CN107632025B - Curved surface high-precision imaging system - Google Patents
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Abstract
The invention relates to a curved surface high-precision imaging system, wherein a motion platform moves to an imaging point of a camera with a product, and the motion trail is confirmed to ensure that each point of the edge of the product can be located on a picture acquisition point of the camera when the product moves; the linear array camera uses external synchronization external triggering to acquire images, and in the motion process, the motion control module can equidistantly pulse the camera, and the distance of each pulse product is equal; when the product moves to a designated image acquisition point, a trigger image acquisition signal is given to the camera, the camera starts to acquire images according to the received pulse, and after the product moves completely, the image acquisition is finished, and a complete image is output; and then outputting the processing result of the image by using an algorithm. The linear array camera and the three-axis linkage high-precision interpolation motion are used for simplifying the problem of an imaging system of the arc surface, effectively shortening the time for detecting the product and greatly helping the imaging and the detection of the product with the related arc surface.
Description
Technical Field
The invention relates to the technical field of curved surface imaging and image processing, in particular to a curved surface high-precision imaging system.
Background
Aiming at appearance detection of curved surface products, as the motion control difficulty is high and the imaging difficulty is high, no good solution is available at present for processing curved surface imaging; the conventional method adopts an area-array camera, but the area-array camera is particularly complicated for imaging a curved surface, the area-array camera needs to shoot for 3 times to shoot a full curved surface, and the area-array camera needs a large visual field, so that an imaging system is complex, and the high-precision detection requirement cannot be met; particularly, when shooting is performed at the R angle, the imaging effect is poor due to the fact that the area array camera is used for shooting for many times, the CT time is long, and the image processing time is long due to the fact that the four straight sides and the four R angles are complex and complicated imaging schemes; if the detection conditions for detecting all defects of the appearance are required to be met, a large installation space is required according to the area array scheme, and the difficulty of shooting matching between cameras is also high; the cost is high if a high-precision imaging system is used; and cannot shoot at multiple angles.
Disclosure of Invention
The invention aims to solve the technical problems that: the curved surface high-precision imaging system solves the problems that in the prior art, the imaging precision of an area array camera is low, the shooting times are more, the detection time is longer, the installation space of a light source camera is larger, and the like.
The technical scheme adopted by the invention is as follows: a curved surface high-precision imaging system comprises a motion platform for carrying objects, an imaging mechanism for shooting products on the motion platform and a motion control system; the motion platform moves to an imaging point of the imaging mechanism with the product, confirms a motion track and ensures that each point of the edge of the product is located on a drawing point of the imaging mechanism during motion; the imaging mechanism adopts external synchronization external triggering to acquire images, and in the motion process, the motion control system can equidistantly pulse the imaging mechanism, and the distance of each pulse is equal; when the product moves to a designated image acquisition point, a trigger image acquisition signal is given to the imaging mechanism, the imaging mechanism starts image acquisition according to the received pulse, and after the image acquisition is finished after the product moves for a complete circle, a complete image is output; and then outputting the processing result of the image by using an algorithm.
Further, the imaging mechanism comprises a linear camera, a telecentric lens and an imaging light source; the motion platform is a three-axis linkage motion platform; including X, Y, R triaxial.
Still further, before the product is detected, the outline CAD drawing of the product is imported into a motion control system; after the motion control system reads the CAD drawing, capturing the data of the outer contour and converting the data into an electronic cam; the motion of the X, Y, R triaxial at each point is controlled according to the electronic cam.
Still further, the product center of the present invention overlaps the center of the R axis and ensures product level.
Still further, the invention also comprises an alignment compensation mechanism; the product moves to an alignment compensation station of the alignment compensation mechanism and is shot by the alignment compensation mechanism; and obtaining the deviation between the product center and the actual rotation center through an algorithm, and giving the deviation value to the PLC for interpolation operation.
Still further, when the image acquisition is completed, the algorithm starts to process the image, and when each product is detected, the algorithm automatically reads the code of the product scan and binds the image and the processing result while processing the image; after all shooting and detection of the product are finished, outputting a product detection result, feeding back the product detection result to the PLC through IO communication, and displaying the product result by the PLC.
Still further, the moving platform of the present invention is a marble moving platform.
Still further, in the motion process of the motion platform, the distance between the imaging point of the 3D surface of the product and the front end surface of the lens is always kept unchanged.
Still further, the imaging light source of the present invention comprises a dome light source, a reflective light source, or a coaxial light source; the number of the two linear array cameras is two, and the two linear array cameras form an included angle.
