CN108760765B - Side-view camera shooting-based surface damage defect detection device and method - Google Patents
Side-view camera shooting-based surface damage defect detection device and method Download PDFInfo
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- CN108760765B CN108760765B CN201810507932.3A CN201810507932A CN108760765B CN 108760765 B CN108760765 B CN 108760765B CN 201810507932 A CN201810507932 A CN 201810507932A CN 108760765 B CN108760765 B CN 108760765B
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- G01—MEASURING; TESTING
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Abstract
The invention belongs to the technical field of automatic defect detection of panels, and discloses a surface damage defect detection device and method based on side-view camera shooting, which comprises a camera, a strip-shaped light source, a position adjusting mechanism and a central controller, wherein the camera is used for shooting a plurality of side-view cameras; the camera and the position adjusting mechanism are connected with the central controller through a control cable; the strip-shaped light source and the camera are arranged on the position adjusting mechanism positioned on one side of the display screen to be detected; the camera and the bar-shaped light source are positioned on the same side of the display screen, and a set shooting angle is formed between the camera and the display screen; the invention adopts a strip light source as a light source, and arranges the shooting camera and the strip light source at the same side of the display screen, thereby avoiding the condition of uneven shooting pictures of the camera caused by a plurality of light sources, enabling the defects to be imaged on the shooting pictures of the camera with higher contrast ratio, and improving the accuracy of defect detection.
Description
Technical Field
The invention belongs to the technical field of automatic defect detection of panels, and particularly relates to a side-view camera shooting-based surface damage defect detection device and method.
Background
The production process of the novel display screen such as the LCD/OLED comprises nearly hundreds of working procedures, and although most of the working procedures of the display screen are finished in a dust-free room, various defects such as cracks, scratches, surface dirt, bubbles, surface particles and the like are inevitable; the defects can seriously affect the display performance of the display screen, so that the defect detection is required before delivery;
in the current detection method, Automatic Optical Inspection (AOI) is mostly adopted, and an optical imaging technology (usually using a camera and a lens) is adopted to obtain an image of a detected object, and then a certain image processing algorithm is used to obtain a defect position from the shot image.
Fig. 1 shows a defect detection device in the prior art, in which a camera is placed right above a screen and is illuminated by two side light sources, and the light source illumination mode has the following defects:
1. because the camera is arranged right above the display screen, reflected lights of the two side light sources enter the camera, and the difference of the positions, heights and luminous intensities of the left light source and the right light source can cause the non-uniform shooting picture of the camera, thereby affecting the shooting effect and further affecting the accuracy of defect detection;
2. in order to make the brightness of the picture shot by the camera uniform, the positions of the camera and the two side-looking light sources need to be adjusted; at present, manual adjustment is mostly adopted, the precision is not high, and the manpower is wasted; in addition, aiming at display screens with different sizes, the positions and angles of the adaptive camera and the light source are different, and the existing detection device does not automatically adjust the positions of the camera and the light source according to the size of the display screen, so that the imaging effect of some display screens is poor, and the defect detection effect is influenced;
3. on the actual production line, on the premise of meeting the working requirement, the used equipment devices are fewer, the larger the reserved space allowance is, the better the reserved space allowance is, and the installation of other mechanisms is facilitated; because the defect type of the display screen is not only surface damage, but also inaccurate brightness caused by the internal defect of the display panel, the defect needs the front-view camera with other resolution ratios to be placed at the top part for shooting downwards, and therefore, the camera for detecting the surface defect is placed right above the display screen, which is not beneficial to the installation of the camera for detecting the internal defect of the display panel.
Disclosure of Invention
The invention provides a surface damage defect detection device and method based on side-view camera shooting, aiming at solving the problems that the existing surface defect detection device is not high in defect detection accuracy and cannot automatically adjust the positions of a camera and a light source according to the size of a display screen.
