CN103743749A - Device and method for detecting surface quality of flaky parts - Google Patents
Device and method for detecting surface quality of flaky parts Download PDFInfo
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Abstract
The invention discloses a device and method for detecting the surface quality of flaky parts. According to the device and the method, a means of dual-light-source far-and-near cooperation is adopted, different defects can be highlighted through the cooperation of different far-and-near lighting intensities, good detection performance can be guaranteed, and one work station is adapted to the detection on a variety of defects of the flaky parts, so that the overall efficiency is increased greatly. Moreover, the used optical equipment is relatively simple, so that the overall structural configuration cost is relatively low. The different defects can be highlighted through the cooperation of the far-and-near lighting intensities, the good detection performance can be guaranteed, and one work station is adapted to the detection on a variety of defects of the flaky parts, so that the overall efficiency is increased greatly. Moreover, the used optical equipment is relatively simple, so that the overall structural configuration cost is relatively low.
Description
Technical field
The present invention relates to a kind of surface quality of workpieces pick-up unit on chip, and use the detection method of this pick-up unit.
Background technology
Flat parts is a kind of conventional industrial parts, can be used for vehicle, equipment, the field such as electric.Its material can be various metals, plastics, macromolecular material etc.In some applications, for assembling requirement, on flat parts also with small radian.
An index very important in the quality testing of flat parts is surface quality.Conventionally the surface quality defect of flat parts comprises cut, impurity and piebald three classes.Cut refers to leptosomatic defect; Impurity refers to spot defect; Piebald refers to the defect of sheet.
Tradition flat parts surface quality detects and manually completes, but manual detection has many shortcomings, so as high in cost of labor, examination criteria disunity consistance is poor, human eye detection is limited in one's ability, detection efficiency is low etc.And adopt the Automatic Measurement Technique based on machine vision technique, can overcome above-mentioned shortcoming.
The ultimate principle detecting is to take pictures by camera, and then on processor, the image to gained is processed, and carrys out whether defectiveness of automatic decision part.In cost of labor, significantly increase, produce assembly precision requirement raising and production efficiency need to improve in the situation that, robotization quality detection apparatus just progressively replaces manual operation.
In process of production, can encounter the situation of sizes part.Here said sizes comprises the part of multiple internal diameter or multiple external diameter.This situation also need to be resolved in automated quality.
Chinese patent literature CN202678288U discloses a kind of crystal silicon polished silicon wafer surface defects detection equipment, and it adopts laser system to scan crystal silicon polished silicon wafer surface, then by test pattern system, the image of scanning is processed.The laser system of this checkout equipment need to configure laser generator, laser that laser generator produces is carried out to the lens combination of shaping, and the equipment that laser scans is controlled in configuration, one-piece construction is very complicated, and because scan mode only can provide a kind of illumination optical of form, due to the response difference of different defects to light, as under different brightness conditions obtain image in defect have very big-difference with the contrast at normal position, therefore, this class checkout equipment can not adapt to the detection of number of drawbacks.
Based on foregoing, a kind of solution of those skilled in the art is the detection that the brightness of transformation light source adapts to different objects, but for defects different on same flat parts, do not have specific aim solution, and simple brightness variation often obtains good detected image.
And then, as Chinese patent literature CN202406192U, a kind of visual pattern pick-up unit is disclosed, it by arranging vaulted lamp light source below CCD camera, and at the wing-room of vaulted lamp light source, polarizing appliance is set, utilize polarizing appliance to eliminate the impact of detected object surface reflection, and then guarantee that vision detection system can obtain high-quality image.But this scheme is still short of the means that number of drawbacks is detected, and its complicated structural design is also only used for eliminating reflective on detecting the impact of quality, and cost is relatively large.
Summary of the invention
Therefore, the object of the present invention is to provide a kind of structure deployment cost low, and there is the flat parts surface quality detection device of good detection performance, and a kind of detection method of using this pick-up unit.
