CN107657641B - Intelligent stone cutting method based on machine vision - Google Patents
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- 239000004575 stone Substances 0.000 title claims abstract description 122
- 238000005520 cutting process Methods 0.000 title claims abstract description 107
- 238000000034 method Methods 0.000 title claims abstract description 38
- 238000012545 processing Methods 0.000 claims abstract description 29
- 238000012937 correction Methods 0.000 claims description 11
- 239000000463 material Substances 0.000 claims description 11
- 238000000605 extraction Methods 0.000 claims description 8
- 238000012163 sequencing technique Methods 0.000 claims description 8
- 239000011159 matrix material Substances 0.000 claims description 6
- 238000004458 analytical method Methods 0.000 claims description 4
- 238000006243 chemical reaction Methods 0.000 claims description 4
- 238000003384 imaging method Methods 0.000 claims description 4
- 238000012706 support-vector machine Methods 0.000 claims description 4
- 239000000203 mixture Substances 0.000 claims description 3
- 230000007547 defect Effects 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 230000001502 supplementing effect Effects 0.000 description 2
- 230000009466 transformation Effects 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
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- 238000004806 packaging method and process Methods 0.000 description 1
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T5/00—Image enhancement or restoration
- G06T5/80—Geometric correction
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28D—WORKING STONE OR STONE-LIKE MATERIALS
- B28D1/00—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor
- B28D1/22—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor by cutting, e.g. incising
- B28D1/24—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor by cutting, e.g. incising with cutting discs
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T2207/00—Indexing scheme for image analysis or image enhancement
- G06T2207/10—Image acquisition modality
- G06T2207/10004—Still image; Photographic image
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T2207/00—Indexing scheme for image analysis or image enhancement
- G06T2207/30—Subject of image; Context of image processing
- G06T2207/30108—Industrial image inspection
- G06T2207/30132—Masonry; Concrete
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Abstract
The invention relates to an intelligent stone cutting method based on machine vision, which comprises the following steps: (1) calibrating an industrial camera; (2) analyzing the order; (3) acquiring an image; (4) extracting the stone profile; (5) typesetting and cutting; (6) and carrying out real-time statistics on processing information. The method can effectively replace a series of procedures of manually checking orders, manually measuring stone slabs, manually making typesetting and cutting schemes, manually cutting the stones, manually counting processing information and the like in the traditional stone cutting process, and really realizes intelligent, efficient, stable and reliable automatic stone cutting.
Description
Technical Field
The invention belongs to the technical field of stone cutting, relates to a stone cutting method, and particularly relates to an intelligent stone cutting method based on machine vision.
Background
In the use process of the stone, the stone needs to be cut so as to meet different requirements of shape, size and the like. However, at present, before the stone is cut by the stone cutting machine, the dimension of the stone needs to be manually measured, and then the typesetting scheme and the cutting scheme are manually established according to the actual processing requirements, so as to ensure the high utilization rate of the whole stone. In the process, time and labor are wasted, the precision is low, and human errors are easy to occur, so that the typesetting and cutting scheme cannot be optimal frequently.
In view of the above technical defects in the prior art, it is urgently needed to develop a novel stone cutting method.
Disclosure of Invention
The invention aims to overcome the defects in the prior art, and provides an intelligent stone cutting method based on machine vision, which can effectively replace a series of procedures of traditional stone cutting, such as manual order checking, manual stone plate measuring, manual typesetting and cutting scheme making, manual tool setting and cutting, manual processing information statistics and the like, and really realizes intelligent, efficient, stable and reliable automatic stone cutting.