To achieve the above object, according to one aspect of the present invention, there is provided a surface damage defect detecting apparatus based on side view camera photographing, including a camera, a bar light source, a position adjusting mechanism, and a central controller; the camera and the position adjusting mechanism are connected with the central controller through control cables;
the strip-shaped light source and the camera are both arranged on the position adjusting mechanism positioned on one side of the display screen to be detected; the camera and the bar-shaped light source are positioned on the same side of the display screen, and a set shooting angle is formed between the camera and the display screen;
the central controller generates position information of a camera according to parameter information of a display screen to be detected and a camera lens, and generates a first adjusting signal according to the position information; the position adjusting mechanism adjusts the position of the camera according to the first adjusting signal so that the position of the camera is matched with the position information generated by the central controller;
the central controller is also used for detecting the brightness uniformity of the surface image of the display screen acquired by the camera, calculating the coordinate information of the area with uneven brightness and generating a second adjusting signal according to the coordinate information; the position adjusting mechanism adjusts the position of the strip-shaped light source according to the second adjusting signal until the brightness of the picture of the image on the surface of the display screen shot by the camera is uniform; and the defect detection module is used for detecting the defects of the surface image of the display screen acquired by the camera to obtain the number of the surface defects and the coordinate positions corresponding to the defects.
Preferably, in the surface damage defect detecting apparatus, the position adjusting mechanism includes a movable displacement table, and a first supporting mechanism and a second supporting mechanism mounted on the movable displacement table;
the movable displacement table controls the first supporting mechanism to move according to a first adjusting signal sent by the central controller so as to adjust the position of a camera arranged on the first supporting mechanism; and the second support mechanism is controlled to move according to a second adjusting signal sent by the central controller so as to adjust the position of the strip-shaped light source arranged on the second support mechanism.
Preferably, the central controller of the surface damage defect detection device comprises a parameter setting unit, a calculating unit, an electric control adjusting unit, an image acquisition unit and an image processing unit;
the parameter setting unit is used for acquiring parameter information of the display screen to be detected and the camera lens, wherein the parameter information comprises the size of the display screen to be detected, the size of a target surface of the camera and the focal length of the camera lens;
the calculation unit is used for calculating the working distance between the camera and the center of the display screen according to the parameter information; the camera is used for calculating the height of the camera and the distance between the camera and the side edge of the display screen according to the working distance and the set shooting angle;
the electronic control adjusting unit is used for generating a first adjusting signal according to the height of the camera and the distance information between the camera and the side edge of the display screen, and the first adjusting signal is used for indicating the position adjusting mechanism to adjust the position of the camera;
the image acquisition unit is used for generating an acquisition signal and acquiring a surface image of a display screen shot by the camera under the instruction of the acquisition signal;
the image processing unit is used for detecting the brightness uniformity of the surface image and judging whether the brightness of the picture is uniform or not; if yes, feeding back correct information to the image acquisition unit; if not, calculating the coordinate information of the area with uneven brightness; generating position adjusting information of the bar-shaped light source according to the coordinate information;
the electronic control adjusting unit is also used for generating a second adjusting signal according to the position adjusting information; the second adjusting signal is used for indicating the position adjusting mechanism to adjust the position of the strip-shaped light source;
the image acquisition unit is also used for controlling the camera to shoot the surface image of the display screen after receiving the correct information fed back by the image processing unit; the image processing unit is also used for detecting the defects of the surface image acquired by the image acquisition unit to obtain the number of the surface defects and the coordinate positions corresponding to the defects.
Preferably, the center controller of the surface damage defect detecting apparatus further includes a display unit configured to visually present the surface image generated by the image processing unit, the number of defects, and coordinate positions corresponding to the defects.
Preferably, the surface damage defect detecting device has a camera angle of more than 30 degrees and less than 45 degrees.
Preferably, the surface damage defect detection apparatus further includes a transmission stage connected to the central controller via a control cable, and the central controller further includes a transmission control unit;
the transmission carrier is used for bearing the display screen to be detected and transmitting the display screen to a specified detection position under the signal control of the transmission control unit.
Preferably, the first support mechanism of the surface damage defect detecting apparatus includes a first support rod vertically disposed on the movable displacement table, and the camera is fixed to a top end of the first support rod.