The present invention is by the following technical solutions:
In preferably implementing, on the one hand, a kind of flat parts surface quality detection device, comprise the process equipment for locating flat parts, the light source arranging corresponding to the position location of process equipment, flat parts on position location is carried out to the steering logic unit that the image capture device of image acquisition carries out image processing with being connected this image capture device, described light source disposes a pair of in flat parts normal direction, form near-end light source and far-end light source, and then be furnished with and control the near-end control circuit of near-end light-source brightness and the far-end control circuit of control far-end light-source brightness.
On the other hand, a kind of flat parts quality determining method, by flat parts location, and then configures a near-end light source and a far-end light source in the normal direction of flat parts, and two light sources should have brightness adjustment ability;
Mate flat parts to be detected, conversion near-end light source and far-end light source, verify the recognition capability to different defects under the illumination combination condition of different near-end light sources and far-end light source, selects the illumination combination of each defect best identified ability;
To similar flat parts, the illumination of this flat parts is carried out in the illumination combination of traversal all defect and coupling, and corresponding extraction image, to output detections result after extracted graphical analysis.
From such scheme, can find out, according to the present invention, adopt the far and near means that coordinate of two light sources, by different distance-lights, according to strength coordination, different defects can be highlighted, can guarantee good detection performance, and the detection of number of drawbacks on adapting to flat parts on a station, whole efficiency improves greatly.Add the optical device why coming relatively simple, the structure deployment cost of entirety is lower.
Again in further improved structure, above-mentioned flat parts surface quality detection device, described near-end control circuit and far-end control circuit are connected in described steering logic unit, the variation of the output power logic by steering logic unit controls near-end control circuit and far-end control circuit, conveniently carries out the identification of defect on flat parts automatically fast.
Preferably, the distance of described near-end light source distance position location is less than maximum 2 distances on flat parts, and the distance of far-end light source distance position location is greater than maximum 2 distances on flat parts, under this state, easily makes two light sources produce and better influence each other.
In order to improve the recognition efficiency that but seems on flat parts, described light source and described image capture device form a station unit, there are two covers this station unit, correspondingly, described process equipment is also furnished with two covers, and a set of is flat parts pick device, pick up after flat parts, by a set of station unit, flat parts one side is thrown light on and taken pictures, pick device is positioned over flat parts after another process equipment, by another set of station unit, the another side of flat parts is thrown light on and is taken pictures.
In certain embodiments, another process equipment is turntable, at the upper surface of this turntable, is circumferentially with multiple location divisions or positioning element, can reduce like this impact of loading and unloading on other structures, avoid loading and unloading equipment with as the conflict of light fixture.
And then described location division or positioning element are even number, thereby a side of turntable is material loading side, and a side relative with material loading side is image acquisition side.
In cost control, relatively preferably in situation, in order to improve illuminating effect, described light source is annular light source, and the internal diameter of annular light source is greater than on flat parts at 2 apart from maximal value, and is less than on the flat parts of 1.5 times at 2 apart from maximal value.
In certain embodiments, flat parts is carried out to double detection, each station arranges a set of near-end light source and far-end light source, and the image capture device adapting; And then, first station is the detection station after flat parts picks up, at this detection station, the non-face that picks up of flat parts is thrown light on and taken pictures, then sheet-like workpiece is passed to another station in double by detecting station, non-ly pick up the placement that faces down, to picking up face, throw light on and take pictures.Pick up and be also decided to be a detection station, merge and pick up and detect two actions, whole efficiency improves, and holistic cost reduces.
The distance of described near-end light source distance position location is less than maximum 2 distances on flat parts, and the distance of far-end light source distance position location is greater than maximum 2 distances on flat parts.
Accompanying drawing explanation
Fig. 1 is a kind of overview flow chart of image processing.
Fig. 2 is a kind of piebald overhaul flow chart.
Fig. 3 is a kind of scratch detection process flow diagram.