The beneficial effects of the invention are as follows: the linear array camera and the three-axis linkage high-precision interpolation motion are used for simplifying the problem of an imaging system of the arc surface, effectively shortening the time for detecting the product and greatly helping the imaging and the detection of the product with the related arc surface.
Drawings
The invention will be further described with reference to the drawings and examples.
FIG. 1 is a schematic diagram of the present invention in configuration;
FIG. 2 is a schematic diagram of the structure of the invention in normal detection;
FIG. 3 is a schematic diagram of the linear array shooting station structure of the invention;
FIG. 4 is a schematic illustration of a three-axis linkage structure of the present invention;
FIG. 5 is a schematic diagram of the alignment compensation mechanism of the present invention;
In the figure: 1. a three-axis linkage rotary workbench; 2. an imaging light source; 3. a telecentric lens; 4. a line camera; 5. an area array camera station; 6. an alignment compensation mechanism; 7. an X axis; 8. a Y axis; 9. and an R axis.
Detailed Description
The invention will now be described in further detail with reference to the drawings and a preferred embodiment. The drawings are simplified schematic representations which merely illustrate the basic structure of the invention and therefore show only the structures which are relevant to the invention.
As shown in FIG. 1, the curved surface high-precision imaging system comprises a three-axis linkage rotary workbench, an imaging light source, a telecentric lens, a linear array camera, an area array camera station, a PLC control system, an image processing system and an alignment compensation mechanism.
The motion platform moves to an imaging point of the camera with the product, and confirms the motion trail to ensure that each point of the edge of the product can be located on the drawing point of the camera when the product moves; the linear array camera uses external synchronization external triggering to acquire images, and in the motion process, the motion control module can equidistantly pulse the camera, and the distance of each pulse product is equal. When the product moves to a designated image acquisition point, a trigger image acquisition signal is given to the camera, the camera starts to acquire images according to the received pulse, and after the product moves completely, the image acquisition is finished, and a complete image is output; and then outputting the processing result of the image by using an algorithm.
The three-axis linkage rotary workbench comprises two mutually perpendicular linear motor assemblies capable of being displaced in the horizontal direction and respectively used as an X axis and a Y axis; and a rotating DD motor serving as the R-axis as shown in FIG. 4.
The imaging light source is a double-station or multi-station light source structure driven by a servo motor, namely, two or more imaging light sources can be configured on the structure, and the imaging light source can be switched in real time in the detection process; the light source used in this embodiment is a dome light source, and a reflective light source or a coaxial light source may be used according to other embodiments. Because the product is not only arc-shaped at the R angle, but also curved surface on the surface vertical to the movement direction, if only one camera is used for horizontal shooting, the arc-shaped outline of the product cannot be shot at one time, and taking the point into consideration, the product is shot by adopting a double camera (or a multi-camera) with a fixed included angle and a combined light source, so that the surface of the product can be completely imaged, as shown in figures 1 and 3. The linear array camera at the R angle is matched with interpolation motion and pulse matching at the R angle to shoot the R angle of the product into a plane image, so that the complexity of R angle imaging is reduced.
The telecentric lens and the linear array camera are of a structure with fixed angles, and can shoot the upper arc surface and the lower arc surface of the mobile phone back shell type arc product at the same time.
Area array camera station: the area array camera is horizontally arranged and mainly shoots holes on the frame of the back shell of the mobile phone. The shooting hole sites mainly comprise: the multifunctional hole, the SIM card slot, the locking hole, the sound volume hole and the IO hole are all expected to be shot once, and shooting scheme design can be carried out according to the hole position to be detected of the product; the arc angle can be selectively shot according to the condition of the product so as to meet the detection requirement.
The alignment compensation mechanism is two area array cameras with adjustable intervals, as shown in fig. 5, and is used for shooting the diagonal arc frame of the back shell of the mobile phone, and is only used when acquiring the center of a product and performing track debugging, and is removed after the debugging is completed, as shown in fig. 2. The principle of alignment compensation structure is described as follows: taking the deviation between the rotation center of the product and the actual rotation center of the jig into consideration, a group of positioning stations are used during equipment debugging, and the diagonal position of the product is shot through two area array cameras (the area array cameras are accurately installed through a calibration plate); the initial angle of the product rotation is obtained, the product is rotated 180 degrees after photographing once, the deviation between the center of the product and the actual rotation center is obtained through an algorithm, the deviation value is obtained and is fed to the PLC for interpolation operation, and the running track is more accurate. The mechanism is only used when the product is replaced, and is not used in the normal detection process.