Preferably, the first supporting mechanism of the surface damage defect detecting device further comprises an angle adjusting adapter and an adapter rod;
one end of the adapter rod is fixed on the first support rod through the angle adjusting adapter piece, and the other end of the adapter rod is used for placing a camera; the angle adjustment adaptor is used for finely adjusting the shooting angle of the camera.
Preferably, the second supporting mechanism of the surface damage defect detecting apparatus includes a second supporting rod, the second supporting rod is vertically disposed on the movable displacement table, and the strip light source is disposed at a top end of the second supporting rod.
According to another aspect of the present invention, there is provided a surface defect detection method based on side view camera photographing, including the steps of:
s1: placing the camera and the strip-shaped light source at the same side of the display screen to be detected;
s2: acquiring parameter information of a display screen to be detected and a camera lens, wherein the parameter information comprises the size of the display screen to be detected, the size of a target surface of the camera and the focal length of the camera lens;
s3: calculating to obtain the working distance between the camera and the center of the display screen according to the parameter information; calculating the height of the camera and the distance between the camera and the side edge of the display screen according to the working distance and the set shooting angle;
s4: generating a first adjusting signal according to the height of the camera and the distance from the side edge of the display screen, and adjusting the position of the camera according to the first adjusting signal so that the real-time position of the camera is matched with the position information in the step S3;
s5: generating a collection signal and acquiring a surface image of a display screen shot by a camera under the indication of the collection signal;
s6: detecting the brightness uniformity of the surface image, and judging whether the brightness of the picture is uniform or not; if yes, generating correct information, and proceeding to step S8; if not, calculating the coordinate information of the area with uneven brightness; generating position adjusting information of the bar-shaped light source according to the coordinate information;
s7: generating a second adjusting signal according to the position adjusting information; adjusting the position of the bar-shaped light source according to the second adjusting signal, and executing the steps S5-S6 until the brightness of the image on the surface of the display screen shot by the camera is uniform;
s8: and acquiring a surface image of the display screen according to the correct information and detecting the defects to obtain the number of the surface defects and the corresponding coordinate position information.
Preferably, the method for detecting surface damage defects further includes the steps of:
s9: visually presenting the surface image, the number of the defects and the coordinate positions corresponding to the defects;
s10: and (5) transferring the next display screen to the designated position, and repeating the steps S2-S9 to detect the defects.
In general, compared with the prior art, the above technical solution contemplated by the present invention can achieve the following beneficial effects:
(1) the invention provides a device and a method for detecting surface damage defects based on side-looking camera shooting, which are based on the characteristics of a strip-shaped light source output light field, adopts a strip-shaped light source as a light source, and arranges a shooting camera and the strip-shaped light source at the same side of a display screen, thereby avoiding the condition of uneven camera shooting pictures caused by a plurality of light sources, enabling the defects to be imaged on the camera shooting pictures with higher contrast, and improving the accuracy of defect detection;
(2) according to the surface damage defect detection device and method based on side-looking camera shooting, the positions of the camera and the light source are automatically adjusted according to the size of the display screen through signal interaction between the central controller and the movable displacement table and the camera, the adjustment precision is higher, manpower resources are saved, the situation that the imaging effect of some display screens is poor and the defect detection effect is affected is avoided, and the detection device can be applied to defect detection of display screens with different sizes;
(3) according to the surface damage defect detection device and method based on side-view camera shooting, more space allowance can be reserved above the display screen, and the device and method are used for erecting other cameras for detecting non-surface damage type defects.