Fig. 4 is a kind of impurity overhaul flow chart.
Fig. 5 is the structured flowchart according to the flat parts surface quality detection device of one embodiment of the present of invention.
Fig. 6 is the structured flowchart of the flat parts surface quality detection device of another embodiment.
Fig. 7 is the plan structure schematic diagram of turntable.
Fig. 8 is sheet ring-shaped work pieces surface imperfection type schematic diagram.
Fig. 9 is that reverse side detects schematic diagram.
Figure 10 is the positive schematic diagram that detects.
Figure 11 is overhaul flow chart.
In figure: 1, cut, 2, impurity, 3, piebald; 4, flat parts, 5, vacuum slot, 6, annular light source, 7, annular light source, 8, camera; 9, camera, 10, annular light source, 11, annular light source, 12, turntable locating slot.
Embodiment
With reference to the structural principle of the flat parts surface quality detection device shown in Figure of description 5 and 6, his basic comprising, as existing checkout equipment, all by machine vision technique and modern electrical machine and control technology realization, thereby replace artificial, reduce labour cost, improve detection efficiency.
Be different from existing checkout equipment, it is furnished with two covers illuminations at detection station, and the characteristic feature of flat parts is only need to pay close attention to his two faces, and does not need that other parts are had to too many concern.Conventionally illumination directly projects on face to be detected, therefore, conventionally, light source is also arranged on the normal direction of flat parts, corresponding to detecting station, it is the normal direction that detects station locating surface (being different from location workplace), two light sources, as shown in Figure 9 and Figure 10, dispose a pair of with respect to the normal direction of flat parts to be detected 4, form near-end light source and far-end light source, and then be furnished with the near-end control circuit of controlling near-end light-source brightness and the far-end control circuit of controlling far-end light-source brightness.Annular light source 6 as shown in Figure 9 forms near-end light source, and annular light source 7 forms far-end light source, two light sources are the problem due to ray cast to flat parts 4, can produce different impacts to the defect on flat parts 4, the brightness variation meeting of far and near light source produces different impacts to different defects, thereby some defect is highlighted more, and other defect Relative Fuzzies, therefore,, by adjusting the brightness of two light sources, can make the defect of required detection more highlight.
Note, the far-end light source is here a pair of relative concept with near-end light source, and those skilled in the art is to be understood that this.
As shown in Figure 8, in the quality testing of flat parts, a very important index is surface quality.Conventionally the surface quality defect of flat parts comprises cut 1, impurity 2 and piebald 3 three classes.Cut 1 refers to leptosomatic defect; Impurity 2 refers to spot defect; Piebald 3 refers to the defect of sheet.
In order to highlight all kinds of defects, as shown in Figure 5 and Figure 6, by 6 kinds of assemblies, formed: the camera 8 that carries out image acquisition, the lighting source that flat parts 4 is thrown light on, the processor module that image that camera gathers is processed, the device that flat parts 4 is picked up, as vacuum slot, and the controller module of controlling, wherein control module and processor module can unite two into one, adopt the structure of uniprocessor, if operand is larger, can be furnished with bi-processor architecture, one of them is specifically designed to computing, and be mainly that image is processed here.In some preferred embodiments, adopt two vision-based detection stations, be respectively used to detect part pro and con.
Camera.In device, two vision-based detection stations respectively contain a camera.The effect of camera is the pro and con photo that is used for respectively taking flat parts.Can be black and white camera, can be also color camera.The axis of camera and the dead in line of part.Camera is connected with processor module.
About lighting source, in device, each station comprises two lighting modules, and as Fig. 9 and Figure 10, one is closer from flat parts, belongs to low angle illumination, namely near-end light source, and because distance is closer, angle is all larger; Another from flat parts relatively away from, corresponding to far-end light source, belong to high angle illumination.
The brightness of two lighting source assemblies can independent regulation, by suitable brightness combination, reaches optimal detection effect.Lighting module can be the solid-state illumination technology such as LED, can be also the light fixtures such as fluorescent light.