In order to achieve the above purpose, the invention provides the following technical scheme: an intelligent stone cutting method based on machine vision is characterized by comprising the following steps:
(1) calibrating an industrial camera: the method comprises the steps that a calibration plate is placed on a working base table, an industrial control computer sends an instruction to a PLC (programmable logic controller), a cutting machine is driven to move under the control of the PLC, an industrial camera fixed on the cutting machine moves to the position right above the working base table, an image of the calibration plate is shot, distortion correction is carried out, a distortion coefficient is obtained, then a front view of the calibration plate is obtained, a conversion matrix of the front view is obtained, and then calibration parameters are stored;
(2) and order analysis: classifying and sequencing the stones involved in the order to be processed; setting a feeding sequence and a processing sequence of the stones involved in the order according to the sequencing result;
(3) and acquiring an image: the industrial control computer sends an instruction to enable the cutting machine to drive the industrial camera to move to the position right above the working base table under the control of the PLC, and images of the working base table when no stone is placed are shot; then, placing the stone to be processed on the working base table, and shooting the image again; finally, distortion correction is carried out on the images shot twice, and the front views of the working base platform without the stone and the front views of the working base platform with the stone are respectively obtained;
(4) and extracting the stone profile: firstly, preliminarily acquiring the outline of the stone according to the front view of the working base table when the stone is not placed and placed; then, further obtaining a high-accuracy profile of the stone; finally, manually correcting the profile of the stone according to the requirement;
(5) and typesetting and cutting: firstly, calculating the maximum inscribed rectangle of the outline of the stone material, and determining a typesetting area; then, based on the typesetting area and the processing order, a typesetting scheme capable of completing one cutting is formulated, and a cutting path is planned; finally, the industrial control computer sends a cutting path to the PLC, and the PLC controls the cutting machine to cut the stone;
(6) and processing information real-time statistics: in the cutting process, the orders which are cut completely and the processing quantity of the orders are counted, and the states of the orders are updated in real time.
Further, the calibration board used in the calibration of the industrial camera is a checkerboard calibration board with high precision and large picture size, distortion correction is performed by using a fish-eye lens imaging model in the calibration process of the industrial camera, a distortion coefficient is obtained, a front view of the calibration board is obtained by using a perspective projection method, a conversion matrix of the front view is obtained, and then calibration parameters are stored.
Further wherein the order is parsed as: the method comprises the steps of classifying orders according to stone materials and thicknesses of stones involved in the orders, sorting the orders in the same class in a descending order according to the size of the area of the single body, and setting a feeding order and a processing order of the stones involved in the orders according to a sorting result.
Still further, wherein the contour extraction is: firstly, modeling a background based on a Gaussian mixture model, and preliminarily obtaining a stone profile; then, further acquiring the high-accuracy contour of the stone by adopting a contour extraction algorithm based on a support vector machine; and finally, manually correcting the profile of the stone according to the requirement.
The cutting system adopted by the intelligent stone cutting method based on machine vision comprises a working base table, an industrial control computer and a PLC (programmable logic controller), wherein a stone plate to be cut is placed on the working base table, two sides of the working base table are respectively provided with a cutting machine edge beam, each cutting machine edge beam is provided with a cross beam guide rail, two cross beam guide rails are provided with a cross beam, each cross beam is provided with a longitudinal beam, each longitudinal beam is provided with a feeding sucker manipulator and a cutting machine, the upper end of each cutting machine is provided with a support, each support is provided with a light source and an industrial camera, each industrial camera is connected with the industrial control computer, the industrial control computer is connected with the PLC, and the PLC is connected with a driver of the cutting machine.
Compared with the existing stone cutting method, the intelligent stone cutting method based on machine vision has the following beneficial technical effects:
1. the stone material order processing system can pour the order into the cutting system and automatically analyze order data, and determines the feeding sequence and the order processing sequence of the stone material according to the analysis result without manual intervention.
2. The intelligent high-precision contour recognition technology is adopted, and the problem of high-precision extraction of the stone slab contour under the complex background is successfully solved.
3. On the basis of finishing the extraction of the stone outline, the method successfully replaces the manual calculation of the typesetting area, the manual typesetting and the manual cutting, and realizes the comprehensive intelligent and automatic cutting.
4. The cutting information can be counted in real time, the order can be updated in real time, and a foundation is laid for automatic packaging and distribution in the future and realization of comprehensive automation of the whole production line.
5. It can reduce the cost of labor, improves the stone material utilization ratio, improves cutting efficiency to possess the processing information function of traceing back.
Drawings
Fig. 1 is a schematic view of a cutting system used in the intelligent stone cutting method based on machine vision according to the present invention.
Fig. 2 is a schematic flow chart of the intelligent stone cutting method based on machine vision according to the present invention.
Detailed Description
The present invention is further described with reference to the following drawings and examples, which are not intended to limit the scope of the present invention.
