CN103464384B - The damaged hierarchy system of a kind of logistics flat pallet based on machine vision and method - Google Patents

The damaged hierarchy system of a kind of logistics flat pallet based on machine vision and method Download PDF

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CN103464384B
CN103464384B CN201310410442.9A CN201310410442A CN103464384B CN 103464384 B CN103464384 B CN 103464384B CN 201310410442 A CN201310410442 A CN 201310410442A CN 103464384 B CN103464384 B CN 103464384B
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black region
damaged
pallet
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CN103464384A (en
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梁启荣
朱安定
王毅君
尚伟
冯丰
陆海良
李钰靓
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China Tobacco Zhejiang Industrial Co Ltd
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Abstract

The present invention relates to the damaged hierarchy system of a kind of logistics flat pallet based on machine vision and method, system architecture is detected station limit switch formed by four industrial cameras, transport tape, measurement processor, electrical control cabinet, pallet; The invention solves the problem of Tray side image taking industrial camera and the conflict of position, tray motion direction, four industrial cameras synchronously process, automaticity is high, detection efficiency is high, quantitatively accurate, provide technological means for continuing in enormous quantities at circulation logistics flat pallet with property detection, have broad application prospects.

Description

The damaged hierarchy system of a kind of logistics flat pallet based on machine vision and method
Technical field
The present invention relates to the damaged hierarchy system of a kind of logistics flat pallet based on machine vision and method, particularly relate to and the system and method that machine vision detects automatically is carried out to the breakage at circulation logistics flat pallet, belong to and utilize logistics checkout equipment technical field.
Background technology
Logistics flat pallet is the standardized important carriers of modern logistics, and be widely used in the logistics progresses such as Storage of Goods, carrying, transport, especially in full-automatic overhead stereo warehouse, logistics flat pallet has more high, the safe and reliable feature of efficiency.
Logistics flat pallet is as the carrier of freight handling, and in ongoing operations process, the impact several times of the haulage equipment such as fork truck, piler, friction, be easy to cause crack, cut; The side extruding that the goods Action of Gravity Field of logistics flat pallet carrying, maloperation cause, also can cause distortion, distortion, fall apart; High temperature, low temperature, high humidity environment can cause plastic pallet aging, be full of cracks, wood pallets iron nail gets rusty, Chisel grain expand so that fall apart, defect.
All these breakages all can cause logistics flat pallet mechanical strength to decline, thus in circulation process, break down, although logistics flat pallet low price, once break down, the lighter causes its bearing goods to damage, severe one causes full-automatic shelf magazine fault, out of service.
Therefore, the mechanical strength of logistics flat pallet, form parameter turn most important to its normal stream in warehousing system.At present, the quality testing of logistics flat pallet has multiple test item, comprise: outward appearance detection, fall-down test, stacking test, hoisting test, dimensional discrepancy test, dynamic load test, static load test, top bed board edge impact test, compression test, bend test, fall-down test, vibration test etc., corresponding detection has more detailed standard verification both at home and abroad, such as:
Standard ISO 8611-1-2004, ISO/TS8611-2-3005, ISO/TS8611-3-2005 have respectively provided the content such as test method, performance requirement of material process flat pallet; ISO8611-1991 defines the contents such as the test method of universal intermodal flat pallet.
But whether these logistics flat pallet test items and method are all the logistics flat pallets for new production, namely up-to-standard to it, can the access that enter logistic storage transport flow system detect.Because new product is all mass production, material therefor, mould are all identical, and new quality is also close to identical, and therefore, it is all carry out sampling Detection by the professional testing agency with measurement verification qualification that this type of pallet detects.
Logistics flat pallet is once enter circulation circulation, and aging breakage is different, cannot be assessed by sampling observation to its breakage, needs regularly to carry out general inspection to each logistics flat pallet.
At present, the assessment of this breakage is that artificial naked eyes judge, in use, finding levelling pallet badly broken, is just eliminated experienced operating personnel.This method does not have quantitative standard, only with subjective judgement, random large.The pallet caused is eliminated too early, increases the cost purchasing pallet, and some pallets are eliminated not in time, cause production accident.
Summary of the invention
The object of the present invention is to provide the damaged hierarchy system of a kind of logistics flat pallet based on machine vision, system architecture is detected station limit switch formed by four industrial cameras, transport tape, measurement processor, electrical control cabinet, pallet;
Pallet is sent to detection station along tray transport direction by described transport tape, and pallet arrives and detects station, and pallet detects station limit switch and triggers, and sends feedback signal, and transport tape stops;
Described four industrial cameras take the image of pallet four sides respectively; Industrial camera installation site perpendicular to transport tape both sides is just to Tray side, the positive image of shooting pallet two sides; Being parallel to the industrial camera of transport tape both sides, in order to avoid colliding with pallet, being arranged on the prism of transport tape, the tilted image of shooting another two sides of pallet;
