CN104822046A - Noncontact electroplating bath liquid level controller based on vision technology - Google Patents
Noncontact electroplating bath liquid level controller based on vision technology Download PDFInfo
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Abstract
The invention relates to the technical field of liquid level detecting equipment, and particularly to a noncontact electroplating bath liquid level controller based on vision technology. The noncontact electroplating bath liquid level controller comprises the components of a camera, an image acquisition analysis module, a controller module and a display module. The liquid level in the electroplating bath is monitored in a non-contact manner, thereby preventing problems of liquid level sensor corrosion or crystallization and regular replacement caused by direct contact with electrolyte, and greatly reducing equipment cost and manpower cost. Furthermore centralized monitoring for the liquid levels of a plurality of electroplating baths can be realized by one system. Configuration of one system for each electroplating bath and on-field man inspection are not required. Equipment cost and manpower cost can be further reduced.
Description
Technical field
The present invention relates to liquid level detection device technical field, especially a kind of contactless bath solution level controller of view-based access control model technology.
Background technology
At electroplating industry, in electroplating bath, the liquid level of electroplate liquid and temperature are important Con trolling index, and wherein, electroplate liquid height of liquid level is the key factor of impact safety in production.If electroplate liquid liquid level is too low, heating rod dry combustion method may be caused and initiation fire.For this reason, need electroplate liquid liquid level implementing monitoring.Traditional monitor mode is generally manual patrol, but so too labor intensive and be not suitable with the demand of current automated production.
More existing monitor mode adopts liquid level sensor to gather liquid level, and by Signal transmissions to fluid level controller, energy automatic liquid supply or the automatic power supply cutting off heating rod when liquid level is on the low side, prevent dry combustion method and can handled easily personnel monitor in control room, automatic liquid feeder is electroplated as Chinese patent CN203807588U discloses a kind of FPC, Chinese patent CN202929494U discloses a kind of bath solution level controller, but this two schemes is liquid level sensor and directly contacts with liquid, highly acid or strong basicity is had owing to being permitted eurypalynous electroplate liquid, and the liquid level sensor of direct contact type is easy to be corroded under this kind of environment, even if adopt the tetrafluoro corrosion liquid level meter that electroplating industry is special, the phenomenon that is corroded is there is unavoidably after the use several months, also easily there is crystalline polamer in liquid level sensor and electrolyte contacts position simultaneously, thus cause level gauging to occur deviation.For this reason, for guaranteeing production safety, current plating producer can only while outfit liquid level sensor and Liquid level strategy, by increase on-the-spot tour personnel, supplementary observation is carried out to height of liquid level again and also regularly replace the liquid level gauge being corroded and occurring crystallization, cause the increase of equipment cost and human cost.
Summary of the invention
The technical problem to be solved in the present invention is: usually adopt liquid level sensor to gather liquid level to solve electroplate liquid monitoring in existing electroplating bath, liquid level sensor is easy to be corroded and crystallization easily occurs and causes level gauging to occur deviation, plating producer need increase on-the-spot tour personnel and carries out supplementary observation to height of liquid level and regularly replace the liquid level gauge being corroded and occurring crystallization, cause the problem increasing equipment cost and human cost, the invention provides a kind of contactless bath solution level controller of view-based access control model technology, be provided with camera, IMAQ analysis module, controller module and display module, by adopting contactless method, the liquid level in electrolysis tank is monitored, avoid the liquid level sensor caused owing to directly contacting with electrolyte be corroded or occur crystallization, need the problem of periodic replacement, greatly reduce equipment cost and human cost.
The technical solution adopted for the present invention to solve the technical problems is:
A contactless bath solution level controller for view-based access control model technology, comprises camera, IMAQ analysis module, controller module and display module, wherein,
Camera, for the picture signal in acquisition monitoring range areas,
IMAQ analysis module, for obtaining the picture signal of camera collection, and carrying out treatment and analyses to the picture signal gathered, judging that in electroplating bath, whether liquid level is too low, when liquid level is too low in electroplating bath, sends alarm signal to controller,
Controller module, for obtaining the analysis result signal that IMAQ analysis module exports, and being converted into control signal by corresponding signal, controlling whether cut off electroplating bath heating rod power circuit,
Display module, for receiving the display of controller module output and showing.
Particularly, camera is made to gather a picture signal every certain time interval T by external trigger mode.
