CN102721702A - Distributed paper defect detection system and method based on embedded processor - Google Patents
Distributed paper defect detection system and method based on embedded processor Download PDFInfo
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Abstract
The invention relates to a distributed paper defect detection system and a distributed paper defect detection method based on an embedded processor. A plurality of paths of industrial linear array charge coupled device (CCD) cameras which are arranged side by side are used for acquiring image data of moving paper amplitude; the image data is transmitted to corresponding embedded paper defect detection processors through CameraLink cables; the embedded paper defect detection processors acquire and preprocess images through field programmable gate arrays (FPGA) and detect data such as the types, the areas and the positions of paper defects in the images through a digital signal processor (DSP); detection results of the detection processors and the corresponding paper defect images are transmitted to a central server through a gigabit Ethernet; and the central server displays the detection results and the paper defect images through sub windows in an updating manner and stores the detection results and the paper defect images into a background database. The system has the advantages of low construction cost, large speed increase space and simplicity in distributed detection and can be applied to high-speed and on-line detection for conventional paper defects such as black spots, holes, drapes and the like of moving paper amplitude at the speed not less than 1 km/min.
Description
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Technical field
The present invention relates to paper defect detecting technique field, relate in particular to a kind of distributed web inspection system and method based on flush bonding processor based on machine vision.
Background technology
In the paper production process, paper surface can produce some defectives inevitably, i.e. paper defects, like spot, hole, gauffer, scratch etc., these paper defects are to have a strong impact on paper quality, thus paper defects to detect be an important step in the production run.Traditional paper defects detects by manual work and accomplishes, but modern paper already has wide, the fireballing characteristics of paper web, relies on manual detection page paper defects can not meet the demands.In recent years, along with machine computing machine and development of digital image, obtained widespread use based on the paper defects on-line monitoring system of machine vision at some large-scale papermaking enterprises, this system can realize the online detection of paper web paper defects fast and effectively.But in this system; Paper defects detects the main image processing software that operates on the PC that relies on and realizes; This detection scheme is unfavorable for realizing large-scale distributed online detection on the one hand; On the other hand since its construction cost generally all than higher, be restricted in the application of the papermaking enterprise of middle and small scale.To these problems, in the paper defects detection range that progressively is applied to based on the machine vision technique of flush bonding processor, and some application systems have appearred; These systems adopt the core processor of high-speed dsp chip as the paper defects graphical analysis mostly; Overcome shortcoming to a certain extent, but because all processing operations such as the collection of paper defects image, pre-service, paper defects detection are all accomplished by DSP, the computational load of DSP own is just very big based on the paper defects detection of PC; And dsp chip also needs frequent and External memory equipment carries out exchanges data; Therefore detect for real-time online, argin is not enough, adopts the speed of this technical scheme to promote limited.
Summary of the invention
The object of the invention is exactly in order to overcome the defective that existing paper defects detection technique exists; A kind of distributed web inspection system based on flush bonding processor is provided; It constitutes that cost is low, the speed room for promotion big, is easy to realize Distributed Detection can realize the online detection of common paper defects such as blackspot, hole, fold, scratch.
To achieve these goals, the present invention adopts following technical scheme:
A kind of distributed web inspection system based on flush bonding processor, it comprises at least one group of high speed camera, high speed camera is installed in motion paper web top, below the motion paper web, then is provided with led light source; High speed camera is connected with embedded paper defects measurement processor, and embedded paper defects measurement processor is communicated by letter with central server through Ethernet switch; Wherein, Embedded paper defects measurement processor is realized by FPGA and DSP cooperation; Comprise the image acquisition units in the FPGA, it is communicated by letter with transceiving chip with the outer kilomega network control of dual port RAM, paper defects image pretreatment unit, Ethernet interface control module and FPGA in the FPGA successively; Paper defects image pretreatment unit detects DSP with paper defects, high-speed SRAM is communicated by letter; Image acquisition units is through LVDS/ LVTTL conversion chip acquisition of image data, through LVTTL/ LVDS conversion chip control high speed camera; Paper defects image pretreatment unit receives the view data of image acquisition units, and it is carried out pre-service, and paper defects detects the view data that DSP receives paper defects image pretreatment unit, and carries out paper defects and detect; The Ethernet interface control module is controlled kilomega network control on the one hand and with the camera that transceiving chip receives from Ethernet parameter is set; And be sent to image acquisition units; Receive paper defects testing result data on the other hand, and the control of control kilomega network is sent to Ethernet with transceiving chip from the image pretreatment unit.