Described electrical control cabinet receives the feedback signal that pallet detects station limit switch, receives measurement processor process and completes status signal, the speed of controls transfer band and start and stop, and send detected state signal to measurement processor;
Described measurement processor is machine vision processing unit, receive the detected state signal that electrical control cabinet sends, arrive at pallet and detect station, and after coming to a complete stop, control the image that four industrial cameras take four sides, and carry out the damaged hierarchical detection of pallet, after having detected, to electrical control cabinet transmission processing completion status signal.
On the basis of the damaged hierarchy system of above-mentioned logistics flat pallet, present invention also offers the damaged stage division of a kind of logistics flat pallet based on machine vision, concrete steps are as follows:
Step 1: obtain four side images, comprises the positive image perpendicular to transport tape two sides and the tilted image being parallel to transport tape two sides;
Step 2: tilted image motion correction, four side images are measure-alike;
Step 3: get luminance component image, four side coloured images are converted to luminance component image;
Step 4: get Threshold segmentation luminance component image;
Step 5: binaryzation, obtains the binary image only having black/white dichromatism;
Step 6: denoising, carries out denoising to noise black region chequered with black and white in binary image, and final generation connects block black region closely;
Step 7: to each black region label, different black region pixels puts on area code separately, for distinguishing different black regions;
Step 8: the morphological parameters calculating each black region, comprises area, length, highly, the area of black region refers to the sum of all pixels of black region; Length refer to black region image in a lateral direction institute across length in pixels; Highly refer to black region on image longitudinal direction institute across pixels tall;
Step 9: remove noise black region, setting area threshold value, the black region being less than area threshold is judged to noise black region; Arrange length to height ratio threshold value, calculate length to height ratio, if the length of black region is greater than height, then length to height ratio is length divided by height, otherwise length to height ratio be that the black region that the ratio that grows tall is greater than length to height ratio threshold value is judged to noise black region highly divided by length; Remove all noise black regions;
Step 10: determine damaged part, if do not leave black region, then illustrates obviously not damaged, goes to step 13;
Otherwise by the black region contrast support holder structure stayed, determine damaged part, belong to I level damaged area, II level damaged area or III level damaged area;
Step 11: calculate black region average chrominance, in original color image, find black region correspondence position, calculates the average chrominance of original image corresponding to black region, if such as pallet is blue, then calculates blue color component;
Step 12: judge surface fracture/structural failure, compare with pallet average chrominance, Chroma threshold is set, if the absolute value of the difference of black region average chrominance and pallet average chrominance is less than Chroma threshold, black region not yet recurring structure disappearance is described, belongs to surface fracture; Otherwise illustrate that black region there occurs structure disappearance, belong to structural failure;
Step 13: the damaged grade of assessment pallet:
Damage index is calculated to each side , span ;
(1) after step 10, black region is not left, damage index ;
(2) damaged area parameter , belong to I level damaged area, then ; Belong to II level damaged area, then , belong to III level damaged area, then , wherein for constant;
(3) damaged type parameter , belong to structural failure type, then ; Belong to surface fracture type, then , wherein for constant;
(4) damaged degree parameter , , wherein for pallet damaged area area, for side, the pallet side gross area, for damaged degree parameter upper limit value, it is constant;
(5) damage index is calculated ;
(6) pallet breakage point five grades:
Serious damage: ;
Structural failure: ;
Surface fracture: ;
Little damage: ;
Without obviously damaged: ;
Wherein for constant, four side damage indexes are respectively , total damage index , the pallet of serious damage and structural failure cannot continue for shelf magazine, but can continue for flat paper storaged building used as a sacrifice to the dead.
In sum, the significant technique effect of the present invention is: by four side images of subject levelling pallet, use the method for machine vision, motion correction is done to side image, Threshold segmentation, binaryzation, Denoising disposal, determine damaged black region, and be structural failure or surface fracture according to the average chrominance differentiation of damaged area, according to damaged area area determination damaged degree, the damaged influence degree to pallet machinery anti-compression property is determined according to damaged part, last comprehensive each parameter weighting assessment pallet damaged degree, and carry out the damaged classification of pallet, the invention solves the problem of Tray side image taking industrial camera and the conflict of position, tray motion direction, four industrial cameras synchronously process, automaticity is high, detection efficiency is high, quantitatively accurately, technological means is provided with property detection for continuing in enormous quantities at circulation logistics flat pallet, have broad application prospects.
Accompanying drawing explanation
Fig. 1 is the system construction drawing of the damaged hierarchy system of a kind of logistics flat pallet based on machine vision of the present invention.
Fig. 2 is the pallet prism image schematic diagram of the damaged stage division of a kind of logistics flat pallet based on machine vision of the present invention.