Drawings
FIG. 1 is a schematic structural diagram of a conventional defect detecting apparatus;
FIG. 2 is a schematic structural diagram of a side view camera based surface damage defect detection apparatus and method according to an embodiment of the present invention;
FIG. 3 is a logic block diagram of a central controller provided by an embodiment of the present invention;
FIG. 4 is a schematic optical path diagram for detecting surface scratch-like defects according to an embodiment of the present invention;
FIG. 5 is a schematic diagram of an optical path for detecting surface particle defects according to an embodiment of the present invention;
FIG. 6 is a schematic flowchart of a surface damage defect detection method based on side view camera shooting according to an embodiment of the present invention;
in all the figures, the same reference numerals denote the same features, in particular: the system comprises a camera 1, a strip light source 2, a movable displacement table 3, a first support mechanism 4, a first support rod 41, an angle adjusting adapter 42, an adapter rod 43, a second support mechanism 5, a central controller 6, a display screen 7 and a transmission carrier station 8.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention. In addition, the technical features involved in the embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
FIG. 2 is a schematic structural diagram of a side view camera based surface damage defect detection apparatus and method according to an embodiment of the present invention; as shown in fig. 2, the surface damage defect detecting apparatus includes a camera 1 (with a lens), a bar light source 2, a movable displacement table 3, a first support mechanism 4, a second support mechanism 5, and a central controller 6; the camera 1 and the movable displacement table 3 are both connected with a central controller 6 through control cables;
the movable displacement table 3 is arranged on one side of the display screen 7, and the first supporting mechanism 4 and the second supporting mechanism 5 are both arranged on the movable displacement table 3; the movable displacement table 3 can respectively control the first supporting mechanism 4 and the second supporting mechanism 5 to move according to the adjusting signal sent by the central controller 6;
the camera 1 is arranged on the first supporting mechanism 4, and the height of the camera 1, the shooting angle from the camera 1 to the center of the display screen 7 and the distance between the camera 1 and the side edge of the display screen 7 are adjusted through the first supporting mechanism 4;
the bar-shaped light source 2 is placed on the second supporting mechanism 5, and the distance and the height between the bar-shaped light source 2 and the display screen 7 are adjusted through the second supporting mechanism 5;
fig. 3 is a logic block diagram of the central controller provided in the present embodiment, and as shown in fig. 3, the central controller 6 includes a parameter setting unit, a calculating unit, an electric control adjusting unit, an image capturing unit, an image processing unit, and a display unit;
the parameter setting unit is used for acquiring parameter information of the display screen 7 to be detected and the lens of the camera 1, wherein the parameter information comprises the size of the display screen 7 to be detected, the size of the target surface of the camera 1 and the focal length of the lens;
the calculating unit is used for calculating the working distance between the camera 1 and the center of the display screen 7 according to the parameter information acquired by the parameter setting unit; the calculation formula is as follows:
WD＝f(1+L/l) (1)
wherein: WD is the working distance between the camera 1 and the center of the display screen 7;
f is the focal length of the lens of the camera;
l is the length of the display screen;
l is the camera target surface length;
calculating the height of the camera 1 and the distance between the camera and the side edge of the display screen 7 through a trigonometric function according to the working distance and the set shooting angle; it should be noted here that, in order to ensure that the camera 1 captures the entire image of the display screen 7 to be measured and a margin is left on the edge of the image, the actual working distance of the camera 1 needs to be set to be slightly greater than the calculated working distance, generally, the actual working distance is set to be 1.1 times of the calculated working distance, and the height of the camera 1 and the distance from the side of the display screen 7 are calculated according to the actual working distance;
the shooting angle of the camera 1 is the included angle between the axis of the lens of the camera 1 and the display screen 7, and in order to ensure that the surface defects can be imaged on the shooting picture of the camera 1 with high contrast, the shooting angle of the camera 1 needs to be set between 30 degrees and 45 degrees.