Particularly, described IMAQ analysis module comprises the whether too low classifier design of image capture module, Edge extraction module, hough conversion extraction module, electrolysis tank and electrolyte image characteristics extraction module and electrolyte liquid level and discriminant classification module, wherein, image capture module is for obtaining the picture signal of camera collection; Edge extraction module is for determining the edge of the image that image capture module gathers; Hough conversion module, the circle extracted for recognition image edge extracting module or rectangle, namely corresponding circular electrolysis tank or rectangular electrolyte groove; Electrolysis tank and electrolyte image characteristics extraction module, for extracting the electrolysis tank and the characteristics of image of electrolyte that hough conversion module obtains; The classifier design whether electrolyte liquid level is too low and discriminant classification module, for the characteristic Design grader extracted according to electrolysis tank and electrolyte image characteristics extraction module, carry out discriminant classification to whether liquid level in groove is too low.
Particularly, described IMAQ analysis module is provided with for analyzing the whether fuzzy image quality analysis module of picture signal that described camera collection arrives, when image blurring, the rain brush started on camera carries out lens cleaning, and Resurvey image again after being set in lens cleaning, so repeat the times N preset.
Particularly, the image mist elimination that described IMAQ analysis module is also provided with for carrying out mist elimination enhancing to image strengthens module.
Particularly, described controller is PLC control cabinet.
Particularly, described camera is more than waterproof Grade I P67, the camera being provided with rain brush and wifi transfer function.
Particularly, described IMAQ analysis module is communicated with camera by wifi.
Particularly, described IMAQ analysis module is located in described PLC control cabinet.
Particularly, described image quality analysis module adopt AVERAGE GRADIENT METHOD WITH to analyze whether picture signal that described camera collection arrives fuzzy.
The invention has the beneficial effects as follows: the contactless bath solution level controller that the invention provides a kind of view-based access control model technology, be provided with camera, IMAQ analysis module, controller module and display module, by adopting contactless method, the liquid level in electrolysis tank is monitored, avoid the liquid level sensor caused owing to directly contacting with electrolyte be corroded or occur crystallization, need the problem of periodic replacement, set of system can be implemented in the liquid level of the multiple electrolysis tank of control desk centralized monitor simultaneously, without the need to an electroplating bath configuration set of system and without the need to manually making an inspection tour at the scene, greatly reduce equipment cost and human cost, namely the present invention is on the basis of limited input, hardware deterioration and the human cost of electroplating workshop can be reduced widely, make camera gather a picture signal every certain time interval T by external trigger mode, reduce image transmitting amount and treating capacity, IMAQ analysis module comprises image capture module, Edge extraction module, hough converts extraction module, electrolysis tank and electrolyte image characteristics extraction module and the whether too low classifier design of electrolyte liquid level and discriminant classification module, IMAQ analysis module is provided with for analyzing the whether fuzzy image quality analysis module of picture signal that camera collection arrives, when image blurring, the rain brush started on camera carries out lens cleaning, and Resurvey image again after being set in lens cleaning, so repeat the times N preset, reduce the camera brought due to factors such as camera lens fogs and observe inaccurate problem, the image mist elimination that IMAQ analysis module is also provided with for carrying out mist elimination enhancing to image strengthens module, the inaccurate problem of observation that further minimizing brings because of factors such as workshop fogs, controller is PLC control cabinet, and camera is more than waterproof Grade I P67, the camera being provided with rain brush and wifi transfer function, and IMAQ analysis module is communicated with camera by wifi, avoids the image blur problem that camera lens fog causes, IMAQ analysis module is located in PLC control cabinet, reduces fog impact further, reduces because equipment is covered by fog simultaneously and be easy to damage problem, whether image quality analysis module adopts AVERAGE GRADIENT METHOD WITH to analyze the picture signal that arrives of camera collection fuzzy, is conveniently used for the fog-level of evaluation map picture.
Accompanying drawing explanation
Below in conjunction with drawings and Examples, the present invention is further described.
Fig. 1 is the overall structure schematic diagram of the contactless bath solution level controller of a kind of view-based access control model technology of the present invention;
Fig. 2 be the contactless bath solution level controller of a kind of view-based access control model technology of the present invention electroplating bath in the schematic flow sheet of liquid level identification.