About lighting source, preferably annular light source, as becoming coniform, LED array is radiated at testee surface with oblique angle, by diffuse reflection mode, illuminate a small region, operating distance is when 10-15MM, this light source can highlight the variation of testee edge and height, the part that outstanding script is difficult to see clearly.About the far-end light source in two light sources, the detected flat parts of distance had better not be greater than 15cm.
Lighting source can be connected with camera, also can be connected with processor module, can also be connected with aforesaid controller module, the power of lighting source can independently be adjusted, as controller module provides an analog quantity, the output power of controlling lighting source reaches suitable limit, also can carry out switch control, by the power adjustment unit in lighting circuit, according to the lasting length of switching value, carries out the adjustment of power.
By controller module, carry out tracking, easily a structure service part obtains steering logic, as the right moment for camera of camera and coordinating of lighting source etc.
About processor module, in certain embodiments, processor module comprises processor, storer, interface circuit etc., the photo of taking for the treatment of camera.By image processing, can identify flat parts, and whether can detect the surface quality of part qualified.
Processor module is connected with camera, controls the photo opportunity of camera, and passes gathered image back.
In certain embodiments, dispose turntable, as shown in Figure 7.Above turntable, have multiple sunk type circular supports, turntable locating slot as shown in figure 10, for depositing flat parts.Part will rotate together along with turntable, can form in different positions as feeding station, detect station etc.
Further, as described in location division or positioning element be even number, thereby a side of turntable is material loading side, a side relative with material loading side is image acquisition side.Other process equipment of so easy layout, avoids producing each other conflict.
About the location structure on turntable, can also be configured to positioning element.
For sheet shape part, can use and pick up as vacuum slot 5, after picking up, move to certain position, just can detect, form one and detect station, coupling a set of vision-based detection station wherein.Vacuum slot can hold flat parts.For part is put into turntable from turntable outside, also part can be removed from turntable.
And then circulation that can control strip shape part about controller module, as the motion for controlling suction nozzle, turntable, also will follow processor module communication, obtains the testing result of surface quality of workpieces.
In order to reduce resetting, improve detection efficiency, in order to improve the shooting quality of image, on two stations of pros and cons, adopted respectively two lighting sources, illumination adopts annular light source 6,7,10,11, the better effects if of illumination.
Two light sources of same station are placed by low angle and high angle respectively, and its brightness can independent regulation.Wherein, the distance of low angle light source distance part is generally 5 centimetres or lower, or is highly less than the diameter of part, but should not be excessively near, otherwise projectional angle all can have a great impact, and conventionally can not be less than 1 centimetre.
And the distance of high angle light source distance part is 6 centimetres even higher, or be highly greater than diameter of part, but can not the excessive diameter of part that generally can not be greater than twice.
The diameter is here an equivalent distances, and flat parts may be circular, may be also square or rectangle, and other structures are relatively less, and diameter can be expressed as 2 ultimate ranges on sheet shape part, as the catercorner length of square parts.
The brightness of two light sources can be different, form a kind of brightness combination.During actual photographed, adopt two kinds of brightness of illumination combinations, take two photos.For example, in brightness of illumination combination 1, the illumination intensity of low angle light source is more weak, even close, and the illumination intensity of high angle light source is more intense; On the contrary, in brightness of illumination combination 2, the illumination intensity of high angle light source is more weak, even close, and the illumination intensity of low angle light source is more intense.Object is better the defect on part to be highlighted.
Following table provides the detector efficiency of defect under Different Light illumination intensity combination condition
The surface imperfection of part is to determine by the mode of image processing.First, with location, part, exist detection, size confirmation and polar coordinate transform algorithm to carry out pre-service to image.Then with piebald detection, scratch detection and impurity, detect three kinds of image processing modules respectively and carry out the screening of defect classification.Finally by polar coordinates inverse transformation, obtain the image under part rectangular coordinate system after treatment.