The linear motion is very simple to realize, the interpolation of X, Y axes is accurately controlled to realize the curvilinear motion consisting of multiple circular arcs, the linear motion is the outer contour of a product curve, each circular arc rotates around the circle center of the circular arc, and therefore the interpolation motion of X, Y motion axes is required to ensure that the rotation center of each circular arc is accurate. The X, Y linear shaft ensures the accuracy of the rotation center, and simultaneously the DD motor is matched with the rotation to complete the curve motion.
Because the high-precision imaging system has high requirements on the accuracy of the motion platform and the motion trail, how to realize the accuracy of the motion trail and meet the stable motion condition is a great technical difficulty; the following solutions are given for the above technical difficulties: in order to complete accurate motion trail, PLC motion control is selected, CAD (computer aided design) drawing of the outer contour (drawing trail required to move) of the product is imported into the PLC by adopting a CAD importing function, the system automatically generates the motion trail, realizes trail by controlling a servo motor and a DD motor three-shaft, and completes the outer contour imaging of the whole product by matching with a camera; in order to ensure that imaging can be completely vertical and imaging does not shake, a marble motion platform is adopted, and the machining precision of the mechanism is high; meanwhile, the rigidity of the servo motor is required to be very high, proper rigidity is required to be found in the debugging process, levelness of the machine is required to be ensured before debugging, and requirements on levelness of a jig for placing a product and levelness roughness of a product contact plane are very high. The method is characterized in that when the straight edge enters the circular arc motion, acceleration and deceleration are generated, if an internal synchronous image is adopted by a camera, the phenomenon of stretching is generated, if the image is stretched very little or little, the acceleration is infinite, but the acceleration is practically impossible, in order to reach very large acceleration as much as possible, the mass borne by the motion is reduced (the inertia is reduced), the rigidity and the mass are required to be good for the whole jig and the material of a rotating shaft are small, and the external synchronous working mode (the camera is sent by a fixed pulse with the same distance when the motion is carried out) is adopted for drawing, so that the phenomenon of stretching of the image caused by acceleration and deceleration can be avoided, but the control on pulse signals is accurate, and particularly, stable differential pulse signals are required to be sent at the straight edge and the R angle. In order to avoid shaking caused by rotation at the R angle, a linear guide rail is adopted to enhance the movement stability at the corner.
In order to solve the technical problem of shaking or stretching caused by acceleration and deceleration at the corner, an electronic cam control mode is adopted, the cam mode can output pulses at equal distance, and the pulses are used for drawing a camera line signal, so that the acceleration and deceleration at the corner can not cause image stretching; when the straight line enters the interpolation motion, the uniform rotation is not considered, namely the motion direction is suddenly changed at a certain speed, so that the image has a shaking phenomenon at a corner, in order to solve the shaking of the straight line entering an R angle, the equidistant pulse output of the electronic cam is adopted, the speed of the straight line direction at the corner is reduced by 0 (the motion speed is zero and the shaking is not caused by the sudden change of the motion direction), the interpolation motion in the simulation direction is started at the same time, the simulation interpolation motion speed is zero at the corner from the R angle to the straight line (the R angle enters the straight line motion, the shaking influence is small), and then the straight line motion is entered.
Because the outer contour of the detected product is not only a curved surface (moving direction) at the R angle, but also a curved surface perpendicular to the moving direction, the imaging system is required to have certain difficulty, one camera with larger curved surface radian cannot complete full shooting, and the depth of field requirement of the camera is somewhat high; in order to match with the imaging scheme, the customized light source is adopted, the lighting of a plurality of cameras can be simultaneously met, and the light source is integrated with the two camera designs which are convenient to install and are specially designed for a certain angle.
The multi-station imaging system uses a plurality of light sources to image various defects, the imaging can be realized by only switching the light sources, the camera is switched to the next light source after the image acquisition is completed by matching one light source, so as to avoid the interference of each light source, the light source of the station is automatically lightened when the light source is switched to one light source, and other light sources are automatically turned off.
The method comprises the following specific steps:
1. Before detecting a product, the outline CAD drawing of the product is imported into a motion control system. After the motion control system reads the CAD drawing, the motion control system grabs the data of the outer contour and converts the data into an electronic cam. And controlling the motion of the XYR triaxial at each point according to the electronic cam.