Embodiment
In conjunction with the accompanying drawings, the present invention is further detailed explanation.These accompanying drawings are the schematic diagram of simplification, only basic structure of the present invention are described in a schematic way, and therefore it only shows the formation relevant with the present invention.
Embodiment 1
As shown in Figure 1-2, a kind of contactless bath solution level controller of view-based access control model technology, comprise camera, IMAQ analysis module, PLC control cabinet and display module, wherein, camera is more than waterproof Grade I P67, the camera being provided with rain brush and wifi transfer function, for the picture signal in acquisition monitoring range areas; The classifier design that IMAQ analysis module comprises image capture module, image mist elimination strengthens module, Edge extraction module, hough convert extraction module, electrolysis tank and electrolyte image characteristics extraction module and whether electrolyte liquid level is too low and discriminant classification module, wherein, image capture module is for obtaining the picture signal of camera collection; Image mist elimination strengthens module and is used for carrying out mist elimination enhancing to image; Edge extraction module is for determining the edge of the image that image capture module gathers; Hough conversion module, the circle extracted for recognition image edge extracting module or rectangle, namely corresponding circular electrolysis tank or rectangular electrolyte groove; Electrolysis tank and electrolyte image characteristics extraction module, for extracting the electrolysis tank and the characteristics of image of electrolyte that hough conversion module obtains; The classifier design whether electrolyte liquid level is too low and discriminant classification module, for the characteristic Design grader extracted according to electrolysis tank and electrolyte image characteristics extraction module, carry out discriminant classification to whether liquid level in groove is too low; IMAQ analysis module is located in PLC control cabinet, communicated with camera by wifi, for obtaining the picture signal of camera collection, and treatment and analyses is carried out to the picture signal gathered, judge that in electroplating bath, whether liquid level is too low, when liquid level is too low in electroplating bath, send alarm signal to controller; PLC control cabinet, for obtaining the analysis result signal that IMAQ analysis module exports, and being converted into control signal by corresponding signal, controlling whether cut off electroplating bath heating rod power circuit; Display module, for receiving the display of PLC control cabinet output and showing.
A roof-mounted camera is used to observe several electroplating baths vertically downward, by the image transmitting that collects to image procossing and analytical equipment, in the electroplating bath observed in analysis visual field, whether liquid level is normal, if certain bath solution is biased low, a high level signal is sent to PLC transmit button amount input port, control to cut off heating rod power supply by PLC and stop heating or supplementary electrolyte, and show a liquid level warning signal in man-machine interaction monitoring picture.
IMAQ analysis module, find electroplating bath and identify that wherein the whether normal process of liquid level comprises the following steps:
(1) strengthen module by image mist elimination and mist elimination enhancing carried out to image, due to camera fix, scene also do not change substantially, and wavelet field retinex algorithm can be adopted to reach the effect removing fog interference;
(2) by Edge extraction module, canny operator extraction edge is used to the image after mist elimination;
(3) by the circle in hough conversion extraction module extraction image or rectangle, namely this correspond to the electroplating bath in image;
(4) correlated characteristic (shared by the cell wall color histogram of each electroplating bath, cell wall and liquid pixel ratio etc.) of cell wall and liquid in electroplating bath is extracted by electrolysis tank and electrolyte image characteristics extraction module, design is training classifier also, differentiate that in each electroplating bath, whether liquid level is too low, if certain electrolysis tank liquid level is too low, then will send alarm signal to PLC, and control heating rod power-off corresponding to this electroplating bath by PLC thus prevent dry combustion method phenomenon.
Embodiment 2
Substantially identical with embodiment 1, difference is: make camera gather a picture signal every certain time interval T by external trigger mode, IMAQ analysis module is also provided with for analyzing the whether fuzzy image quality analysis module of picture signal that camera collection arrives, whether the picture signal adopting AVERAGE GRADIENT METHOD WITH analysis camera collection to arrive is fuzzy, when image blurring, the rain brush started on camera carries out lens cleaning, and Resurvey image again after being set in lens cleaning, so repeat the number of times preset 3 times.
In image acquisition, due to electroplating workshop high humidity, fog weight, especially summer, be easy to occur camera lens covered by fog or the situation of filling the air fog in workshop everywhere (in the following description, we are called covering the fog of camera lens " camera lens fog ", and by filling the air everywhere of occurring in workshop and don't uniform fog is called " workshop fog ").