Before the intelligent stone cutting method based on machine vision of the invention is introduced, a cutting system used by the method is introduced.
Fig. 1 is a schematic view showing a cutting system used in the intelligent stone cutting method based on machine vision according to the present invention. As shown in fig. 1, the intelligent stone cutting system based on machine vision of the present invention comprises a work base 1, an industrial control computer 12 and a PLC controller 13. Wherein, the stone 2 to be cut can be placed on the working bottom table 1. Preferably, the work base table 1 is formed by splicing wooden boards.
And two sides of the working base table 1 are respectively provided with a cutting machine edge beam 3. Each cutting machine edge beam 3 is provided with a beam guide rail 4. And a cross beam 5 is arranged on the two cross beam guide rails 4. The cross beam 5 can move back and forth along the cross beam guide 4.
The beam 5 is provided with a longitudinal beam 6. The longitudinal beams 6 can be moved to the left and right along the cross beams 5.
And a feeding sucker manipulator 7 and a cutting machine 8 are arranged on the longitudinal beam 6. The feeding sucker manipulator 7 is used for sucking the stone to realize the movement of the stone. The cutting machine 8 is used for cutting stone. Preferably, the lower end of the cutting machine 8 is provided with a disc cutter, by which the cutting of the stone 2 to be cut is achieved. The cutter 8 can move up and down along the longitudinal beam 6. In this way, the cutting machine 8 can move back and forth, right and left, and up and down with respect to the stone 2 to be cut placed on the work bed 1.
In addition, the upper end of the cutter 8 is provided with a bracket 9. The bracket 9 is provided with a light source 10 and an industrial camera 11. The industrial camera 11 is used to acquire images of the cutting area. Preferably, the industrial camera 11 is equipped with a wide-angle lens. The light source 10 is used for supplementing light to a shooting area to reduce the influence of ambient light on shooting, so as to obtain a high-quality image. Preferably, the light source 10 is an LED light source.
The industrial camera 11 is connected with the industrial personal computer 12, so that the obtained high-quality pictures can be transmitted to the industrial personal computer 12, and the industrial personal computer 12 plans a cutting path according to the pictures. The industrial control computer 12 is connected with the PLC controller 13 to transmit a planned cutting path instruction to the PLC controller 13. In addition, the processing order data can be imported into the industrial computer 12 through a usb disk, a network, or the like. The PLC controller 13 is connected to the driver of the cutting machine 8 to control the driver of the cutting machine 8 according to an instruction from the industrial control computer 12, thereby achieving cutting.
Preferably, the cross beam 5 is provided with a transverse driver for driving the cross beam 5 to move back and forth along the cross beam guide rail 4. And a longitudinal driver for driving the longitudinal beam 6 to move left and right along the cross beam 5 is arranged on the longitudinal beam 6. And an up-and-down driver for driving the cutting machine 8 to move up and down along the longitudinal beam 6 is arranged on the cutting machine 8. And, the lateral driver, the longitudinal driver, and the up-down driver are connected to the PLC controller 13. In this way, the PLC controller 13 can drive the horizontal driver, the vertical driver, and the up-down driver according to instructions from the industrial control computer 12, thereby driving the cutting machine 8 to a proper cutting position to achieve a proper cutting.
Fig. 2 shows a flow chart of the intelligent stone cutting method based on machine vision of the present invention. As shown in fig. 2, the intelligent stone cutting method based on machine vision of the present invention comprises the following steps:
firstly, calibrating an industrial camera.
Before cutting, an industrial camera calibration is first performed to make the acquired picture more standard. In the invention, when the industrial camera is calibrated, a calibration plate is horizontally placed on the working base table 1, then the industrial control computer 12 sends an instruction to the PLC 13, the cutting machine 8 is driven to move under the control of the PLC 13, the industrial camera 11 fixed on the cutting machine 8 moves to the position right above the working base table 1, and the image of the calibration plate is shot. And then, carrying out distortion correction on the image of the calibration plate to obtain a distortion coefficient. Then, a front view of the calibration plate is acquired and a transformation matrix of the front view is acquired. And finally, storing the calibration parameters.