2. After the data is imported, normal detection can be performed. The product is scanned and coded before detection, then the product is placed on a detection carrier, the product is fixed by a positioning mechanism on the carrier, the center of the product is ensured to be overlapped with the center of the R shaft, and the product level is ensured.
3. The product moves to the alignment compensation station and is shot by the alignment compensation mechanism. And obtaining the deviation between the product center and the actual rotation center through an algorithm, and giving the deviation value to the PLC for interpolation operation.
4. The product removes to detecting the station, and the dome light source lights, and the product reaches suitable position (the motor can send pulse signal always when the motion), and voltage trigger (two cameras trigger simultaneously) of a 24V rising edge is given to the acquisition card to the PLC, and the linear array camera begins to adopt the picture (the product moves the orbit under the drive of work tool), and the tool moves to the avoiding position after accomplishing to adopt the picture, and the light source switches, and when switching, the dome light source is closed, and the profile modeling light source lights (the light source only lights when working), and the product moves according to the angle of debugging after switching and cooperates the camera to adopt the picture.
5. In any one process of the linear array shooting, the area array station can snapshot the frame or the arc surface of the back shell of the mobile phone.
6. When each station finishes drawing, the algorithm starts to process the image, and when each product is detected, the algorithm automatically reads the code of the product sweep and binds the image and the processing result while processing the image; after the product is shot and detected by all work stations, the product detection result is output and fed back to the PLC through IO communication, the PLC can display the result display of OK (green light) and NG (red light) of the product (or inform the manipulator to perform OK and NG classification operations).
The three-axis linkage rotary workbench can realize high-precision interpolation motion in the process of rotation or horizontal movement, so that the distance between a 3D surface imaging point and the front end surface of the lens is kept unchanged all the time; under the condition that the angles of the camera and the light source are unchanged all the time, the illumination angle and the imaging angle are ensured to be unchanged in the differential compensation process; the imaging scheme of the external synchronization of the linear array camera can realize the image acquisition of high-speed and variable-speed motion and has high-precision imaging resolution; the multiple cameras are matched with the customized special light source at an angle to shoot the arc surface, so that the imaging of the arc surface can be completed at one time.
The imaging system of the linear array camera has high resolution, the maximum acquisition line frequency can reach 40k, high-speed acquisition can be realized, and imaging of products can be completed at one time; the cost is far lower than that of a high-precision area array imaging system.
In carrying out the cell-phone back shell detection project, the circular arc face that runs into when carrying out imaging test to the 3D face formation of image problem, imaging through two linear array cameras formation of angle, then satisfy the requirement of polishing of two linear array cameras simultaneously through customizing special light source. Therefore, the complex imaging mode is simplified, the installation space of hardware is reduced, the higher resolution requirement can be achieved, and the CT is greatly improved.
The linear array camera is used, the target surface is larger, and the precision is high; the linear array camera is matched with the triaxial linkage high-precision interpolation motion platform at a certain angle to carry out motion shooting and one-time imaging on the product, so that the problem of multiple shooting of the multi-position area array camera is solved; the highest line frequency of the linear array camera matched with the high-speed acquisition card can reach 40K, so that the CT length problem is solved; the two linear array cameras and the customized light source can meet the detection requirement, and can replace a plurality of area array cameras and area array light sources, so that the system and the hardware installation space are simplified. Aiming at the arc surface included at the R angle (the arc surface perpendicular to the moving direction), the linear array camera is relatively simple and quite easy to meet the illumination condition, and the illumination detection of the linear array camera can be met as long as the illumination uniformity of the line illuminated by the pixel target surface is met; the linear array camera can easily adjust the imaging angle, change the imaging effect and meet the detection of various types of defects; the method can complete the outer contour shooting of one product at a time, and the scanning is combined into one image so as to facilitate the algorithm processing.
The linear array imaging scheme has more polishing imaging modes and more polishing imaging solutions for the diversity of appearance detection defects.
The foregoing description is merely illustrative of specific embodiments of the invention, and the invention is not limited to the details shown, since modifications and variations of the foregoing embodiments may be made by those skilled in the art without departing from the spirit and scope of the invention.