In reality detects, if detect three kinds of defects with a kind of image processing algorithm, efficiency can be lower, because for dissimilar defect, the parameter of the optimization of algorithm is different.So in this programme, detect respectively three kinds of defects with three kinds of different algorithm groups are incompatible.At piebald detection, scratch detection and impurity, detect in three image processing modules, adopt respectively different image processing algorithms to realize.
As shown in Figure 2, piebald has been used pyramid filtering, region division, average drifting filtering, Canny filtering, has been merged the image processing algorithm that region, area filling, UNICOM's domain analysis and area judge in detecting.
The feature of piebald is that defect area is larger, so adopt average drifting filtering and Canny filtering, retains the feature of cut.
As used in Fig. 3 scratch detection, trend pass filtering, local threshold binarization, UNICOM's domain analysis, direction connect, shape is selected and the image processing algorithm of skeleton analysis.The feature of cut is leptosomatic defect, and direction is uncertain.Algorithm focuses on the selection of connected domain analysis, shape and direction.In some cases, part internal diameter edge has tiny cut or slight crack, needs so to this Region Segmentation out, to make selective analysis.
As shown in Figure 4, impurity has been used the image processing algorithm that pyramid filtering, obfuscation, region division, Canny filtering, UNICOM's domain analysis, region merging and area are selected in detecting.The feature of impurity is that defect is spot defect, first filtering obfuscation again, and the interference of as far as possible removing background, then mainly selects to determine with connected domain analysis and area whether this kind of defect exists.
Above content relates to the content of image processing, lays particular emphasis on the improvement of image acquisition part here, and emphasis is embodied in following aspect:
By flat parts location, and then configure a near-end light source and a far-end light source in the normal direction of flat parts, two light sources should have brightness adjustment ability;
Mate flat parts to be detected, conversion near-end light source and far-end light source, verify the recognition capability to different defects under the illumination combination condition of different near-end light sources and far-end light source, selects the illumination combination of each defect best identified ability;
To similar flat parts, the illumination of this flat parts is carried out in the illumination combination of traversal all defect and coupling, and corresponding extraction image, to output detections result after extracted graphical analysis.
It is evident that, for the production of flat parts, the machine of its surface quality detects obviously for batch production, therefore, the work in early stage, the complex steps that illumination combination is in other words mated with defect does not affect the whole efficiency of batch production at all.
In further improved plan, continue from the preceding paragraph, flat parts is carried out to double detection, each station arranges a set of near-end light source and far-end light source, and the image capture device adapting; And then, first station is the detection station after flat parts picks up, at this detection station, the non-face that picks up of flat parts is thrown light on and taken pictures, then sheet-like workpiece is passed to another station in double by detecting station, non-ly pick up the placement that faces down, to picking up face, throw light on and take pictures.
About said method snake structure, possess the general advantage of current machine recognition, can realize automatic flat parts surface quality and detect, surface quality is mainly three kinds: cut, piebald, impurity.Can replace manually, reduce labour cost.Can significantly promote productive capacity, complete the detection that manually cannot realize.
Than general machine recognition, owing to having adopted the configuration of new lighting source, make various defects by the identifying of order, to improve the reliability of identification, guaranteed the precision detecting.
Embodiment 1: circular ring type sheet surface defects detection:
The part to be detected of this embodiment is circular ring type part, and its diameter is that 40 millimeters, external diameter are 1 millimeter of 550 millimeter, part thickness.Part to be detected may have three kinds of defect types, as shown below.
Above turntable, there are eight sunk type circular supports, for depositing flat parts.In device, two vision-based detection stations respectively contain a camera.The effect of camera is the pro and con photo that is used for respectively taking flat parts.Each station comprises two ring illumination modules, is positioned between camera and part, and one closer from flat parts, belongs to low angle illumination; Another is distant from flat parts, belongs to high angle illumination.The dead in line of camera, ring illumination module and part.Overhaul flow chart as shown in figure 11.Wherein illumination is synchronous lighting.In figure, clearly provided detecting step, do not repeated them here.