In the present invention, preferably, the calibration board is a checkerboard calibration board with high precision and large format. And, shooting the image of the calibration plate includes acquiring the angular point image coordinates and angular point physical coordinates of the calibration plate, and calibrating the industrial camera 11 based on the angular point image coordinates and the angular point physical coordinates of the calibration plate. Of course, in order to obtain accurate calibration parameters, during the calibration process of the industrial camera, the fisheye lens imaging model may be used to perform distortion correction on the image of the calibration plate, obtain a distortion coefficient, and obtain a front view of the calibration plate and obtain a transformation matrix of the front view by using a perspective projection method. And then, obtaining accurate calibration parameters and storing the calibration parameters.
Secondly, order analysis.
The order to be processed can be poured into the industrial personal computer 12 through a USB flash disk or a network, and the stone involved in the order to be processed is classified and sequenced by the industrial personal computer 12; and setting the loading sequence and the processing sequence of the stones involved in the order according to the sequencing result.
In the present invention, preferably, in the order parsing process, first, the order is classified according to the stone material and the thickness of the stone material involved in the order. Then, the orders in the same class are sorted in descending order according to the size of the single area. And finally, setting the loading sequence and the processing sequence of the stones involved in the order according to the sequencing result.
And thirdly, acquiring an image.
The industrial control computer 12 sends an instruction to make the cutting machine 8 drive the industrial camera 11 to move to the position right above the working base table 1 under the control of the PLC controller 13, and first, images of the working base table 1 when no stone 2 is placed are shot. Then, the stone 2 to be processed is placed on the work base 1, and an image is photographed again. And finally, carrying out distortion correction on the images shot twice, and respectively obtaining the front views of the working base table 1 when the stone 2 is not placed and the stone 2 is placed.
In the invention, distortion correction can be carried out on the images shot twice by using a fisheye lens imaging model to obtain a distortion coefficient. In addition, the front view of the work base 1 without the stone 2 and with the stone 2 can also be obtained by a perspective projection method.
And fourthly, extracting the stone profile.
First, the profile of the stone 2 is preliminarily obtained based on the front view of the work bed 1 when the stone 2 is not placed and when the stone 2 is placed. Then, a high accuracy profile of the stone material 2 is further obtained. Finally, the profile of the stone 2 can be manually corrected as required.
In the present invention, preferably, the background is modeled based on a gaussian mixture model according to the front view of the work bed 1 without placing the stone 2 and with placing the stone 2, and the stone profile is preliminarily obtained. And preferably, a contour extraction algorithm based on a support vector machine is adopted to further obtain the high-accuracy contour of the stone. Finally, the profile of the stone 2 can be manually corrected as required. So as to obtain a precise profile of said stone 2.
Fifthly, typesetting and cutting.
Firstly, under the condition of considering the thickness of the stone, automatic plane measurement is carried out, the maximum inscribed rectangle of the outline of the stone 2 is calculated, and the typesetting area is determined. Then, based on the typesetting area and the processing order, a typesetting scheme capable of completing one cutting is formulated, and a cutting path is planned. Finally, the industrial control computer 12 sends a cutting path to the PLC controller 13, and the PLC controller 13 controls the cutting machine 8 to cut the stone 2.
In the invention, preferably, when the layout scheme is planned, different layout algorithms can be selected to make a layout scheme capable of finishing one cutting according to whether the stone slab has a pattern trend and whether a bad area, and an optimal cutting path is planned.
And sixthly, counting the processing information in real time.
In the cutting process, the orders which are cut completely and the processing quantity of the orders are counted, and the states of the orders are updated in real time. Meanwhile, the processing data can be recorded, so that a user can trace back the historical processing data.
According to the intelligent stone cutting method based on machine vision, the industrial camera provided with the wide-angle lens is fixed on the cutting machine, and the LED light source is used for supplementing light to a shooting area so as to reduce the influence of ambient light on shooting; the industrial control computer controls the industrial camera to obtain an image of a working base platform without stone, after the stone to be processed is placed on the working base platform, the industrial camera shoots the image again, distortion correction is carried out on the shot image to obtain an orthographic image of the working base platform area, then modeling is carried out on a background to preliminarily obtain a stone profile, and then the high-accuracy stone profile is further obtained based on a profile extraction algorithm of a support vector machine; calculating the maximum inscribed rectangle of the stone outline and determining a typesetting area; based on the typesetting area and the processing order, a scheme of intelligent typesetting capable of completing one-time cutting is formulated, and an optimal cutting path is planned; the computer sends a cutting path to the PLC control system, and the PLC control system controls the cutting machine to cut the stone; in the cutting process, the orders which are cut completely and the processing quantity of the orders are counted, the order states are updated in real time, and after cutting is completed, the processing information is counted and recorded so as to prepare for the user to trace back historical processing information. Therefore, the intelligent stone cutting method based on machine vision can finish stone contour recognition, high-precision automatic measurement, intelligent typesetting, automatic cutting and cutting information statistics based on machine vision, and intelligent and automatic stone cutting is realized.