(1) for reducing image data transmission amount and treating capacity, the process of electroplating bath being carried out to IMAQ and liquid level identification is carried out without the need to continuing, and only needs (a few hours once) external trigger camera collection image at a certain time interval;
(2) whether the IMAQ analysis module image that uses average gradient methods analyst to collect is fuzzy, if fuzzy, then illustrate there is camera lens fog, then to start on camera be with rain brush clean lens, and Resurvey image after clean lens again, so repeat 3 times;
(3) if the continuous image repeating to obtain after clean lens for 3 times is still judged to be blurred picture, then illustrate it is image blur because workshop fog causes, at this moment no longer clean lens, but the IMAQ analysis module entering next step processes.
With above-mentioned according to desirable embodiment of the present invention for enlightenment, by above-mentioned description, relevant staff in the scope not departing from this invention technological thought, can carry out various change and amendment completely.The technical scope of this invention is not limited to the content on specification, must determine its technical scope according to right.
Claims (10)
1. a contactless bath solution level controller for view-based access control model technology, is characterized in that:
Comprise camera, IMAQ analysis module, controller module and display module, wherein,
Camera, for the picture signal in acquisition monitoring range areas,
IMAQ analysis module, for obtaining the picture signal of camera collection, and carrying out treatment and analyses to the picture signal gathered, judging that in electroplating bath, whether liquid level is too low, when liquid level is too low in electroplating bath, sends alarm signal to controller,
Controller module, for obtaining the analysis result signal that IMAQ analysis module exports, and being converted into control signal by corresponding signal, controlling whether cut off electroplating bath heating rod power circuit,
Display module, for receiving the display of controller module output and showing.
2. the contactless bath solution level controller of a kind of view-based access control model technology according to claim 1, is characterized in that: make camera gather a picture signal every certain time interval T by external trigger mode.
3. the contactless bath solution level controller of a kind of view-based access control model technology according to claim 1 and 2, it is characterized in that: described IMAQ analysis module comprises the whether too low classifier design of image capture module, Edge extraction module, hough conversion extraction module, electrolysis tank and electrolyte image characteristics extraction module and electrolyte liquid level and discriminant classification module, wherein, image capture module is for obtaining the picture signal of camera collection; Edge extraction module is for determining the edge of the image that image capture module gathers; Hough conversion module, the circle extracted for recognition image edge extracting module or rectangle, namely corresponding circular electrolysis tank or rectangular electrolyte groove; Electrolysis tank and electrolyte image characteristics extraction module, for extracting the electrolysis tank and the characteristics of image of electrolyte that hough conversion module obtains; The classifier design whether electrolyte liquid level is too low and discriminant classification module, for the characteristic Design grader extracted according to electrolysis tank and electrolyte image characteristics extraction module, carry out discriminant classification to whether liquid level in groove is too low.
4. the contactless bath solution level controller of a kind of view-based access control model technology according to claim 3, it is characterized in that: described IMAQ analysis module is provided with for analyzing the whether fuzzy image quality analysis module of picture signal that described camera collection arrives, when image blurring, the rain brush started on camera carries out lens cleaning, and Resurvey image again after being set in lens cleaning, so repeat the times N preset.
5. the contactless bath solution level controller of a kind of view-based access control model technology according to claim 4, is characterized in that: the image mist elimination that described IMAQ analysis module is also provided with for carrying out mist elimination enhancing to image strengthens module.
6. the contactless bath solution level controller of a kind of view-based access control model technology according to claim 1 and 2, is characterized in that: described controller is PLC control cabinet.
7. the contactless bath solution level controller of a kind of view-based access control model technology according to claim 1 and 2, is characterized in that: described camera is more than waterproof Grade I P67, the camera being provided with rain brush and wifi transfer function.
8. the contactless bath solution level controller of a kind of view-based access control model technology according to claim 7, is characterized in that: described IMAQ analysis module is communicated with camera by wifi.
9. the contactless bath solution level controller of a kind of view-based access control model technology according to claim 1 and 2, is characterized in that: described IMAQ analysis module is located in described PLC control cabinet.
10. the contactless bath solution level controller of a kind of view-based access control model technology according to claim 4, is characterized in that: described image quality analysis module adopt AVERAGE GRADIENT METHOD WITH to analyze whether picture signal that described camera collection arrives fuzzy.
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