CN106053479A - System for visually detecting workpiece appearance defects based on image processing - Google Patents

Abstract

The invention discloses a system for visually detecting workpiece appearance defects based on image processing, comprising an industrial personal computer, a coaxial light source, a CCD (charge coupled device) industrial camera, an image acquisition card and a rejecting mechanism; both the coaxial light source and the rejecting mechanism are connected with the industrial personal computer; the CCD industrial camera is connected with the industrial personal computer through the image acquisition card; wherein the coaxial light source is used for providing a diffuse reflection light source for a workpiece to be detected; the CCD industrial camera is used for taking an image of the workpiece at a detection station; the rejecting mechanism is used for rejecting from a production line, workpieces detected to be defective; the industrial personal computer has a defect detection module based on image processing; the system is high in detection efficiency and easy to implement.

Description

A kind of vision detection system of workpiece appearance defects based on image procossing

Technical field

The invention belongs to automatic detection field, the vision particularly to a kind of workpiece appearance defects based on image procossing is examined Examining system.

Background technology

The main production flow process of metal works is machining, punching press, hot investment casting, powder metallurgy, metal injection Molding, size detection, open defect detection etc..Being affected by manufacturing process in whole production process, workpiece size is with outer Sight can exist defective to a certain extent.Wherein open defect specifically includes that breach, sizing, cracking, impression, pinprick, cut With foaming etc..If the workpiece that there is Appearance quality defect flows into next production process, assembling can be caused to be obstructed, deform, affect group The quality of piece installing, may cause assembly to scrap and shut down, greatly have impact on the production efficiency of automatic production line time serious, Potential economic loss and reputational risk is brought to manufacturing enterprise.

Traditional appearance defect inspection method has artificial range estimation and strobe light to detect.Automated production linear velocity quickly, human eye Cannot quickly capture defect information accurately, the least defect, human eye cannot tell conjunction completely at all Whether lattice, defects detection precision is low, false drop rate is high problem that this results in.Strobe light detection is mainly according to the retina pair of people Arrest reaction produced by certain pulse flash.The method is specific video camera and stroboscopic light source to be combined, by fixing Ground is observed detector and is determined surface of the work situation.Its shortcoming is the with a low credibility of testing result, and Aulomatizeted Detect degree is also Low.

Automatic Measurement Technique has infrared, misfortune stream and Magnetic Flux Leakage Inspecting technology, and these three detection method Ye Shi China applies at present The most widely.Eddy detection technology mainly detection surface of the work lower floor choked flow defect, but its power consumption is big, causes production enterprise The waste of the industry energy.Eddy current detection method prescription to workpiece own is higher, the necessary pure free from admixture of surface of the work, temperature Uniformly, conveyer belt rate request is relatively slow, and this results in production and detects limited, it is impossible to meet two-forty, high-quality production is wanted Ask.In recent years, the development of machine vision and image processing techniques makes Machine Vision Detection on production line replace artificial inspection Survey is possibly realized.Open defect uses visible sensation method detection identification to be method most effective, the most promising.High resolution industrial phase Machine can provide abundant workpiece appearance images information, it is possible to accurately, efficiently and reliably complete workpiece appearance defects volume detection and Identify.

The main method of workpiece appearance defects vision-based detection at present: (1) processes form by genetic algorithm and visual pattern Learning the automatic detection realizing surface of workpiece defect, system is good to Detection results such as cracking and pinpricks, but tiny cut, pressure Trace and Blister Detection results are poor；(2) by utilizing gradation of image feature, judge to produce by the ANOMALOUS VARIATIONS of gray value The existence of product defect, but due to the strong reflective characteristic of metal surface so that system flase drop is higher.

Therefore, it is necessary to design the vision of the high workpiece appearance defects based on image procossing of a kind of efficient accuracy of detection Detecting system.

Summary of the invention

The technical problem to be solved is to provide the vision inspection of a kind of workpiece appearance defects based on image procossing Examining system, the vision detection system detection efficiency being somebody's turn to do workpiece appearance defects based on image procossing is high, it is easy to implement.

The technical solution of invention is as follows:

A kind of vision detection system of workpiece appearance defects based on image procossing, it is characterised in that include industrial computer, with Axle light source, CCD industrial camera, image pick-up card and rejecting mechanism；

Coaxial light source is all connected with industrial computer with rejecting mechanism；

CCD industrial camera is connected with industrial computer by image pick-up card；

Wherein: coaxial light source is for providing diffuse-reflectance light source for workpiece to be detected；CCD industrial camera is in for shooting The image of the workpiece of detection station；Rejecting mechanism is for rejecting the workpiece by detecting existing defects from production line；

Industrial computer has defects detection module based on image procossing；

Defects detection module based on image procossing implements defects detection according to following steps:

Step 1: workpiece image obtains and pretreatment；

Step 2: image segmentation is corrected with workpiece pose；

Step 3: detect following open defect: breach, sizing, cracking, impression, pinprick, cut and foaming.

In step 1, illuminated by coaxial light source, utilize CCD industrial camera and image pick-up card gather workpiece image f (x, Y), workpiece image is gray level image, then workpiece image is sent into industrial computer and carries out pretreatment, and pretreatment is to the work collected Part image carries out medium filtering process.

In step 2:

(1) image segmentation:

Based on histogram method, pretreated image being carried out image segmentation, the grey level histogram of workpiece image can show two Individual crest: one is the workpiece as prospect, and one is background, take trough gray value be segmentation threshold with effective segmentation prospect and Background:

In formula, (x, y) for the workpiece image being partitioned into, Th for F_fFor segmentation threshold

(2) image flame detection is translation and the anglec of rotation rectification being realized workpiece in image by affine transformation.Affine transformation For existing mature technology.

