part is produced.Traditional still relies on manual detection to the detection of micro parts, and because the part detecting is little, manual detection labour intensity is large, and efficiency is low, and loss is high, certainly will cause the defect of part quality control, thereby in the urgent need to a kind of online automatic checkout system.Although image processing techniques has use at a lot of detection fields, major part be all for larger part detection, or for the detection of accessory size.In the production of micro parts, generally with short production cycle, product quantity is large, and the detection method one adopting is at present to be difficult to meet its accuracy of detection and resolution requirement, the 2nd, be difficult to meet its detection speed requirement, particularly requiring detection speed to reach per minute more than 3000.
In current existing patent, patent of invention CN101832951A discloses a kind of " the PVC circular pipe surface blemish online test method based on Vision Builder for Automated Inspection ", it is mainly to detect for large pipe surface quality, its detection method only limits to large-scale part, and do not need to detect the work such as automatic screening sequence and the automatic rejection in later stage in early stage, cannot meet the requirement of sorting speed that micro parts proposes in detecting, thereby and not be suitable for the sorting work of micro parts.
From the document of publishing at present " micro parts physical dimension automatic detection device " (" war industry's robotization " in Dec, 2009): its size mainly for micro parts detects, and cannot realize the detection to concavo-convex, the pit in end face circle, crackle etc.
To sum up, for overcoming for small cylindrical part screening difficulty, disturb each other large and the higher problem of detection resolution, need to detect the defects such as concavo-convex, the scratch, crackle, pit of piece surface simultaneously, be necessary to develop a kind of novel sorting system for micro parts.
Summary of the invention
Technical matters to be solved by this invention is: a kind of micro parts Automated Sorting System based on image processing is provided, this sorting system can be realized online motion detection sorting to small cylindrical part, particularly can play accurate differentiation rejecting for defects such as concavo-convex, the scratch of piece surface, crackle, pits; Can process the image of this micro parts, reached higher accuracy of detection simultaneously.
The present invention solves its technical matters and adopts following technical scheme:
Micro parts Automated Sorting System based on image processing provided by the invention, is made up of workpiece screening module, detection module, software control system and detection post-processing module, wherein: detection module is in workpiece screening module track both sides; Detection module is connected with the software control system on computing machine by data line; Detect post-processing module and be directly connected with detection module, be subject to the control of computer software control system simultaneously.
Described workpiece screening module is mainly made up of feed mechanism, hyperchannel screening track, gear driver plate, barrel, and this module is screened, sorted for micro parts, makes micro parts become same direction equidistantly to arrange and enter measurement.
Described detection module looks like to gather to the end view drawing of micro parts, and its hardware device comprises CCD industrial camera, industrial lens, image pick-up card and light-source system, wherein: industrial lens is connected with CCD industrial camera by C/CS interface; CCD industrial camera is connected with image pick-up card by data line; Image pick-up card is connected with computing machine by computer PCI slot; Light-source system provides the illumination condition of requirement to detection module.
Described detection post-processing module receives by PLC control system the testing result signal that software control system provides, and controls the valve switch of air gun, and rejected part is rejected.
Described software control system looks like to process in real time to the end view drawing collecting, and judges.
Described software control system adopts Microsoft Visual C++6.0 exploitation, can carry out hardware communications with image pick-up card, and the micro parts image that image pick-up card is collected is processed in real time and judges, and meets the requirements of resolution and precision.
The step that described software control system carries out processing in real time for micro parts image comprises:
(1) pre-service of image: the processing of coloured image gray processing, filtering processing.The coloured image collecting is transformed into gray level image, and is carried out filtering processing, the interference while processing to reduce;
(2) binary conversion treatment of image.Gray level image is carried out to binary conversion treatment, to facilitate subsequent treatment work;
(3) adopt hough conversion to carry out circularity matching, to improve accuracy of detection, and obtain image center of circle parameter;
(4) according to the image center of circle parameter obtaining, take the center of circle as benchmark, its center of circle is overlapped whole image translation with the home position of standard masterplate;
(5) by workpiece image to be detected and standard stencil matching.
The present invention, in utilizing CCD application technology to obtain workpiece image, looks like to process to the micro parts end view drawing obtaining based on image processing techniques, therefore compares and has following major advantage with existing technology:
One. can carry out rapid sorting to micro parts, in the process of part sorting, the screening of part and rejected Automatic Control, without manual intervention, the sorting time is short, and efficiency is high, and accuracy of detection can reach 0.02mm.
They are two years old. and easy to use, simple to operate.After rigging up and debugging is complete, only need a people to get final product operation control software, click completely without manual intervention, can complete sorting work after starting to detect.