Said high speed camera is made up of multichannel Industry thread array CCD camera, laterally is installed in the top of motion paper web side by side; Every road camera is connected to embedded paper defects measurement processor separately through Camera Link cable.
A kind of detection method that adopts based on the distributed web inspection system of flush bonding processor, its step is:
(1) parameter setting
Software operation is detected on foreground through central server, and the parameters such as line frequency, time shutter and picture size of each road high speed camera are provided with;
(2) detect startup
After parameter is provided with completion, detects software through the foreground of central server and send the paper defects sense command, this order is sent to the embedded paper defects measurement processor in each road through Ethernet, starts online paper defects and detects;
(3) page IMAQ
The embedded paper defects measurement processor in each road is saved in the dual port RAM in the FPGA through the image acquisition units in the FPGA and the Camera Link interface page view data with the camera collection;
(4) image pre-service
Embedded paper defects measurement processor is passed through the image pretreatment unit reads image data from dual port RAM in the FPGA, and it is carried out medium filtering and segmentation gray scale linear transformation pre-service;
(5) paper defects detects and the location
Pretreated view data input paper defects detects DSP, and paper defects detects DSP and utilizes thresholding method that speck, scratch class high brightness paper defects zone and blackspot, fold class low-light level paper defects zone in the image are separated from background respectively; Calculate the circularity in each paper defects zone then, and distinguish hole and scratch, blackspot and fold according to circularity;
(6) have paper defects if paper defects detection DSP detects in the page image, then type, area, location parameter and the corresponding paper defects image with each paper defects is sent to central server through gigabit Ethernet;
(7) central server carries out update displayed through a plurality of subwindows to multichannel testing result and paper defects image, simultaneously it is saved in the background data base.
In the said step (1); At the detection software on the central server parameters such as the line frequency of each road high speed camera, time shutter, image size are directly called in internal memory from hard disk; Be sent to the image acquisition units in the FPGA in the embedded paper defects measurement processor through Ethernet then; Image acquisition units produces camera control signal thus, and is sent to high speed camera by LVTTL/LVDS conversion chip and Camera Link cable.
In the said step (3), the effective pixel data of high speed camera output image is sent to the image acquisition units in the FPGA through Camera Link stube cable and LVDS/LVTTL interface conversion chip; Image acquisition units, is written in the dual port RAM as writing the view data of clock with high speed camera with pixel clock as with imitating signal with line synchronizing signal.
In the said step (4), after collecting a frame image data, the image pretreatment unit in the FPGA reads the view data in the dual port RAM; According to picture size image being carried out the border cutting earlier handles; Carry out medium filtering then,, carry out piecewise linear gray transformation afterwards again to eliminate random noise disturbance; Strengthen the paper defects zone in the image, suppress its background area; The pre-service result is saved in the outer high-speed SRAM of FPGA; After pre-service finished, the image pretreatment unit detected DSP to paper defects and sends look-at-me.
In the said step (5), after paper defects detection DSP receives look-at-me, read view data among the SRAM; Utilize publish picture in picture hole and scratch class high brightness paper defects zone and spot, fold class low-light level paper defects of Threshold Segmentation regional earlier; After utilizing opening operation to remove noise, utilize labelling method to confirm the position and the area in each paper defects zone in the image again; Calculate each paper defects area circumference then and square obtain circularity with the area ratio, the zone that circularity is bigger is fold or scratch, and circularity is blackspot and speck than the zonule.
In the said step (6); After paper defects detects DSP completion image detection; If the number of paper defects is non-vanishing, then parameters such as the type of each paper defects, area, position are sent to the Ethernet interface control module of FPGA, paper defects parameter, paper defects image and affiliated phase plane No. data are packed in this unit; And the control kilomega network controls and transceiving chip is sent to Ethernet with data, is sent to central server by Ethernet again.
In the said step (7), detect on the software interface on the foreground of central server, each camera all has the subwindow of a correspondence, is used to show this road camera testing result; After software receives the data that Ethernet sends, according to the phase plane No. under it paper defects image of gathering and corresponding paper defects parameter are presented in the corresponding subwindow, and it is saved in the background data base.
The present invention has adopted multichannel Industry thread array CCD camera side by side to gather motion paper web view data; View data is sent to each self-corresponding embedded paper defects measurement processor through Camera Link interface; Because the transfer rate of Camera Link interface reaches as high as 2.1Gbps, can guarantee the high speed property of data acquisition.