Image after correcting is carried out morphology processing；Processing procedure is, by structural element B, image is applied shape State opening operation removes edge of work burr, the smooth edge of work, has:

In formula,For opening operation operator,According with for erosion operation, accord with for dilation operation, B is structural element, and size is 3, element is all 1, for disc structure.

In step 3:

Demarcating the edge of work is notch detection region, is designated as Reg_qk；

Demarcating whole surface of the work region is sizing, cracking, impression, pinprick, cut and Blister detection region；Wherein Sizing and pinprick detection region are designated as Reg_nlAnd Reg_zy；Cut and cracking detection region are designated as Reg_hhAnd Reg_kl；Impression detection zone Territory is designated as Reg_yh；Foaming detection region is designated as Reg_qp；

The area judgment threshold of defect:

In formula, Th is the area judgment threshold of defect；φ is defect tolerant degree；W and H is width and the height of workpiece in image, In units of pixel；M and N is actual (tube) length and the width of workpiece, in units of millimeter；

Local dynamic station segmentation threshold determines method:

Filtering mask initially with (2D+1) × (2D+1) is smoothed, and in formula, D is the diameter being extracted target； Then calculate smooth after image intensity value average Mean (x, y) and standard deviation sigma (x, y)；It is shown as bright when being extracted target During pixel, (x, y) (x y) is segmentation threshold to+γ σ to choose T=Mean；When being extracted target and being shown as dark pixel, choose T (x, y) (x, is y) segmentation threshold to-γ σ to=Mean, and in formula, γ is standard deviation intensity.

1. notch detection:

1) image segmentation threshold T is used_qkAt region Reg_qkThe Blob candidate blocks of middle segmentation breach, by eight connectivity region Identify Blob connected domain, be designated as Bl_qk；

Segmentation threshold T_qkDetermination: use (2D_qk+1)×(2D_qk+ 1) filtering mask is smoothed, D in formula_qkFor The diameter of chips defect；Calculate average Mean of the image intensity value after smoothing_qk(x, y) and standard deviation sigma_qk(x,y)；Owing to lacking Mouth defect is shown as dark pixel, then select T_qk=Mean_qk(x,y)-γ_qk·σ_qk(x y) is segmentation threshold, γ_qkLack for breach The standard deviation weight fallen into.The span of weight is [0,1], need to determine occurrence according to priori.

2) pixel counts method is utilized to extract Bl_qkElemental area feature Area of connected domain_qk；Bl is judged according to following formula_qkWhether For chips defect:

In formula, defect area judgment threshold Th_qkDetermined by formula 3, wherein the span of φ be [0.0120, 0.0130], YES and NO represents respectively and there is chips defect and there is not chips defect；

2. sizing and pinprick detection:

1) segmentation threshold T is used_zzAt region Reg_nlAnd Reg_zyMiddle segmentation sizing and the Blob candidate blocks of pinprick, by eight Connected component label goes out Blob connected domain, is designated as Bl_nlAnd Bl_zy；

Segmentation threshold T_zzDetermination:

T_zz=Mean '_zz(x,y)-δ_zz·V′_zz(x,y)

Mean ' in formula_zz(x, y) with V '_zz(x, y) for average and variance, the δ of detection region grey scale pixel value_zzFor sizing and The variance weight of pinprick defect；

In image, the pixel region less than segmentation threshold is defect candidate blocks；

2) pixel counts method is utilized to extract Bl_nlElemental area feature Area of connected domain_nlAnd the round degree of characteristicsBl_zyElemental area feature Area of connected domain_zyAnd the round degree of characteristicsAccording to following formula 5,6 points Do not judge Bl_nlWhether it is sizing defect and Bl_zyWhether it is pinprick defect:

In formula, defect area judgment threshold Th_nl1And Th_zy1Being determined by formula 3, wherein the span of φ is respectively [0.0020,0.0021] and [0.0024,0.0025]；Defect circularity judgment threshold Th_nl2And Th_zy2Span be respectively [0.5,1] and [0.85,1]；∩ represents logic "and" operation；YES and NO represents it is with no respectively；

Number of pixels in elemental area feature i.e. region, the round degree of characteristics description i.e. area of target area and external disc Long-pending ratio, shape is closer to circle, and ratio is closer to 1, and the span of the round degree of characteristics is:Meter Calculation formula isWherein r is the circumradius being extracted target, and the target that is extracted herein refers to glue Material and pinprick defect；

3. cut and cracking detection:

1) topography's variance intensity algorithm is used to ask for segmentation threshold T_hk, at region Reg_hhAnd Reg_klMiddle segmentation cut With the Blob block candidate of cracking, go out Blob connected domain by eight connectivity area identification, be designated as Bl_hhAnd Bl_kl；

Topography's variance intensity is that the expansion of image local threshold concept extends, owing to detected workpiece is by production technology Impact can be had powerful connections uneven situation, is therefore difficult to find fixed threshold by target defect and background full segmentation.Therefore proposition office The method that portion's threshold detection method, i.e. local gray level feature combine with entirety；In conjunction with the characteristic of local variance Yu variance, first adopt With (2D_hk+1)×(2D_hk+ 1) filtering mask is smoothed, D in formula_hkFor cut and the length of cracking defect；Calculate again The standard deviation sigma of image intensity value after smooth_hk(x, y) with variance V_hk(x,y)；Segmentation threshold determination as the following formula:

$T_{hk}=\left\{\begin{array}{cc}{\mathrm{\&sigma;}}_{hk}(x,y)+V_{hk}(x,y),& {\mathrm{\&sigma;}}_{hk}(x,y)>{{\mathrm{\&sigma;}}^{\&prime;}}_{hk}(x,y)\\ {\mathrm{\&sigma;}}_{hk}(x,y)-V_{hk}(x,y),& {\mathrm{\&sigma;}}_{hk}(x,y)<{{\mathrm{\&sigma;}}^{\&prime;}}_{hk}(x,y)\end{array}\right.;$

Wherein σ '_hk(x, y) with V '_hk(x y) represents standard deviation and the variance of the entire image before smoothing；

2) pixel counts method is utilized to extract Bl_hhElemental area feature Area of connected domain_hhWith internal longest diameter feature Diameter_hhAnd Bl_klElemental area feature Area of connected domain_klWith internal longest diameter feature Diameter_kl；According to formula 7,8 judge Bl respectively_hhWhether it is scratch defects, and Bl_klWhether it is cracking defect:

In formula, defect area judgment threshold Th_hh1And Th_kl1Being determined by formula 3, wherein the span of φ is respectively [0.0110,0.0120] and [0.0048,0.0049]；Defect longest diameter judgment threshold Th_hh2And Th_kl2Span by warp Test value to determine；∩ represents logic "and" operation；

The distance of two pixels farthest on internal longest diameter i.e. zone boundary, distance and area are all to be with pixel Unit, i.e. this number of pixels comprised in interior or this region；

4. impression detection:

1) by Laplce's Gaussian transformation algorithm and threshold T_yhThe Blob candidate blocks of segmentation impression；

T_yhDetermination: use (2D_yh+1)×(2D_yh+ 1) filtering mask is smoothed, D in formula_yhFor impression defect Diameter；Calculate average Mean of smooth rear image intensity value_yh(x, y) and standard deviation sigma_yh(x,y)；Owing to impression defect is being drawn Image after this Gaussian transformation of pula is shown as bright pixel, therefore selects T_yh=Mean_yh(x,y)+γ_yh·σ_yh(x, y) for segmentation Threshold value, γ_yhStandard deviation weight for impression defect；Go out Blob connected domain by eight connectivity area identification, be designated as Bl_yh；

The span of weight is [0,1], need to determine occurrence according to priori；

2) pixel counts method is utilized to extract Bl_yhElemental area feature Area of connected domain_yhWith rectangular degree feature Rectan_yh, Rectangular degree is to describe to be extracted the region full level to its boundary rectangle, and computing formula isWherein S_m For being extracted the area of region circumscribed rectangular region；Bl is judged according to formula 9_yhWhether it is impression defect:

In formula, area judgment threshold Th_yh1Being determined by formula 3, wherein the span of φ is [0.0160,0.0170]；Rectangle Degree judgment threshold Th_yh2Span be [0.7,1]；∩ represents logic "and" operation；

Laplce's Gauss algorithm:

The method is gaussian filtering and Laplace operator to be combined.Algorithm key step is as follows:

(1) filtering: first (x, y) carries out smothing filtering, and filter function is Gaussian function, i.e. to image F

$G(x,y)=\frac{1}{2{\mathrm{\&pi;\&sigma;}}^2}\exp \&lsqb;-\frac{1}{2{\mathrm{\&pi;\&sigma;}}^2}(x^2+y^2)\&rsqb;$

By image F, (x, y) (x, y) carries out convolution, can obtain a smooth image, i.e. with G

G (x, y)=F (x, y) * G (x, y)

(2) image enhaucament: (x y) carries out Laplace's operation, i.e. to smoothed image g

$h(x,y)={\&dtri;}^2\&lsqb;F(x,y)*G(x,y)\&rsqb;$

Owing to smoothed image g, (x y) carries out Laplace's operation and can be equivalent to g (x, Laplace's operation y) and F (x, convolution y), therefore above formula becomes:

$h(x,y)=F(x,y)*{\&dtri;}^{2}G(x,y)$

In formulaBecoming LOG wave filter, it is:

${\&dtri;}^{2}G(x,y)=\frac{{\&part;}^{2}G}{\&part;x^2}+\frac{{\&part;}^{2}G}{\&part;y^2}=\frac{1}{{\mathrm{\&pi;\&sigma;}}^4}(\frac{x^2+y^2}{2{\mathrm{\&sigma;}}^2}-1)\exp (-\frac{x^2+y^2}{2{\mathrm{\&sigma;}}^2})$

Effect: Laplce's Gauss operator combines Gaussian filter and laplacian spectral radius wave filter, first Graduation falls noise, then image is carried out edge enhancing, it is possible to effectively highlight impression defect.

5. bubble detection:

1) by fast fourier transform, image function is changed to frequency domain from transform of spatial domain, use low pass filter to smooth Image, then by inverse fourier transform by image from frequency domain transformation to spatial domain；According to image grey level histogram, choose trough Gray value is the Blob candidate blocks that the segmentation of segmentation threshold segmentation object is bubbled, and goes out Blob connected domain by eight connectivity area identification, It is designated as Bl_qp；

The rectangular histogram only one of which trough of image, because after Fourier transform and the disposal of gentle filter, foaming position The brightest compared with one-piece machine member background, so rectangular histogram shows two crests and a trough, and in two crests one belong to Workpiece background, another belongs to Blister, so using trough gray value background and Blister to be split；

2) pixel counts method is utilized to extract Bl_qpElemental area feature Area of connected domain_qpAnd the round degree of characteristicsBl is judged according to formula 10_qpWhether it is Blister:

In formula, area judgment threshold Th_qp1Being determined by formula 3, wherein the span of φ is [0.0123,0.0124]；Circularity Judgment threshold Th_qp2Span be [0.5,1]；∩ represents logic "and" operation.Location, navigational figure gatherer process in, Annular is used to diffuse source lighting；In detection image acquisition process, use coaxial light source illumination.