The electronic control adjusting unit is used for generating a first adjusting signal according to the camera position information generated by the calculating unit, and the first adjusting signal is used for indicating the movable displacement table 3 to control the first supporting mechanism 4 to move so as to enable the position of the camera 1 to be matched with the position information generated by the calculating unit;
after the position of the camera 1 is fixed, adjusting the focusing function of the lens to enable the camera 1 to clearly focus the center of the display screen 7, adjusting the aperture of the lens to be minimum, and adjusting the exposure time of the camera to enable the average brightness value of a shot picture to be about 100;
the image acquisition unit is used for generating an acquisition signal and acquiring a surface image of the display screen 7 shot by the camera 1 under the instruction of the acquisition signal;
the image processing unit is used for processing the surface image acquired by the image acquisition unit and judging whether the brightness of the picture is uniform or not; if yes, feeding back correct information to the image acquisition unit; if not, calculating the coordinate information of the area with uneven brightness; generating position adjusting information of the bar-shaped light source 2 according to the coordinate information;
specifically, the image processing unit divides the surface image of the display screen 7 into a plurality of regions, calculates the brightness value of each region, and calculates the average brightness value of the surface image according to the brightness value of each region; when the strip-shaped light source 2 irradiates the surface of the display screen 7, if the brightness of the surface of the display screen 7 is not uniform, the average brightness values of all areas in the surface image shot by the camera 1 have great difference; the image processing unit respectively calculates the deviation between the brightness value of each area and the average brightness value, if the absolute value of the deviation of a certain area exceeds a set brightness deviation threshold value, the brightness of the area is judged to be non-uniform, and the coordinate information of the area with non-uniform brightness is calculated; the more the number of the divided regions of the surface image is, and the smaller the area of each region is, the more accurate the calculation result is, and the longer the processing time of the image processing unit is; to compromise result accuracy and processing speed, the present embodiment chooses to divide the surface image into 9 or 16 regions.
The electronic control adjusting unit is used for generating a second adjusting signal according to the position adjusting information generated by the image processing unit; the second adjusting signal is used for indicating the movable displacement table 3 to control the second supporting mechanism 5 to move so as to adjust the position of the bar-shaped light source 2 until the brightness of the picture of the surface image of the display screen 7 shot by the camera 1 is uniform;
after the image acquisition unit receives the correct information fed back by the image processing unit, the camera 1 is controlled to shoot the surface image of the display screen 7; the image processing unit detects the surface image acquired by the image acquisition unit to obtain the number of surface defects and corresponding coordinate position information;
specifically, the brightness of each position on the display screen 7 without defects is basically uniform, and the brightness value does not have mutation; when the defects such as scratches or protruding particles appear on the display screen 7, the brightness of the defects is increased rapidly due to the reflection of light;
the image processing unit divides the surface image of the display screen 7 into a plurality of small block areas by taking pixels as a unit and numbers the small block areas, respectively calculates the gray value of each small block area and the deviation between the gray value of each small block area and the gray values of four adjacent small block areas, and judges that a certain area has defects if the absolute value of the deviation of the certain area exceeds a set gray deviation threshold; the larger the absolute value of the deviation, the more serious the surface defect.
The number of the divided small block areas is determined according to the accuracy to be achieved by the detection result, and the higher the required accuracy is, the more the divided small block areas are, the smaller the number of pixels occupied by each small block area is, and the longer the processing time of the image processing unit is.
The display unit is used for visually presenting the surface image, the number of the defects and the coordinate positions corresponding to the defects, so that a worker can conveniently analyze and timely find out the reasons for the defects.
Further, the device and method for detecting surface damage defects based on side view camera shooting provided by this embodiment further include a transmission stage 8 connected to the central controller 6 through a control cable, and the central controller 6 further includes a transmission control unit;
the conveying carrier 8 is used for bearing the display screen 7 to be detected and conveying the display screen 7 to a specified detection position under the signal control of the conveying control unit 6; after the defect detection of the previous display screen 7 is completed, the central controller 6 controls the conveying carrying platform to convey the next display screen 7 to the designated position, and the defect detection is sequentially performed.
Further, the first supporting mechanism 4 comprises a first supporting rod 41, the first supporting rod 41 is vertically arranged on the movable displacement table 3, the camera 1 is fixed at the top end of the first supporting rod 41, and the shooting angle of the camera 1 is set between 30 degrees and 45 degrees;
further, the first supporting mechanism 4 further includes an angle adjusting adapter 42 and an adapter rod 43, one end of the adapter rod 43 is fixed on the first supporting rod 41 through the angle adjusting adapter 42, and the other end is used for placing the camera 1; the angle adjustment adaptor 42 is used to adjust the shooting angle of the camera 1.
Further, the second supporting mechanism 5 comprises a second supporting rod, the second supporting rod is vertically arranged on the movable displacement table 3, and the strip-shaped light source 2 is arranged at the top end of the second supporting rod.