Fig. 3 is the structural failure image procossing contrast figure of the embodiment one of the damaged stage division of a kind of logistics flat pallet based on machine vision of the present invention.
Fig. 4 is the surface fracture image procossing contrast figure of the embodiment two of the damaged stage division of a kind of logistics flat pallet based on machine vision of the present invention.
Fig. 5 is the flow chart of the damaged stage division of a kind of logistics flat pallet based on machine vision of the present invention.
Fig. 6 is the pallet damaged grade position schematic diagram of the damaged stage division of a kind of logistics flat pallet based on machine vision of the present invention.
Detailed description of the invention
With reference to accompanying drawing, describe the present invention below.
As shown in Figure 1, the present invention is based on the damaged hierarchy system structure chart of logistics flat pallet of machine vision, system architecture by four industrial cameras 102,103,104,105, transport tape 101, measurement processor 109, electrical control cabinet 108, pallet detect station limit switch 107 and form;
Pallet 100 is sent to detection station along tray transport direction 106 by described transport tape 101, and pallet 100 arrives and detects station, and pallet detects station limit switch 107 and triggers, and send feedback signal, transport tape 101 stops;
Described four industrial cameras 102,103,104,105 take the image of pallet 100 4 sides respectively; Industrial camera 102,103 installation site perpendicular to transport tape 101 both sides is just to pallet 100 side, the positive image of shooting pallet 100 two sides; Being parallel to the industrial camera 104,105 of transport tape 101 both sides, in order to avoid colliding with pallet 100, being arranged on the prism of transport tape 101, the tilted image of shooting another two sides of pallet 100;
Described electrical control cabinet 108 receives the feedback signal that pallet detects station limit switch 107, receives measurement processor 109 and has processed status signal, the speed of controls transfer band 101 and start and stop, and send detected state signal to measurement processor 109;
Described measurement processor 109 is machine vision processing unit, receive the detected state signal that electrical control cabinet 108 sends, arrive at pallet 100 and detect station, and after coming to a complete stop, control the image that four industrial cameras 102,103,104,105 take four sides, and carry out the damaged hierarchical detection of pallet 100, after having detected, to electrical control cabinet 108 transmission processing completion status signal.
As shown in Figure 2, in pallet prism image schematic diagram, Tray side image captured by the industrial camera 203 be parallel on tray transport direction 106 is the positive image of pallet 200 laterally inclined image 205 after affine transformation, proportionally on the width of therefore image to reduce, but the constant rate that the damaged part of Tray side and damaged degree are shared in whole Tray side image, after being corrected by affine transformation, the size that image 200 positive with pallet is identical can be obtained;
Although imagination just can take the positive image 200 of pallet to shooting industrial camera 202, and different perpendicular to the industrial camera 204 in tray transport direction 106, meeting and pallet collide.
As shown in Figure 3, in the embodiment one of support holder structure breakage, structural failure region 301 is stressed column, and side structure lacks, and mechanical bearing capacity declines to a great extent;
After Threshold segmentation binary conversion treatment, structure lack part is the black region 302 of bulk; But in the image after Threshold segmentation binaryzation, local is more residual noise black regions 303 also, and be cause due to stained, be characterized in that area is less, monochrome pixels is alternate;
As shown in Figure 4, in the embodiment two of tray surface breakage, surface fracture region 401 is general edge, and non-stress column, and damaged portion is that surface has crackle, and not yet form structure disappearance, mechanical bearing capacity declines to some extent, but and not serious;
After Threshold segmentation binary conversion treatment, surface fracture part is the black region 402 of bulk; But in the image after Threshold segmentation binaryzation, some noise black regions 403 of Local residues cause because pallet circular edge causes brightness to reduce; Noise black region 404 causes because tray bottom fluffing causes brightness to reduce; Noise black region 405 causes owing to there is prismatic impression in pallet original structure; Be characterized in that area is less, monochrome pixels is alternate, and mostly is strip;
As shown in Figure 6, in the schematic diagram of pallet damaged grade position, the mechanical anti-pressure ability of damaged part on pallet of pallet has different impacts, II level damaged area 502 is bottom margin positions of pallet, if there is surface fracture or structural failure, pallet pressure-bearing pillar construction not yet touches, less on the impact of pallet machinery anti-pressure ability;
III level damaged area 501 is pallet side stud, play a supporting role often in vertical direction in these positions, or connection function is played to pallet Each part, if there is surface fracture or structural failure, the bearing structure of pallet will be destroyed, pallet is caused to decline at this position machinery anti-pressure ability, especially pallet upper side centre position, due to pallet hollow structure design often, this position is pallet left and right two halves tie point, if occur damaged, pallet likely disintegrates as left and right two halves;
500, I level damaged area is the less generation of breakage in other tray surface regions except II level damaged area 502 and III level damaged area 501, these regions, even if to deform, damaged, little on the mechanical anti-pressure ability impact of pallet.
As shown in Figure 5, pallet Damage Assessment classification schematic flow sheet of the present invention.