Beneficial effect:

The vision detection system of the workpiece appearance defects based on image procossing of the present invention, using coaxial light source is that workpiece carries For illumination, use camera and image pick-up card to obtain workpiece image, use industrial computer to realize defects detection based on image procossing, inspection The workpiece surveying existing defects is rejected by rejecting mechanism；In defect inspection process, first pass through visual system guided robot, It is accurately positioned target workpiece pose according to template matching algorithm based on gray value, then carries out workpiece appearance defects detection, its Step is: (1) obtains workpiece image, uses medium filtering to carry out pretreatment；(2) global threshold segmentation object workpiece is utilized, and Carry out workpiece pose rectification；(3) remove edge of work burr by mathematical morphology open operator to disturb；(4) detect breach, glue Material, cracking, impression, pinprick, cut and foaming open defect.

It is an advantage of the current invention that:

1. locating speed is fast, precision is high.Template matching based on gray value, uses normalized crosscorrelation algorithm, and utilizes Image pyramid realizes multistage coupling, improves matching precision and speed；

2. defects detection is with strong points, and speed is fast.

Using Blob algorithm simple, effective, first the original image obtained does pretreatment, suppression noise jamming strengthens The performance tension force of image useful information.The present invention is directed to different defects and use detection method targetedly, it is easy to implement, side Method is ingenious, specifically includes demarcation detection region and by binarization segmentation ROI, is carried by local gray level threshold value based on ROI region Take chips defect feature；Threshold algorithm extracts sizing and pinprick defect characteristic；Topography's variance intensity algorithm carries Take cut and cracking defect feature；Laplce's Gauss algorithm extracts surface indentation defect characteristic；Fast fourier transform algorithm Extract surface blistering defect characteristic.Finally the defect characteristic extracted is analyzed according to the decision rule in decision rule storehouse Judge and output detections result；

3. wide adaptability, transplantability by force, can detect defect type more comprehensive.This detection algorithm can be widely used in high fast-growing Produce the vision-based detection of precision workpiece presentation quality on line, and may migrate to the vision inspection of electronic devices and components, small parts etc. Survey on production line, there is the strongest adaptability, be a kind of vision detection system with highly versatile type and accuracy.

The system of the present invention can solve that manual detection speed is slow, efficiency is low, the problem of low precision；Current vision can be overcome to examine Survey the problem that defect type is single, image quality is poor and false drop rate is high, improve precision workpiece production automation degree and product matter Amount.

Accompanying drawing explanation

Fig. 1 is the vision-based detection flow chart of workpiece appearance defects based on image procossing；

Fig. 2 is the normal picture and defect image detected, wherein figure a-h respectively corresponding normal, sizing, impression, breach, Cracking, cut, foaming and pinprick image；

Fig. 3 is the population structure block diagram of the vision detection system of workpiece appearance defects based on image procossing.

Detailed description of the invention

For the ease of understanding the present invention, below in conjunction with Figure of description and preferred embodiment, invention herein is done more complete Face, describe meticulously, but protection scope of the present invention is not limited to specific examples below.

Unless otherwise defined, all technical term used hereinafter is generally understood that implication phase with those skilled in the art With.Technical term used herein is intended merely to describe the purpose of specific embodiment, is not intended to limit the present invention's Protection domain.

Embodiment 1:

Such as Fig. 1-3, the vision detection system of a kind of workpiece appearance defects based on image procossing, it is characterised in that include Industrial computer, coaxial light source, CCD industrial camera, image pick-up card and rejecting mechanism；

Coaxial light source is all connected with industrial computer with rejecting mechanism；

CCD industrial camera is connected with industrial computer by image pick-up card；

Wherein: coaxial light source is for providing diffuse-reflectance light source for workpiece to be detected；CCD industrial camera is in for shooting Detection work

The image of the workpiece of position；Rejecting mechanism is for rejecting the workpiece by detecting existing defects from production line；

Industrial computer has defects detection module based on image procossing；

Defects detection module based on image procossing implements defects detection according to following steps:

Step 1: workpiece image obtains and pretreatment；

Step 2: image segmentation is corrected with workpiece pose；

Step 3: detect following open defect: breach, sizing, cracking, impression, pinprick, cut and foaming.

In step 1, illuminated by coaxial light source, utilize CCD industrial camera and image pick-up card gather workpiece image f (x, Y), workpiece image is gray level image, then workpiece image is sent into industrial computer and carries out pretreatment, and pretreatment is to the work collected Part image carries out medium filtering process, removes the noise that may cause in image taking and transmitting procedure, improves signal noise ratio (snr) of image.

In step 2:

(1) image segmentation:

Based on histogram method, pretreated image being carried out image segmentation, the grey level histogram of workpiece image can show two Individual crest: one is the workpiece as prospect, and one is background, take trough gray value be segmentation threshold with effective segmentation prospect and Background:

In formula, (x, y) for the workpiece image being partitioned into, Th for F_fFor segmentation threshold

(2) image flame detection is translation and the anglec of rotation rectification being realized workpiece in image by affine transformation.Affine transformation For existing mature technology.

Image after correcting is carried out morphology processing；Processing procedure is, by structural element B, image is applied shape State opening operation removes edge of work burr, the smooth edge of work, has:

In formula, ° it is opening operation operator,According with for erosion operation, accord with for dilation operation, B is structural element, and size is 3,

Element is all 1, for disc structure.