The following describes in detail the detection principle of the device and method for detecting surface damage defects based on side view camera shooting according to this embodiment with reference to the accompanying drawings.
1. Illumination uniformity of strip light source
The strip light source is a linear light source, wherein the main light-emitting element is an LED light source, a plurality of LED light sources are arranged in a line, when the spacing distance between adjacent LED light sources meets a certain condition, the linear light source is formed, but in the cross section, the light field expression output by the strip light source can be described by the light field output by the LED lamp.
An ideal LED illuminant can be regarded as a lambertian point light source, and its irradiance distribution can be expressed by an approximate cosine conditional formula:
wherein the content of the first and second substances,
in the formula, E represents the light intensity of the surface of the display screen to be detected;
theta represents an included angle between the emergent ray of the LED luminous body and the surface of the display screen;
r represents the linear distance between the LED luminous body and the surface of the display screen;
as can be seen from the expression (1), the light intensity E of the surface of the display screen to be measured is inversely proportional to the square of the distance r from the display screen to the light source; the larger the distance r is, the smaller the light intensity is; meanwhile, the light intensity E is related to the direction angle theta of the emergent ray; wherein the larger the angle theta, the smaller the intensity E in that direction.
Therefore, when the strip light source is horizontally arranged, in the area far away from the light source on the display screen to be detected, the included angle between the surface of the strip light source and the emergent light is small, and in the position close to the light source on the screen, the included angle between the surface of the strip light source and the emergent light is large; the expression shows that the output light of the horizontally emergent strip-shaped light source can be uniformly irradiated on the surface of the display screen to be measured.
2. Optical characteristics of damage defect
The damage defect detection of the surface of the display screen mainly comprises scratches on the screen and particles on the surface, as shown in fig. 4, when no scratches or particles are on the surface of the display screen to be detected, light rays irradiated on the surface of the display screen are reflected to the opposite side of the strip-shaped light source due to specular reflection;
placing a camera above the strip-shaped light source, and shooting a surface image of the display screen at a certain overlooking angle, wherein the whole picture shot by the camera on the surface of the screen is dark;
FIG. 4 is a schematic diagram of an optical path for detecting defects such as surface scratches according to the present embodiment; when the surface is scratched or damaged due to depression, as shown in fig. 4, in the scratched or depressed damaged area, the contact surface between the light and the display screen is no longer a horizontal plane; following the law of reflection of light, the normal is no longer the vertical direction, but the vertical direction of the tangent plane at the defect; therefore, the light emitted by the strip light source is reflected to one side of the strip light source; at this point, the camera placed on the same side of the strip light source will detect the reflected light from these defects, which will contrast strongly with the areas without defects on the picture taken by the camera, thereby indicating the defects there.
FIG. 5 is a schematic diagram of an optical path for detecting surface particle defects according to an embodiment of the present invention; similarly, when particles exist on the surface of the screen or the screen itself has uneven protrusions, as shown in fig. 5, when the light emitted by the strip light source irradiates the defect, the light will be reflected to the same side of the light source; in the defect-free area, the incident light will be reflected to the other side of the light source; therefore, in the image shot by the camera, the areas with higher brightness in the picture have defects, and high contrast is formed between the areas without the defects.