Specifically being calculated as follows of accuracy of detection:
According to hardware parameter, what the industrial CCD camera adopting adopted is 1/3 〞 area array CCD, its target surface is of a size of: h (level) × v (vertically)=4.8mm × 3.6mm, according to camera lens instructions, the lens focus f=17.64mm adopting, detect object distance D=50mm clearly, according to visual field computing formula:
Can be calculated: h ˊ=13.6mm, v ˊ=10.2mm
According to the view data of actual acquisition, its image pixel is H × V=720 pixel × 576 pixels,
Horizontal resolution:
Vertical resolution:
Be that accuracy of detection is about 0.02mm.
In a word, the present invention has mainly solved in current micro parts production low for surface quality of workpieces detection efficiency, and loss is high, the problem that cost of labor is large.This sorting system mainly comprises workpiece screening module, detection module, software control system and detects post-processing module.The present invention is mainly used in solving: to online detection the sorting of small cylindrical part, particularly can play accurate differentiation rejecting for defects such as concavo-convex, the scratch of piece surface, crackle, pits, the qualification rate of the product that guarantee sorts out, and require to reach higher sorting speed.
Brief description of the drawings
Fig. 1 is structural representation of the present invention.
Fig. 2 is the topology layout figure of Fig. 1.
Fig. 3 is the process flow diagram of micro parts image processing.
In Fig. 2: 1. feed mechanism; 2. hyperchannel screening track; 3. barrel; 4. gear driver plate; 5. micro parts; 6.CCD backlight; 7. CCD industrial camera; 8. air gun; 9. unacceptable product storehouse; 10. certified products storehouse; 11.PLC controller; 12. computing machines; 13. image pick-up cards.
Embodiment
Below in conjunction with embodiment and accompanying drawing, the invention will be further described.
Micro parts Automated Sorting System based on image processing provided by the invention, its structure as shown in Figure 1, formed by workpiece screening module, detection module, software control system and detection post-processing module, wherein: detection module is in workpiece screening module track both sides; Detection module is connected with the software control system on computing machine by data line; Detect post-processing module and be directly connected with detection module, be subject to the control of computer software control system simultaneously.
Described workpiece screening module is mainly the screening and sequencing work for micro parts.The structure of this module as shown in Figure 2, formed by parts such as feed mechanism 1, hyperchannel screening track 2, barrel 3, gear driver plates 4, wherein hyperchannel screening track can be to screening, sort for micro parts 5, and prevent rotation, the rolling of micro parts on delivery track with special track, make it become same direction equidistantly to arrange and enter measurement.Described special track is the Baltimore groove track mating with External Shape, prevents that the motion of delivery track from causing rotation and the rolling of micro parts.
Described workpiece screening module, its course of work is: micro parts 5 is sent into hyperchannel screening track 2 by feed mechanism 1, through the three level screen of hyperchannel screening track, make micro parts 5 become the single-row arrangement of individual layer, then pass through the calibration of gear driver plate 3, make its equidistant calibration, then pass through spatial attitude adjustment, described part enters Baltimore groove track, enters detection.
Described detection module is that the end view drawing of micro parts is looked like to gather, and its hardware device comprises CCD industrial camera 7, industrial lens, image pick-up card and light-source system, wherein: industrial lens is connected with CCD industrial camera by C/CS interface; CCD industrial camera is connected with image pick-up card by data line; Image pick-up card is connected with computing machine by computer PCI slot; Light-source system provides the illumination condition of requirement to detection module.
Described detection post-processing module is mainly, for the result detecting, rejected part is carried out to Weeding.This detection post-processing module receives by PLC control system the testing result signal that software control system provides, and controls the valve switch of air gun, and rejected part is rejected.
Described software control system looks like to process in real time and judge to the end view drawing collecting.This control system can adopt Microsoft Visual C++6.0 exploitation, can carry out hardware communications with image pick-up card, the micro parts image that image pick-up card is collected is processed in real time and judges, and meet the requirements of resolution and precision, as shown in Figure 3, its processing for micro parts mainly comprises the steps:
(1) pre-service of image: the processing of coloured image gray processing, filtering processing.The coloured image collecting is transformed into gray level image, and is carried out filtering processing, the interference while processing to reduce.
(2) binary conversion treatment of image.Gray level image is carried out to binary conversion treatment, to facilitate subsequent treatment work.
(3) adopt hough conversion to carry out circularity matching, to improve accuracy of detection, and obtain image center of circle parameter.
It is specifically implemented as follows:
The equation that is located at the circle under cartesian coordinate system is:
（1）
The solution of radius of a circle R is:
（2）
Get number of edge points N=100, marginal point in image
at parameter space
in projection coordinate's point set be combined into
.
Traversal is centered by marginal point, and all pixels in the square that 2R is the length of side, if marginal point is mapped to the element in coordinate points set in parameter space, parameter space totalizer
(totalizer initial value is all 0), cumulative maximum value in last totalizer P
corresponding coordinate is central coordinate of circle
.
(4) according to the image center of circle parameter obtaining, take the center of circle as benchmark, its center of circle is overlapped whole image translation with the home position of standard masterplate.