In step 3:

Demarcating the edge of work is notch detection region, is designated as Reg_qk；

Demarcating whole surface of the work region is sizing, cracking, impression, pinprick, cut and Blister detection region；Wherein Sizing and pinprick detection region are designated as Reg_nlAnd Reg_zy；Cut and cracking detection region are designated as Reg_hhAnd Reg_kl；Impression detection zone Territory is designated as Reg_yh；Foaming detection region is designated as Reg_qp；

The area judgment threshold of defect:

In formula, Th is the area judgment threshold of defect；φ is defect tolerant degree；W and H is width and the height of workpiece in image, In units of pixel；M and N is actual (tube) length and the width of workpiece, in units of millimeter；Local dynamic station segmentation threshold determines method:

Filtering mask initially with (2D+1) × (2D+1) is smoothed, and in formula, D is the diameter being extracted target； Then calculate smooth after image intensity value average Mean (x, y) and standard deviation sigma (x, y)；It is shown as bright when being extracted target During pixel, (x, y) (x y) is segmentation threshold to+γ σ to choose T=Mean；When being extracted target and being shown as dark pixel, choose T (x, y) (x, is y) segmentation threshold to-γ σ to=Mean, and in formula, γ is standard deviation intensity.

1. notch detection:

1) image segmentation threshold T is used_qkAt region Reg_qkThe Blob candidate blocks of middle segmentation breach, by eight connectivity region Identify Blob connected domain, be designated as Bl_qk；

Segmentation threshold T_qkDetermination: use (2D_qk+1)×(2D_qk+ 1) filtering mask is smoothed, D in formula_qkFor The diameter of chips defect；Calculate average Mean of the image intensity value after smoothing_qk(x, y) and standard deviation sigma_qk(x,y)；Owing to lacking Mouth defect is shown as dark pixel, then select T_qk=Mean_qk(x,y)-γ_qk·σ_qk(x y) is segmentation threshold, γ_qkLack for breach The standard deviation weight fallen into.The span of weight is [0,1], need to determine occurrence according to priori.

2) pixel counts method is utilized to extract Bl_qkElemental area feature Area of connected domain_qk；Bl is judged according to following formula_qkWhether For chips defect:

In formula, defect area judgment threshold Th_qkDetermined by formula 3, wherein the span of φ be [0.0120, 0.0130], YES and NO represents respectively and there is chips defect and there is not chips defect；

2. sizing and pinprick detection:

1) segmentation threshold T is used_zzAt region Reg_nlAnd Reg_zyMiddle segmentation sizing and the Blob candidate blocks of pinprick, by eight Connected component label goes out Blob connected domain, is designated as Bl_nlAnd Bl_zy；

Segmentation threshold T_zzDetermination:

T_zz=Mean '_zz(x,y)-δ_zz·V′_zz(x,y)

Mean ' in formula_zz(x, y) with V '_zz(x, y) for average and variance, the δ of detection region grey scale pixel value_zzFor sizing and The variance weight of pinprick defect；

In image, the pixel region less than segmentation threshold is defect candidate blocks；

2) pixel counts method is utilized to extract Bl_nlElemental area feature Area of connected domain_nlAnd the round degree of characteristicsBl_zyElemental area feature Area of connected domain_zyAnd the round degree of characteristicsAccording to following formula 5,6 points Do not judge Bl_nlWhether it is sizing defect and Bl_zyWhether it is pinprick defect:

In formula, defect area judgment threshold Th_nl1And Th_zy1Being determined by formula 3, wherein the span of φ is respectively [0.0020,0.0021] and [0.0024,0.0025]；Defect circularity judgment threshold Th_nl2And Th_zy2Span be respectively [0.5,1] and [0.85,1]；∩ represents logic "and" operation；YES and NO；

Number of pixels in elemental area feature i.e. region, the round degree of characteristics description i.e. area of target area and external disc Long-pending ratio, shape is closer to circle, and ratio is closer to 1, and the span of the round degree of characteristics is:Meter Calculation formula isWherein r is the circumradius being extracted target, and the target that is extracted herein refers to glue Material and pinprick defect；

3. cut and cracking detection:

1) topography's variance intensity algorithm is used to ask for segmentation threshold T_hk, at region Reg_hhAnd Reg_klMiddle segmentation cut With the Blob block candidate of cracking, go out Blob connected domain by eight connectivity area identification, be designated as Bl_hhAnd Bl_kl；

Topography's variance intensity is that the expansion of image local threshold concept extends, owing to detected workpiece is by production technology Impact can be had powerful connections uneven situation, is therefore difficult to find fixed threshold by target defect and background full segmentation.Therefore proposition office The method that portion's threshold detection method, i.e. local gray level feature combine with entirety；In conjunction with the characteristic of local variance Yu variance, first adopt With (2D_hk+1)×(2D_hk+ 1) filtering mask is smoothed, D in formula_hkFor cut and the length of cracking defect；Calculate again The standard deviation sigma of image intensity value after smooth_hk(x, y) with variance V_hk(x,y)；Segmentation threshold determination as the following formula:

$T_{hk}=\left\{\begin{array}{cc}{\mathrm{\&sigma;}}_{hk}(x,y)+V_{hk}(x,y),& {\mathrm{\&sigma;}}_{hk}(x,y)>{{\mathrm{\&sigma;}}^{\&prime;}}_{hk}(x,y)\\ {\mathrm{\&sigma;}}_{hk}(x,y)-V_{hk}(x,y),& {\mathrm{\&sigma;}}_{hk}(x,y)<{{\mathrm{\&sigma;}}^{\&prime;}}_{hk}(x,y)\end{array}\right.;$

Wherein σ '_hk(x, y) with V '_hk(x y) represents standard deviation and the variance of the entire image before smoothing；

2) pixel counts method is utilized to extract Bl_hhElemental area feature Area of connected domain_hhWith internal longest diameter feature Diameter_hhAnd Bl_klElemental area feature Area of connected domain_klWith internal longest diameter feature Diameter_kl；According to formula 7,8 judge Bl respectively_hhWhether it is scratch defects, and Bl_klWhether it is cracking defect:

In formula, defect area judgment threshold Th_hh1And Th_kl1Being determined by formula 3, wherein the span of φ is respectively [0.0110,0.0120] and [0.0048,0.0049]；Defect longest diameter judgment threshold Th_hh2And Th_kl2Span by warp Test value to determine；∩ represents logic "and" operation；

The distance of two pixels farthest on internal longest diameter i.e. zone boundary, distance and area are all to be with pixel Unit, i.e. this number of pixels comprised in interior or this region；

4. impression detection:

1) by Laplce's Gaussian transformation algorithm and threshold T_yhThe Blob candidate blocks of segmentation impression；

T_yhDetermination: use (2D_yh+1)×(2D_yh+ 1) filtering mask is smoothed, D in formula_yhFor impression defect Diameter；Calculate average Mean of smooth rear image intensity value_yh(x, y) and standard deviation sigma_yh(x,y)；Owing to impression defect is being drawn Image after this Gaussian transformation of pula is shown as bright pixel, therefore selects T_yh=Mean_yh(x,y)+γ_yh·σ_yh(x, y) for segmentation Threshold value, γ_yhStandard deviation weight for impression defect；Go out Blob connected domain by eight connectivity area identification, be designated as Bl_yh；

The span of weight is [0,1], need to determine occurrence according to priori；

2) pixel counts method is utilized to extract Bl_yhElemental area feature Area of connected domain_yhWith rectangular degree feature Rectan_yh, Rectangular degree is to describe to be extracted the region full level to its boundary rectangle, and computing formula isWherein S_m For being extracted the area of region circumscribed rectangular region；Bl is judged according to formula 9_yhWhether it is impression defect:

In formula, area judgment threshold Th_yh1Being determined by formula 3, wherein the span of φ is [0.0160,0.0170]；Rectangle Degree judgment threshold Th_yh2Span be [0.7,1]；∩ represents logic "and" operation；

5. bubble detection:

1) by fast fourier transform, image function is changed to frequency domain from transform of spatial domain, use low pass filter to smooth Image, then by inverse fourier transform by image from frequency domain transformation to spatial domain；According to image grey level histogram, choose trough Gray value is the Blob candidate blocks that the segmentation of segmentation threshold segmentation object is bubbled, and goes out Blob connected domain by eight connectivity area identification, It is designated as Bl_qp；

The rectangular histogram only one of which trough of image, because after Fourier transform and the disposal of gentle filter, foaming position The brightest compared with one-piece machine member background, so rectangular histogram shows two crests and a trough, and in two crests one belong to Workpiece background, another belongs to Blister, so using trough gray value background and Blister to be split；

2) pixel counts method is utilized to extract Bl_qpElemental area feature Area of connected domain_qpAnd the round degree of characteristicsBl is judged according to formula 10_qpWhether it is Blister:

In formula, area judgment threshold Th_qp1Being determined by formula 3, wherein the span of φ is [0.0123,0.0124]；Circularity Judgment threshold Th_qp2Span be [0.5,1]；∩ represents logic "and" operation.

Image semantic classification also includes:

A. workpiece location:

Workpiece template image is that (x, y), direction is 0 degree of benchmark with X-axis positive direction to Temp.Shone by annular diffuse-reflectance light source Bright, utilize CCD industrial camera and image pick-up card to gather workpiece image on conveyer belt, then according to template based on gray value (x, target area y) matched calculate its barycentric coodinates (x with known template Temp to join technology search_c,y_c) and deflection angle θ.Wherein template matching uses normalized crosscorrelation algorithm (NCC), and utilizes image pyramid to realize multistage coupling, improves coupling Accuracy and speed.NCC algorithmic formula is shown below:

$ncc(a,b)=\frac{1}{n}\underset{x=1}{\overset{W_T}{\&Sigma;}}\underset{y=1}{\overset{H_T}{\&Sigma;}}\frac{Temp(x,y)-m_T}{\sqrt{s_T^2}}.\frac{f(a+x,b+y)-m_f(a,b)}{\sqrt{s_f^2(a,b)}}$

In formula, n is the quantity of pixel in template area-of-interest；(x, y) is template image to Temp, and template size is W_T ×H_T.Template image is and is partitioned into, it is stipulated that direction is with target workpiece image that X-axis positive direction is 0 degree of benchmark；Interested Region i.e. target workpiece region, because workpiece area is with background area contrast clearly, so using overall situation gray threshold Split-run can extract target workpiece, i.e. area-of-interest.m_TIt is the average gray value of template,It is all pixel grey scales of template The variance of value, m_f(a, b) andIt is all pixels of image in the template area-of-interest moving to image current location Average gray value and variance, ncc (a, b) represent matching similarity, span be-1≤ncc (a, b)≤1.X, y represent figure Pixel coordinate in Xiang.A, b are image pixel coordinates translational movements.

Coupling is to find the target workpiece in the visual field and calculating workpiece posture information quickly and accurately.It is follow-up Robot and the premise of visual processes.

B. robot vision guides:

Target workpiece on conveyer belt is mainly accurately positioned by vision guide system.For same workpiece, robot Having only to a teaching and this teaching position is designated as zero-bit, in production, camera shoots the target workpiece on conveyer belt and by meter The coordinate of workpiece centre characteristic point on nomogram picture, i.e. posture information (x_c,y_c) and θ.Visual system calculates current goal workpiece Coordinate and zero-bit are at X, Y, R_ZThe departure in direction, robot captures path and action according to departure planning, completes target work Part captures task.Wherein R_ZDirection is workpiece direction of rotation in the plane.