Embedded paper defects measurement processor realizes that through the paper defects image being carried out analyzing and processing paper defects detects, and is the core of whole detection system, also is the bottleneck of the whole detection system speed of restriction.In order to guarantee the high speed property of image analysis processing, this unit is realized by FPGA and DSP cooperation, is made full use of the high-speed data processing power of DSP and the complex logic processing power of FPGA.After embedded paper defects measurement processor was accomplished the paper defects detection, testing result and corresponding paper defects image were sent to central server through gigabit Ethernet.Central server is by computing machine and software is detected on operation foreground on computers and background data base is formed.Server receives the testing result of each road detecting unit, and shows and preserve.
The invention has the beneficial effects as follows: realized the quick collection of page image through Camera Link interface line array CCD camera; Utilize FPGA and DSP flush bonding processor to realize that quick paper defects detects and the location; Utilize gigabit Ethernet to guarantee the quick transmission of testing result and paper defects image.The paper defects on-line detecting system that makes up has that cost is low, the speed room for promotion big, be easy to realize the Distributed Detection advantage, can be applicable to the online detections of common paper defects high speed such as blackspot, hole, fold, scratch that the speed of a motor vehicle is not less than the motion paper web of 1km/min.
Description of drawings:
Fig. 1 is based on the distributed web inspection system structural representation of flush bonding processor;
The embedded paper defects measurement processor of Fig. 2 theory diagram;
Fig. 3 paper defects detection algorithm overview flow chart;
Fig. 4 confirms paper defects area, position and separates the algorithm flow chart of hole, scratch;
Fig. 5 example paper defects image and paper defects type identification result.
Wherein, 1. high speed camera, 2. motion paper web, 3.LED light source; 4. embedded paper defects measurement processor, 5. Ethernet switch, 6. central server, 7. LVDS/ LVTTL conversion chip; 8. LVTTL/LVDS conversion chip, 9. image acquisition units, 10. dual port RAM, 11. image pretreatment units; 12. paper defects detects DSP, 13. high-speed SRAM, 14. Ethernet interface control modules, control of 15. kilomega networks and transceiving chip.
Embodiment
Below in conjunction with accompanying drawing and embodiment the present invention is described further.
As shown in Figure 1, mainly comprise led light source 3, motion paper web 2, high speed camera 1, embedded paper defects measurement processor 4, Ethernet switch 5 and central server 6 based on the distributed web inspection system of flush bonding processor.Led light source 3 is installed in the below of motion paper web 2, and high speed camera 1 is made up of the multi-route array CCD camera, laterally is installed in the top of motion paper web 2 side by side.Every road camera is connected to embedded paper defects measurement processor 4 separately through Camera Link interface.As shown in Figure 2; Embedded paper defects measurement processor 4 mainly detects DSP12 by the image acquisition units in the FPGA 9, paper defects image pretreatment unit 11, Ethernet interface control module 14, dual port RAM 10 and paper defects to be formed, comprises outer high-speed SRAM 13 of sheet and external interface chips such as LVDS/LVTTL conversion chip 7, LVTTL/LVDS conversion chip 8, kilomega network control and transceiving chip 15 in addition.Ethernet interface control module 14 in the embedded paper defects measurement processor 4 in each road is connected to central server 6 by Ethernet switch 5 again through being connected to Ethernet switch 5 with kilomega network control with transceiving chip 15.Central server 6 is by computing machine and software is detected on operation foreground on computers and background data base is formed.
Paper defects detection method of the present invention is:
(1) parameter setting.The foreground of central server 6 is detected software and is called in the line frequency, time shutter, image size etc. of each road high speed camera 1 from hard disk parameter is set, and parameter is set is sent to embedded paper defects measurement processor 4 through Ethernet.As shown in Figure 2, the image acquisition units 9 in the FPGA produces the camera control signal of TTL form, and this control signal converts the LVDS form to by LVTTL/ LVDS conversion chip 8, and is sent to each road high speed camera 1 by Camera Link stube cable.
(2) detect startup.Send the paper defects sense command through software interface, this order is sent to embedded paper defects measurement processor 4 through Ethernet, starts online paper defects and detects.
(3) image data acquiring.As shown in Figure 2, the view data of high speed camera 1 output is sent to LVDS to LVTTL conversion chip 7 through Camera Link stube cable, and this chip converts 4 pairs of LVDS data-signals and 1 pair of LVDS clock signal to TTL form 28 bit data and 1 tunnel clock signal.Comprise frame synchronizing signal (FVAL, invalid in the native system) in 28 bit data, row has a synchronizing signal (LVAL).Image acquisition units 9 in the FPGA, writes in the dual port RAM 10 in the FPGA as writing the view data of clock with high speed camera 1 with pixel clock as with imitating signal with LVAL.Being stored in the dual port RAM 10 is 8 gray level images, totally 256 gray shade scales.