Claims (1)

1., based on the damaged stage division of logistics flat pallet of machine vision, it is characterized in that: concrete steps are as follows:
Step 1: obtain four side images, comprises the positive image perpendicular to transport tape two sides and the tilted image being parallel to transport tape two sides;
Step 2: tilted image motion correction, four side images are measure-alike;
Step 3: get luminance component image, four side coloured images are converted to luminance component image;
Step 4: get Threshold segmentation luminance component image;
Step 5: binaryzation, obtains the binary image only having black/white dichromatism;
Step 6: denoising, carries out denoising to noise black region chequered with black and white in binary image, and final generation connects block black region closely;
Step 7: to each black region label, different black region pixels puts on area code separately, for distinguishing different black regions;
Step 8: the morphological parameters calculating each black region, comprises area, length, highly, the area of black region refers to the sum of all pixels of black region; Length refer to black region image in a lateral direction institute across length in pixels; Highly refer to black region on image longitudinal direction institute across pixels tall;
Step 9: remove noise black region, setting area threshold value, the black region being less than area threshold is judged to noise black region; Arrange length to height ratio threshold value, calculate length to height ratio, if the length of black region is greater than height, then length to height ratio is length divided by height, otherwise length to height ratio be that the black region that the ratio that grows tall is greater than length to height ratio threshold value is judged to noise black region highly divided by length; Remove all noise black regions;
Step 10: determine damaged part, if do not leave black region, then illustrates obviously not damaged, goes to step 13;
Otherwise by the black region contrast support holder structure stayed, determine damaged part, belong to I level damaged area, II level damaged area or III level damaged area;
Step 11: calculate black region average chrominance, in original color image, find black region correspondence position, calculates the average chrominance of original image corresponding to black region, if such as pallet is blue, then calculates blue color component;
Step 12: judge surface fracture/structural failure, compare with pallet average chrominance, Chroma threshold is set, if the absolute value of the difference of black region average chrominance and pallet average chrominance is less than Chroma threshold, black region not yet recurring structure disappearance is described, belongs to surface fracture; Otherwise illustrate that black region there occurs structure disappearance, belong to structural failure;
Step 13: the damaged grade of assessment pallet:
Damage index η is calculated to each side, span 0≤η≤100;
(1) after step 10, black region is not left, damage index η=10;
(2) damaged area parameter lambda, belongs to I level damaged area, then λ=λ 1; Belong to II level damaged area, then λ=λ 2, belong to III level damaged area, then λ=λ 3, wherein λ 1, λ 2, λ 3for constant;
(3) damaged type parameter ω, belongs to structural failure type, then ω=ω 1; Belong to surface fracture type, then ω=ω 2, wherein ω 1, ω 2for constant;
(4) damaged degree parameter θ, θ=θ upper-log (S damaged/ S side, side), wherein S damagedfor pallet damaged area area, S side, sidefor side, the pallet side gross area, θ upperfor damaged degree parameter upper limit value, it is constant;
(5) damage index η=(ω+θ) λ is calculated;
(6) pallet breakage point five grades:
Serious damage: η 1< η≤100;
Structural failure: η 2< η≤η 1;
Surface fracture: η 3< η≤η 2;
Little damage: 10 < η≤η 3;
Without obviously damaged: 0≤η≤10;
Wherein η 1, η 2, η 3for constant, four side damage indexes are respectively η a, η b, η c, η d, total damage index η always=max (η a, η b, η c, η d), the pallet of serious damage and structural failure cannot continue for shelf magazine, but can continue for flat paper storaged building used as a sacrifice to the dead.
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