Overall procedure illustrates: workpiece to be checked initially enters upper surface detection station, and photoelectric sensor triggers camera and takes pictures also Gather a two field picture, carry out defects detection by outward appearance detection algorithm, and testing result is sent to by vision detection system Slave computer.Defective work is rejected by device for eliminating, and certified products will enter robot detection station.Utilize vision guide robot accurate Really target workpiece place detection position on pickup conveyer belt, is taken pictures by robot sequence trigger switch polyphaser before and after carrying out workpiece Face, left and right side and the detection of bottom surface open defect.Industrial control computer is comprehensively analyzed polyphaser result and is passed through Vision detection system sends slave computer to, finally realizes the intelligent sorting of workpiece.

Claims (5)

1. the vision detection system of a workpiece appearance defects based on image procossing, it is characterised in that include industrial computer, coaxial Light source, CCD industrial camera, image pick-up card and rejecting mechanism；

Coaxial light source is all connected with industrial computer with rejecting mechanism；

CCD industrial camera is connected with industrial computer by image pick-up card；

Wherein: coaxial light source is for providing diffuse-reflectance light source for workpiece to be detected；CCD industrial camera is in detection for shooting The image of the workpiece of station；Rejecting mechanism is for rejecting the workpiece by detecting existing defects from production line；

Industrial computer has defects detection module based on image procossing；

Defects detection module based on image procossing implements defects detection according to following steps:

Step 1: workpiece image obtains and pretreatment；

Step 2: image segmentation is corrected with workpiece pose；

Step 3: detect following open defect: breach, sizing, cracking, impression, pinprick, cut and foaming.

The vision detection system of workpiece appearance defects based on image procossing the most according to claim 1, it is characterised in that In step 1, illuminated by coaxial light source, utilize CCD industrial camera and image pick-up card gather workpiece image f (x, y), workpiece figure Picture is gray level image, then workpiece image is sent into industrial computer and carries out pretreatment, and pretreatment is to enter the workpiece image collected Row medium filtering processes.

The vision detection system of workpiece appearance defects based on image procossing the most according to claim 2, it is characterised in that In step 2:

(1) image segmentation:

Based on histogram method, pretreated image being carried out image segmentation, the grey level histogram of workpiece image can show two ripples Peak: one is the workpiece as prospect, and one is background, taking trough gray value is that segmentation threshold is with effective segmentation prospect and the back of the body Scape:

In formula, (x, y) for the workpiece image being partitioned into, Th for F_fFor segmentation threshold

(2) image flame detection is translation and the anglec of rotation rectification being realized workpiece in image by affine transformation.

The vision detection system of workpiece appearance defects based on image procossing the most according to claim 3, it is characterised in that Image after correcting is carried out morphology processing；Processing procedure is, by structural element B, image is applied morphology and opens fortune Calculate and remove edge of work burr, the smooth edge of work, have:

In formula,For opening operation operator,Accord with for erosion operation,According with for dilation operation, B is structural element, and size is 3,

Element is all 1, for disc structure.

5., according to the vision detection system of the workpiece appearance defects based on image procossing described in claim 3 or 4, its feature exists In, in step 3:

Demarcating the edge of work is notch detection region, is designated as Reg_qk；

Demarcating whole surface of the work region is sizing, cracking, impression, pinprick, cut and Blister detection region；Wherein sizing It is designated as Reg with pinprick detection region_nlAnd Reg_zy；Cut and cracking detection region are designated as Reg_hhAnd Reg_kl；Impression detection region note For Reg_yh；Foaming detection region is designated as Reg_qp；

The area judgment threshold of defect:

In formula, Th is the area judgment threshold of defect；φ is defect tolerant degree；W and H is width and the height of workpiece in image,

In units of pixel；M and N is actual (tube) length and the width of workpiece, in units of millimeter；

1. notch detection:

1) image segmentation threshold T is used_qkAt region Reg_qkThe Blob candidate blocks of middle segmentation breach, is gone out by eight connectivity area identification Blob connected domain, is designated as Bl_qk；

Segmentation threshold T_qkDetermination: use (2D_qk+1)×(2D_qk+ 1) filtering mask is smoothed, D in formula_qkFor breach The diameter of defect；Calculate average Mean of the image intensity value after smoothing_qk(x, y) and standard deviation sigma_qk(x,y)；Owing to breach lacks Fall into and be shown as dark pixel, then select T_qk=Mean_qk(x,y)-γ_qk·σ_qk(x y) is segmentation threshold, γ_qkFor chips defect Standard deviation weight.

2) pixel counts method is utilized to extract Bl_qkElemental area feature Area of connected domain_qk；Bl is judged according to following formula_qkWhether it is scarce Mouth defect:

In formula, defect area judgment threshold Th_qkBeing determined by formula 3, wherein the span of φ is [0.0120,0.0130], YES Represent respectively with NO and there is chips defect and there is not chips defect；

2. sizing and pinprick detection:

1) segmentation threshold T is used_zzAt region Reg_nlAnd Reg_zyMiddle segmentation sizing and the Blob candidate blocks of pinprick, pass through eight connectivity Area identification goes out Blob connected domain, is designated as Bl_nlAnd Bl_zy；

Segmentation threshold T_zzDetermination:

T_zz=Mean '_zz(x,y)-δ_zz·V′_zz(x,y)

Mean ' in formula_zz(x, y) with V '_zz(x, y) for average and variance, the δ of detection region grey scale pixel value_zzFor sizing and pinprick The variance weight of defect；

In image, the pixel region less than segmentation threshold is defect candidate blocks；