(4) image pre-service.After collecting a frame image data; Image pretreatment unit 9 in the FPGA reads the view data of dual port RAM 10; As shown in Figure 3, earlier image is carried out the border cutting and handle according to picture size, utilize 3 * 3 cruciform template to carry out medium filtering again; Utilize piecewise linear gray transformation that enhancement process is carried out in the paper defects zone then, Fig. 5 a is that a width of cloth is through paper defects image (512 * 512) after the pre-service.Pretreated view data is deposited in the high-speed SRAM 13.After pre-service finished, the image pretreatment unit 9 in the FPGA detected DSP12 to paper defects and sends interrupt request.
(5) paper defects detects.After paper defects detection DSP12 receives interrupt request, read view data in the high-speed SRAM 13, and carry out paper defects and detect and the location.Shown in Fig. 5 a, because led light source 3 is below motion paper web 2, hole and scratch belong to the high-brightness region in the image, and spot and fold are the low brightness area that belongs in the image.As shown in Figure 3, utilize less empirical value
T 1Be partitioned into low-light level paper defects zones such as blackspot, fold, segmentation result is shown in Fig. 5 b.Utilize opening operation to remove noise again, the mark connected domain is confirmed paper defects position, area, calculates each regional circularity then, and what circularity was less is blackspot, and what circularity was bigger is fold, as shown in Figure 4.The blackspot recognition result is shown in Fig. 5 c, and the fold recognition result is shown in Fig. 5 d.As shown in Figure 3, utilize bigger empirical value
T 2Be partitioned into high brightness such as hole, scratch paper defects zone in the image, segmentation result is shown in Fig. 5 e.Use the same method again and distinguish hole and scratch and confirm its position, area parameters.The hole recognition result is shown in Fig. 5 f, and the scratch recognition result is shown in Fig. 5 g.
(6) testing result transmits.After paper defects detects DSP12 completion image detection; If the number of paper defects is non-vanishing; Then data such as the type of each paper defects, area, position are reached the Ethernet interface control module 14 in the FPGA; Number packing paper defects parameter, paper defects image and affiliated high speed camera in this unit, through kilomega network control and transceiving chip 15 data is sent to Ethernet again, is sent to central server 6 by Ethernet again.
(7) testing result is upgraded, is shown.Foreground at central server 6 is detected on the software interface, and every road high speed camera 1 all has the subwindow of a correspondence, is used to show this road high speed camera 1 testing result.After software receives the data that Ethernet sends, number paper defects image and corresponding paper defects parameter are presented in the corresponding subwindow according to the high speed camera under it on the one hand, on the other hand it are saved in the background data base of central server 6.
Claims (9)
1. the distributed web inspection system based on flush bonding processor is characterized in that it comprises at least one group of high speed camera, and high speed camera is installed in motion paper web top, below the motion paper web, then is provided with led light source; High speed camera is connected with embedded paper defects measurement processor, and embedded paper defects measurement processor is communicated by letter with central server through Ethernet switch; Wherein, Embedded paper defects measurement processor is realized by FPGA and DSP cooperation; Comprise the image acquisition units in the FPGA, it is communicated by letter with transceiving chip with the outer kilomega network control of dual port RAM, paper defects image pretreatment unit, Ethernet interface control module and FPGA in the FPGA successively; Paper defects image pretreatment unit detects DSP with paper defects, high-speed SRAM is communicated by letter; Image acquisition units is through LVDS/ LVTTL conversion chip acquisition of image data, through LVTTL/ LVDS conversion chip control high speed camera; Paper defects image pretreatment unit receives the view data of image acquisition units it is carried out pre-service, and paper defects detects the view data that DSP receives paper defects image pretreatment unit, and carries out paper defects and detect; The Ethernet interface control module is controlled kilomega network control on the one hand and with the camera that transceiving chip receives from Ethernet parameter is set; And be sent to image acquisition units; Receive paper defects testing result data on the other hand, and the control of control kilomega network is sent to Ethernet with transceiving chip from the image pretreatment unit.