About the synchronous problem of illumination, lighting system can be divided into long bright formula and synchronous mode.So-called long bright formula, before being exactly after start, preparing to detect, opens illumination, even if take pictures or detect completely, illumination is not also closed, and illumination remains opens.So-called synchronous mode, be exactly only when taking pictures or the imageing sensor of camera when integration (or sensitization), illumination is just opened, and throws light on and all closes At All Other Times.This mode can be saved electric energy, and can extend the life-span of lighting module.
Claims (10)
1. a flat parts surface quality detection device, the steering logic unit that the light source that comprises process equipment for locating flat parts, arrange corresponding to the position location of process equipment, the image capture device that the flat parts on position location is carried out to image acquisition carry out image processing with being connected this image capture device, it is characterized in that, described light source disposes a pair of in flat parts normal direction, form near-end light source and far-end light source, and then be furnished with the near-end control circuit of controlling near-end light-source brightness and the far-end control circuit of controlling far-end light-source brightness.
2. flat parts surface quality detection device according to claim 1, is characterized in that, described near-end control circuit and far-end control circuit are connected in described steering logic unit.
3. flat parts surface quality detection device according to claim 1 and 2, it is characterized in that, the distance of described near-end light source distance position location is less than maximum 2 distances on flat parts, and the distance of far-end light source distance position location is greater than maximum 2 distances on flat parts.
4. flat parts surface quality detection device according to claim 1, it is characterized in that, described light source and described image capture device form a station unit, there are two covers this station unit, correspondingly, described process equipment is also furnished with two covers, a set of is flat parts pick device, pick up after flat parts, by a set of station unit, flat parts one side is thrown light on and taken pictures, pick device is positioned over flat parts after another process equipment, by another set of station unit, the another side of flat parts is thrown light on and is taken pictures.
5. flat parts surface quality detection device according to claim 4, is characterized in that, another process equipment is turntable, at the upper surface of this turntable, is circumferentially with multiple location divisions or positioning element.
6. flat parts surface quality detection device according to claim 5, is characterized in that, described location division or positioning element are even number, thereby a side of turntable is material loading side, and a side relative with material loading side is image acquisition side.
7. flat parts surface quality detection device according to claim 1, it is characterized in that, described light source is annular light source, and the internal diameter of annular light source is greater than on flat parts at 2 apart from maximal value, and is less than on the flat parts of 1.5 times at 2 apart from maximal value.
8. a flat parts quality determining method, is characterized in that, by flat parts location, and then configures a near-end light source and a far-end light source in the normal direction of flat parts, and two light sources should have brightness adjustment ability;
Mate flat parts to be detected, conversion near-end light source and far-end light source, verify the recognition capability to different defects under the illumination combination condition of different near-end light sources and far-end light source, selects the illumination combination of each defect best identified ability;
To similar flat parts, the illumination of this flat parts is carried out in the illumination combination of traversal all defect and coupling, and corresponding extraction image, to output detections result after extracted graphical analysis.
9. flat parts quality determining method according to claim 8, is characterized in that, flat parts is carried out to double detection, and each station arranges a set of near-end light source and far-end light source, and the image capture device adapting; And then, first station is the detection station after flat parts picks up, at this detection station, the non-face that picks up of flat parts is thrown light on and taken pictures, then sheet-like workpiece is passed to another station in double by detecting station, non-ly pick up the placement that faces down, to picking up face, throw light on and take pictures.
10. flat parts quality determining method according to claim 8 or claim 9, it is characterized in that, the distance of described near-end light source distance position location is less than maximum 2 distances on flat parts, and the distance of far-end light source distance position location is greater than maximum 2 distances on flat parts.
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Application publication date: 20140423 |