2) pixel counts method is utilized to extract Bl_nlElemental area feature Area of connected domain_nlAnd the round degree of characteristics Bl_zyElemental area feature Area of connected domain_zyAnd the round degree of characteristicsBl is judged respectively according to following formula 5,6_nlWhether For sizing defect and Bl_zyWhether it is pinprick defect:

In formula, defect area judgment threshold Th_nl1And Th_zy1Determined by formula 3, wherein the span of φ be respectively [0.0020, 0.0021] and [0.0024,0.0025]；Defect circularity judgment threshold Th_nl2And Th_zy2Span be respectively [0.5,1] and [0.85,1]；∩ represents logic "and" operation；YES and NO represents it is with no respectively；

Number of pixels in elemental area feature i.e. region, the round degree of characteristics description i.e. area of target area and circumscribed circle area Ratio, shape is closer to circle, and ratio is closer to 1, and the span of the round degree of characteristics is:Calculate public affairs Formula isWherein r is the circumradius being extracted target, herein be extracted target refer to sizing and Pinprick defect；

3. cut and cracking detection:

1) topography's variance intensity algorithm is used to ask for segmentation threshold T_hk, at region Reg_hhAnd Reg_klMiddle segmentation cut and opening The Blob block candidate split, goes out Blob connected domain by eight connectivity area identification, is designated as Bl_hhAnd Bl_kl；

Topography's variance intensity is that the expansion of image local threshold concept extends, owing to detected workpiece is affected by production technology Can have powerful connections uneven situation, therefore be difficult to find fixed threshold by target defect and background full segmentation.Therefore local threshold is proposed The method that value detection method, i.e. local gray level feature combine with entirety；In conjunction with the characteristic of local variance Yu variance, first use (2D_hk+1)×(2D_hk+ 1) filtering mask is smoothed, D in formula_hkFor cut and the length of cracking defect；Calculate flat again The standard deviation sigma of image intensity value after cunning_hk(x, y) with variance V_hk(x,y)；Segmentation threshold determination as the following formula:

$T_{hk}=\left\{\begin{array}{cc}{\mathrm{\&sigma;}}_{hk}(x,y)+V_{hk}(x,y),& {\mathrm{\&sigma;}}_{hk}(x,y)>{{\mathrm{\&sigma;}}^{\&prime;}}_{hk}\left(x,y\right)\\ {\mathrm{\&sigma;}}_{hk}(x,y)-V_{hk}(x,y),& {\mathrm{\&sigma;}}_{hk}(x,y)<{{\mathrm{\&sigma;}}^{\&prime;}}_{hk}\left(x,y\right)\end{array}\right.;$

Wherein σ '_hk(x, y) with V '_hk(x y) represents standard deviation and the variance of the entire image before smoothing；

2) pixel counts method is utilized to extract Bl_hhElemental area feature Area of connected domain_hhWith internal longest diameter feature Diameter_hhAnd Bl_klElemental area feature Area of connected domain_klWith internal longest diameter feature Diameter_kl；According to formula 7,8 judge Bl respectively_hhWhether it is scratch defects, and Bl_KlWhether it is cracking defect:

In formula, defect area judgment threshold Th_hh1And Th_kl1Determined by formula 3, wherein the span of φ be respectively [0.0110, 0.0120] and [0.0048,0.0049]；Defect longest diameter judgment threshold Th_hh2And Th_kl2Span true by empirical value Fixed；∩ represents logic "and" operation；

The distance of two pixels farthest on internal longest diameter i.e. zone boundary, distance and area are all with pixel as list Position, i.e. this number of pixels comprised in interior or this region；

4. impression detection:

1) by Laplce's Gaussian transformation algorithm and threshold T_yhThe Blob candidate blocks of segmentation impression；

T_yhDetermination: use (2D_yh+1)×(2D_yh+ 1) filtering mask is smoothed, D in formula_yhStraight for impression defect Footpath；Calculate average Mean of smooth rear image intensity value_yh(x, y) and standard deviation sigma_yh(x,y)；Owing to impression defect is at La Pula Image after this Gaussian transformation is shown as bright pixel, therefore selects T_yh=Mean_yh(x,y)+γ_yh·σ_yh(x, y) for segmentation threshold Value, γ_yhStandard deviation weight for impression defect；Go out Blob connected domain by eight connectivity area identification, be designated as Bl_yh；

2) pixel counts method is utilized to extract Bl_yhElemental area feature Area of connected domain_yhWith rectangular degree feature Rectan_yh, rectangle Degree is to describe to be extracted the region full level to its boundary rectangle, and computing formula isWherein S_mFor quilt Extract the area of region circumscribed rectangular region；Bl is judged according to formula 9_yhWhether it is impression defect:

In formula, area judgment threshold Th_yh1Being determined by formula 3, wherein the span of φ is [0.0160,0.0170]；Rectangular degree is sentenced Disconnected threshold value Th_yh2Span be [0.7,1]；∩ represents logic "and" operation；

5. bubble detection:

1) by fast fourier transform, image function is changed to frequency domain from transform of spatial domain, use the smooth figure of low pass filter Picture, then by inverse fourier transform by image from frequency domain transformation to spatial domain；According to image grey level histogram, choose trough ash Angle value is the Blob candidate blocks that the segmentation of segmentation threshold segmentation object is bubbled, and goes out Blob connected domain by eight connectivity area identification, note For Bl_qp；

2) pixel counts method is utilized to extract Bl_qpElemental area feature Area of connected domain_qpAnd the round degree of characteristicsRoot Bl is judged according to formula 10_qpWhether it is Blister:

In formula, area judgment threshold Th_qp1Being determined by formula 3, wherein the span of φ is [0.0123,0.0124]；Circularity judges Threshold value Th_qp2Span be [0.5,1]；∩ represents logic "and" operation.