The image central coordinate of circle detecting for step (3), bidding quasi-mode version home position is
, translational movement:
，
（3）
Each point on image to be detected is done
,
translation.
(5) by workpiece image to be detected and standard stencil matching:
Standard workpiece bianry image and bianry image to be detected are carried out to phase reducing, if coupling, on each pixel, gray-scale value is 0, and workpiece to be detected is qualified; If do not mate, the upper gray-scale value of partial pixel point is not 0, and workpiece to be detected is defective.Wherein: standard masterplate is before detection, first to detect multiple qualified part to obtain, and its detecting step is (1)-(4), and obtains its radius error allowed band, and is deposited in Computer Database.
To detect annular workpiece as example, referring to Fig. 2, sketch the course of work of the present invention below.
After the complete equipment of Installation and Debugging, pour workpiece into feed mechanism 1, switch on to control desk, press start and stop master switch on control desk, power to whole system, workpiece starts to enter screening and sequencing, in the time that the workpiece of marshalling enters detection station, light-source system irradiates workpiece end face, light after 6 reflections of CCD backlight is received by CCD industrial camera 7 through camera lens, now, the picture signal that CCD industrial camera 7 collects is an analog quantity, through the A/D modular converter in image pick-up card 13, image is converted in the buffer memory that digital picture stores computing machine 12 into, by clicking the detection software on computing machine, software reads the image collecting from Computer Cache, process differentiation, and count, to underproof workpiece number record in storer, and send command signal to PLC controller 11, due to the uniform motion of conveying belt, after the set time, this defective workpiece arrives before the air gun 8 of PLC control, PLC time delay transmitted signal, control electromagnetic valve switch, the pressure gas of air gun rifle mouth ejection is rejected this defective workpiece in unacceptable product storehouse 9, qualified workpiece enters certified products storehouse 10, thereby reach the object of sorting.
Claims (4)
1. the micro parts Automated Sorting System based on image processing, is characterized in that by workpiece screening module, detection module, software control system and detects post-processing module forming, wherein: detection module is in workpiece screening module track both sides, detection module is connected with the software control system on computing machine by data line, detect post-processing module and be directly connected with detection module, be subject to the control of computer software control system simultaneously, workpiece screening module is mainly by feed mechanism (1), hyperchannel screening track (2), barrel (3), gear driver plate (4) composition, this module is screened for micro parts, sequence, make micro parts become same direction equidistantly to arrange and enter measurement, its process is: micro parts is sent into hyperchannel screening track (2) by feed mechanism (1), through the three level screen of hyperchannel screening track, make micro parts become the single-row arrangement of individual layer, then pass through the calibration of gear driver plate (4), make its equidistant calibration, pass through again spatial attitude adjustment, described part enters Baltimore groove track, enter detection, described micro parts refers to that External Shape physical dimension is less than the part of 5mm, described detection post-processing module receives by PLC control system the testing result signal that software control system provides, and controls the valve switch of air gun, and rejected part is rejected, described software control system looks like to process in real time to the end view drawing collecting, and judges.
2. the micro parts Automated Sorting System based on image processing according to claim 1, it is characterized in that detection module looks like to gather to the end view drawing of micro parts, its hardware device comprises CCD industrial camera, industrial lens, image pick-up card and light-source system, wherein: industrial lens is connected with CCD industrial camera by C/CS interface; CCD industrial camera is connected with image pick-up card by data line; Image pick-up card is connected with computing machine by computer PCI slot; Light-source system provides the illumination condition of requirement to detection module.
3. the micro parts Automated Sorting System based on image processing according to claim 1, it is characterized in that described software control system adopts Microsoft Visual C++6.0 exploitation, realize with image pick-up card and carry out hardware communications, the micro parts image that image pick-up card is collected is processed in real time and judges, and meets the requirements of resolution and precision.
4. the micro parts Automated Sorting System based on image processing according to claim 3, is characterized in that the step that described software control system carries out processing in real time for micro parts image comprises:
(1) pre-service of image: comprise the processing of coloured image gray processing, filtering processing, specifically the coloured image collecting is transformed into gray level image, and carried out filtering processing, the interference while processing to reduce;
(2) binary conversion treatment of image: gray level image is carried out to binary conversion treatment, to facilitate subsequent treatment work;
(3) adopt hough conversion to carry out circularity matching, and obtain image center of circle parameter;
(4) according to the image center of circle parameter obtaining, take the center of circle as benchmark, its center of circle is overlapped whole image translation with the home position of standard masterplate;
(5) by workpiece image to be detected and standard stencil matching.
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| CN105457898A (en) * | 2014-09-03 | 2016-04-06 | 深圳市佳晨科技有限公司 | Product sorting method and product sorting system |
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| CN105004371A (en) * | 2015-06-30 | 2015-10-28 | 张家港华日法兰有限公司 | Method for detecting flange quality |
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