The embodiment also provides a surface defect detection method based on side view camera shooting, as shown in fig. 6, including the following steps:
s1: placing the camera 1 and the strip-shaped light source 2 at the same side of the display screen 7 to be tested;
s2: acquiring parameter information of a display screen 7 to be detected and a lens of the camera 1, wherein the parameter information comprises the size of the display screen 7 to be detected, the size of a target surface of the camera 1 and the focal length of the lens;
s3: calculating the working distance between the camera 1 and the center of the display screen 7 according to the parameter information; calculating the height of the camera 1 and the distance between the camera and the side edge of the display screen 7 through a trigonometric function according to the working distance and the set shooting angle; in order to ensure that the surface defects can be imaged on the shooting picture of the camera 1 with high contrast, the shooting angle of the camera is set to be between 30 degrees and 45 degrees;
s4: generating a first adjusting signal according to the height of the camera 1 and the distance from the side of the display screen 7, and adjusting the position of the camera 1 according to the first adjusting signal so that the real-time position of the camera 1 matches the position information in the step S2;
s5: after the position of the camera 1 is fixed, the focusing function of the lens is adjusted to enable the camera 1 to clearly focus the center of the display screen 7, the aperture of the lens is adjusted to be minimum, and the exposure time of the camera 1 is adjusted to enable the brightness value of a shot picture to be moderate;
s6: generating a collection signal and acquiring a surface image of the display screen 7 photographed by the camera 1 under the instruction of the collection signal;
s7: processing the surface image and judging whether the brightness of the picture is uniform or not; if yes, generating correct information, and entering step S9; if not, calculating the coordinate information of the area with uneven brightness; generating position adjusting information of the bar-shaped light source 2 according to the coordinate information;
specifically, the surface image of the display screen 7 is divided into a plurality of areas, the brightness value of each area is calculated respectively, and the average brightness value of the surface image is calculated according to the brightness value of each area; respectively calculating the deviation between the brightness value of each area and the average brightness value, if the absolute value of the deviation of a certain area exceeds a set brightness deviation threshold value, judging that the brightness of the area is not uniform, and calculating the coordinate information of the area with non-uniform brightness;
s8: generating a second adjusting signal according to the position adjusting information; adjusting the position of the bar-shaped light source 2 according to the second adjusting signal, and executing the steps S6-S7 until the brightness of the picture of the surface image of the display screen 7 shot by the camera 1 is uniform;
s9: controlling the camera 1 to collect the surface image of the display screen 7 according to the correct information generated in the step S7 and performing defect detection to obtain the number of surface defects and corresponding coordinate position information;
specifically, the surface image of the display screen 7 is divided into a plurality of small block areas by taking a pixel as a unit and numbered, the gray value of each small block area and the deviation between the gray value of each small block area and the gray values of four adjacent small block areas are respectively calculated, and if the absolute value of the deviation of a certain area exceeds a set gray deviation threshold, the area is judged to have a defect; the larger the absolute value of the deviation, the more serious the surface defect.
S10: visually presenting the surface image, the number of the defects and the coordinate positions corresponding to the defects;
s11: and (5) transferring the next display screen to the designated position, and repeating the steps S2-S10 to detect the defects.
Compared with the existing defect detection device, the surface damage defect detection device and method based on side-looking camera shooting provided by the invention have the advantages that based on the characteristics of the light field output by the strip-shaped light source, one strip-shaped light source is adopted as a light source, and the shooting camera and the strip-shaped light source are arranged on the same side of the display screen, so that the condition that the shooting pictures of the camera are not uniform due to a plurality of light sources can be avoided, the defects are imaged on the shooting pictures of the camera with higher contrast, and the accuracy of defect detection can be improved; the automatic adjustment of the positions of the camera and the light source according to the size of the display screen is realized through signal interaction between the central controller and the movable displacement table and the camera, the adjustment precision is higher, manpower resources are saved, the generation of poor imaging effect of certain display screens is avoided, and further the defect detection effect is influenced, so that the detection device can be applied to the defect detection of the display screens with different sizes.
It will be understood by those skilled in the art that the foregoing is only a preferred embodiment of the present invention, and is not intended to limit the invention, and that any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the scope of the present invention.