2. a kind of distributed web inspection system based on flush bonding processor as claimed in claim 1 is characterized in that said high speed camera is made up of multichannel Industry thread array CCD camera, laterally is installed in the top of motion paper web side by side; Every road camera is connected to embedded paper defects measurement processor separately through Camera Link cable.
3. detection method that adopts the described distributed web inspection system based on flush bonding processor of claim 1 is characterized in that its step is:
(1) parameter setting
Software operation is detected on foreground through central server, and parameters such as the line frequency of each road high speed camera, time shutter, picture size are provided with;
(2) detect startup
After parameter is provided with completion, detects software through the foreground of central server and send the paper defects sense command, this order is sent to the embedded paper defects measurement processor in each road through Ethernet, starts online paper defects and detects;
(3) page IMAQ
The embedded paper defects measurement processor in each road is saved in the dual port RAM in the FPGA through the image acquisition units in the embedded FPGA and the Camera Link interface page view data with the camera collection;
(4) image pre-service
Embedded paper defects measurement processor is through the image pretreatment unit reads image data from dual port RAM in the FPGA, and it is carried out medium filtering and pre-service is carried out in the linear transformation of segmentation gray scale;
(5) paper defects detects and the location
Pretreated view data input paper defects detects DSP, and paper defects detects DSP and utilizes thresholding method that speck, scratch class brightness paper defects zone and blackspot, fold class low-light level paper defects zone in the image are separated from background respectively; Calculate the circularity in each paper defects zone then, and distinguish hole and scratch, blackspot and fold according to circularity;
(6) if paper defects detects DSP to be found to have paper defects in the page image, then type, area, location parameter and the corresponding paper defects image with each paper defects is sent to central server through gigabit Ethernet;
(7) central server carries out update displayed through a plurality of subwindows to multichannel testing result and paper defects image, simultaneously it is saved in the background data base.
4. like the said detection method of claim 3; It is characterized in that; In the said step (1), the detection software on the central server is directly called in internal memory with parameters such as the line frequency of each road high speed camera, time shutter, image sizes from hard disk, be sent to the image acquisition units in the FPGA in the embedded paper defects measurement processor through Ethernet then; Image acquisition units produces camera control signal thus, and is sent to high speed camera by LVTTL/LVDS conversion chip and Camera Link cable.
5. detection method as claimed in claim 3 is characterized in that, in the said step (3), the effective pixel data of high speed camera output image is sent to the image acquisition units in the FPGA through Camera Link stube cable and LVDS/LVTTL interface conversion chip; Image acquisition units, is written in the dual port RAM as writing the view data of clock with high speed camera with pixel clock as with imitating signal with line synchronizing signal.
6. detection method as claimed in claim 3 is characterized in that, in the said step (4); After collecting a frame image data, the image pretreatment unit in the FPGA reads the view data in the dual port RAM, according to picture size image is carried out the border cutting earlier and handles; Carry out medium filtering then,, carry out piecewise linear gray transformation afterwards again to eliminate random noise disturbance; Strengthen the paper defects zone in the image, suppress its background area; The pre-service result is saved in the outer high-speed SRAM of FPGA; After pre-service finished, the image pretreatment unit detected DSP to paper defects and sends look-at-me.
7. detection method as claimed in claim 3 is characterized in that, in the said step (5), after paper defects detection DSP receives look-at-me, reads view data among the SRAM; Utilize publish picture in picture hole and scratch class high brightness paper defects zone and spot, fold class low-light level paper defects of Threshold Segmentation regional earlier; After utilizing opening operation to remove noise, utilize labelling method to confirm the position and the area in each paper defects zone in the image again; Calculate each paper defects area circumference then and square obtain circularity with the area ratio, the zone that circularity is bigger is fold or scratch, and circularity is blackspot and speck than the zonule.
8. detection method as claimed in claim 3 is characterized in that, in the said step (6); After paper defects detects DSP completion image detection; If the number of paper defects is non-vanishing, then parameters such as the type of each paper defects, area, position are sent to the Ethernet interface control module of FPGA, paper defects parameter, paper defects image and affiliated phase plane No. data are packed in this unit; And the control kilomega network controls and transceiving chip is sent to Ethernet with data, is sent to central server by Ethernet again.
9. detection method as claimed in claim 3 is characterized in that, in the said step (7), detects on the software interface on the foreground of central server, and each camera all has the subwindow of a correspondence, is used to show this road camera testing result; After software receives the data that Ethernet sends, according to the phase plane No. under it paper defects image of gathering and corresponding paper defects parameter are presented in the corresponding subwindow, and it is saved in the background data base.
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