The above examples of the present invention are merely examples for clearly illustrating the present invention and are not intended to limit the embodiments of the present invention. Other variations and modifications will be apparent to persons skilled in the art in light of the above description. Not all embodiments are exhaustive. All obvious changes and modifications which are obvious to the technical scheme of the invention are covered by the protection scope of the invention.
Claims (1)
1. An intelligent stone cutting method based on machine vision is characterized by comprising the following steps:
(1) calibrating an industrial camera: the method comprises the steps that a calibration plate is horizontally placed on a working base table (1), an industrial control computer (12) sends an instruction to a PLC (programmable logic controller) (13), a cutting machine (8) is driven to move under the control of the PLC (13), an industrial camera (11) fixed on the cutting machine (8) moves to the position right above the working base table (1), an image of the calibration plate is shot, distortion correction is carried out, a distortion coefficient is obtained, then a front view of the calibration plate is obtained, a conversion matrix of the front view is obtained, and calibration parameters are stored;
(2) and order analysis: classifying and sequencing the stones involved in the order to be processed; setting a feeding sequence and a processing sequence of the stones involved in the order according to the sequencing result;
(3) and acquiring an image: the industrial control computer (12) sends an instruction, so that the cutting machine (8) drives the industrial camera (11) to move to the position right above the working base table (1) under the control of the PLC (13), and images of the working base table (1) when the stone (2) is not placed are shot; then, the stone (2) to be processed is placed on the working base table (1), and an image is shot again; finally, distortion correction is carried out on the images shot twice, and the front views of the working base table (1) without the stone (2) and when the stone (2) is placed are respectively obtained;
(4) and extracting the stone profile: firstly, preliminarily acquiring the outline of the stone (2) according to the front view of the working base table (1) when the stone (2) is not placed and the stone (2) is placed; then, further obtaining a high-accuracy profile of the stone material (2); finally, manually correcting the profile of the stone (2) according to the requirement;
(5) and typesetting and cutting: firstly, calculating the maximum inscribed rectangle of the outline of the stone (2) and determining a typesetting area; then, based on the typesetting area and the processing order, a typesetting scheme capable of completing one cutting is formulated, and a cutting path is planned; finally, the industrial control computer (12) sends a cutting path to the PLC controller (13), and the PLC controller (13) controls the cutting machine (8) to cut the stone (2);
(6) and processing information real-time statistics: in the cutting process, counting the cut orders and the processing quantity thereof, and updating the states of the orders in real time;
the calibration plate used in the calibration of the industrial camera is a chessboard calibration plate with high precision and large picture width, distortion correction is carried out by using a fisheye lens imaging model in the calibration process of the industrial camera to obtain a distortion coefficient, a front view of the calibration plate is obtained by using a perspective projection method, a conversion matrix of the front view is obtained, and then calibration parameters are stored;
the order is analyzed as follows: classifying the orders according to the stone materials and the thicknesses of the stones involved in the orders, sequencing the orders in the same class in a descending order according to the size of the area of the single body, and setting the feeding sequence and the processing sequence of the stones involved in the orders according to the sequencing result;
the contour extraction is: firstly, modeling a background based on a Gaussian mixture model, and preliminarily obtaining a stone profile; then, further acquiring the high-accuracy contour of the stone by adopting a contour extraction algorithm based on a support vector machine; finally, the profile of the stone material (2) is manually corrected as required.
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| "石材桥式切机优化排样及加工系统研究";秦自放;《中国优秀硕士学位论文全文数据库 工程科技Ⅱ辑》;20160515;第C038-517 * |
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