Claims (3)
1. A curved surface high-precision imaging system is characterized in that: the device comprises a motion platform for carrying objects, an imaging mechanism for shooting products on the motion platform and a motion control system; the motion platform moves to an imaging point of the imaging mechanism with the product, confirms a motion track and ensures that each point of the edge of the product is located on a drawing point of the imaging mechanism during motion; the imaging mechanism adopts external synchronization external triggering to acquire images, and in the motion process, the motion control system can equidistantly pulse the imaging mechanism, and the distance of each pulse is equal; when the product moves to a designated image acquisition point, a trigger image acquisition signal is given to the imaging mechanism, the imaging mechanism starts image acquisition according to the received pulse, and after the image acquisition is finished after the product moves for a complete circle, a complete image is output; then outputting the processing result of the image by using an algorithm;
the device also comprises an alignment compensation mechanism; the product moves to an alignment compensation station of the alignment compensation mechanism and is shot by the alignment compensation mechanism; obtaining the deviation between the product center and the actual rotation center through an algorithm, and giving the deviation value to the PLC for interpolation operation;
The imaging mechanism comprises a linear array camera, a telecentric lens and an imaging light source; the motion platform is a three-axis linkage motion platform; comprises X, Y, R three axes; the imaging light source comprises a dome light source, a reflecting light source or a coaxial light source; the number of the linear array cameras is two, and the two linear array cameras form an included angle;
The imaging process is as follows:
s1, before detecting a product, importing a CAD drawing of the outline of the product into a motion control system; after the motion control system reads the CAD drawing, capturing the data of the outer contour and converting the data into an electronic cam; controlling the motion of the XYR triaxial at each point position according to the electronic cam;
S2, after data import is completed, normal detection is carried out; the product is scanned, identified and recorded before detection, then the product is placed on a detection carrier, and the product is fixed by a positioning mechanism on the carrier, so that the center of the product is ensured to be overlapped with the center of an R axis, and the product level is ensured;
s3, the product moves to an alignment compensation station and is shot by an alignment compensation mechanism; obtaining the deviation between the product center and the actual rotation center through an algorithm, and giving the deviation value to the PLC for interpolation operation;
S4, the product moves to a detection station, a dome light source is lightened, the product reaches a proper position, a motor always sends out pulse signals when in motion, a 24V rising edge voltage trigger is given to an acquisition card by a PLC, and two cameras are triggered simultaneously; the linear array camera starts to acquire the image, the product moves along the track under the drive of the working jig, the jig is retracted after the image acquisition is completed, the light source is switched, the dome light source is turned off while the light source is switched, the profiling light source is turned on when the light source only works, and the product moves according to the adjusted angle to match with the camera to acquire the image after the switching is completed;
S5, in the process of shooting the linear array at any time, the area array station captures the frame or the arc surface of the back shell of the mobile phone;
S6, when each station finishes drawing, the algorithm starts to process the image, and when each product is detected, the algorithm automatically reads the code of the product sweep and binds the image and the processing result while processing the image; after the product is shot and detected at all stations, outputting a product detection result, and feeding back to the PLC through IO communication, wherein the PLC displays an OK/NG result of the product or informs the manipulator to perform OK/NG classification operation.
2. The curved surface high-precision imaging system according to claim 1, wherein: the motion platform is a marble motion platform.
3. The curved surface high-precision imaging system according to claim 1, wherein: in the motion process of the motion platform, the distance between the imaging point of the 3D surface of the product and the front end surface of the lens is always kept unchanged.
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| CN109379506B (en) * | 2018-09-28 | 2020-03-27 | 深圳市盛世生物医疗科技有限公司 | Linear array camera trigger timing synchronization method, device, equipment and storage medium |
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| CN110018178B (en) * | 2019-04-28 | 2024-06-07 | 华南理工大学 | Device and method for detecting typical defects of curved glass of mobile phone on line |
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| CN110726379B (en) * | 2019-11-13 | 2021-04-23 | 征图新视(江苏)科技股份有限公司 | High-precision imaging method for irregular product contour |
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| CN106272487A (en) * | 2015-06-03 | 2017-01-04 | 广明光电股份有限公司 | Robotic arm stage moving method |
| CN105181601A (en) * | 2015-09-02 | 2015-12-23 | 哈尔滨工业大学 | Fine-tunable microscopic detection apparatus for large-aperture curved surface optical element micro-defect restoration |
| CN207215727U (en) * | 2017-09-21 | 2018-04-10 | 征图新视（江苏）科技有限公司 | A kind of curved surface high accuracy imaging system |
| CN109682826A (en) * | 2019-01-17 | 2019-04-26 | 东莞市三姆森光电科技有限公司 | NI Vision Builder for Automated Inspection and detection method for the detection of cambered surface appearance |
| CN110726379A (en) * | 2019-11-13 | 2020-01-24 | 征图新视(江苏)科技股份有限公司 | High-precision imaging method for irregular product contour |
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