Claims (10)
1. A surface damage defect detection device based on side-looking camera shooting is characterized by comprising a position adjusting mechanism, a central controller, a camera and a strip-shaped light source, wherein the camera and the strip-shaped light source are arranged on the position adjusting mechanism positioned on one side of a display screen to be detected; the camera and the position adjusting mechanism are connected with the central controller through a control cable;
the camera and the bar-shaped light source are positioned on the same side of the display screen to be detected, the bar-shaped light source is horizontally placed, the camera is arranged higher than the bar-shaped light source, and a set shooting angle is formed between the camera and the display screen to be detected;
the central controller generates position information of a camera according to parameter information of a display screen to be detected and a camera lens, and generates a first adjusting signal according to the position information; the position adjusting mechanism adjusts the position of the camera according to the first adjusting signal so that the position of the camera is matched with the position information generated by the central controller;
the central controller is also used for dividing the surface image of the display screen acquired by the camera into a plurality of areas, respectively calculating the brightness value of each area, and calculating the average brightness value of the surface image according to the brightness value of each area; respectively calculating the deviation between the brightness value of each area and the average brightness value, judging the area with the deviation larger than a set deviation threshold value as an area with uneven brightness, calculating the coordinate information of the area, and generating a second adjusting signal according to the coordinate information; the position adjusting mechanism adjusts the position of the strip-shaped light source according to the second adjusting signal until the brightness of the picture of the image on the surface of the display screen shot by the camera is uniform; and the defect detection module is used for detecting the defects of the surface image of the display screen acquired by the camera to obtain the number of the surface defects and the coordinate positions corresponding to the defects.
2. The surface damage defect detecting apparatus of claim 1, wherein the position adjusting mechanism comprises a movable displacement table, and a first supporting mechanism and a second supporting mechanism mounted on the movable displacement table;
the movable displacement table controls the first supporting mechanism to move according to a first adjusting signal sent by the central controller so as to adjust the position of a camera arranged on the first supporting mechanism; and controlling the second supporting mechanism to move according to a second adjusting signal sent by the central controller so as to adjust the position of the strip-shaped light source arranged on the second supporting mechanism.
3. The surface damage defect detecting device of claim 1, wherein the central controller comprises a parameter setting unit, a calculating unit, an electric control adjusting unit, an image acquisition unit and an image processing unit;
the parameter setting unit is used for acquiring parameter information of a display screen to be detected and a camera lens, wherein the parameter information comprises the size of the display screen to be detected, the size of a target surface of the camera and the focal length of the camera lens;
the calculation unit is used for calculating the working distance between the camera and the center of the display screen according to the parameter information; the camera is used for calculating the height of the camera and the distance between the camera and the side edge of the display screen according to the working distance and the set shooting angle;
the electronic control adjusting unit is used for generating a first adjusting signal according to the height of the camera and the distance information between the camera and the side edge of the display screen, and the first adjusting signal is used for indicating the position adjusting mechanism to adjust the position of the camera;
the image acquisition unit is used for generating an acquisition signal and acquiring a surface image of a display screen shot by a camera under the instruction of the acquisition signal;
the image processing unit is used for detecting the brightness uniformity of the surface image and judging whether the brightness of the picture is uniform or not; if yes, feeding back correct information to the image acquisition unit; if not, calculating the coordinate information of the area with uneven brightness; generating position adjusting information of the bar-shaped light source according to the coordinate information;
the electronic control adjusting unit is further used for generating a second adjusting signal according to the position adjusting information; the second adjusting signal is used for indicating the position adjusting mechanism to adjust the position of the strip-shaped light source;
the image acquisition unit is also used for controlling the camera to shoot the surface image of the display screen after receiving the correct information fed back by the image processing unit; the image processing unit is also used for detecting the defects of the surface image acquired by the image acquisition unit to obtain the number of the surface defects and the coordinate positions corresponding to the defects.
4. The surface damage defect detecting apparatus of claim 3, wherein the central controller further comprises a display unit for visually presenting the surface image generated by the image processing unit, the number of defects, and the coordinate positions corresponding to the defects.
5. The surface damage defect detecting apparatus of claim 1 or 3, wherein the photographing angle is greater than 30 degrees and less than 45 degrees.
6. The surface damage defect detecting apparatus of claim 3 or 4, further comprising a transport stage connected to the central controller via a control cable, the central controller further comprising a transport control unit;
the transmission carrying platform is used for bearing the display screen to be detected and transmitting the display screen to a specified detection position under the signal control of the transmission control unit.
7. The surface damage defect detecting apparatus of claim 2, wherein the first supporting mechanism comprises a first supporting rod, the first supporting rod is vertically disposed on the movable displacement table, and the camera is fixed to a top end of the first supporting rod;
the second supporting mechanism comprises a second supporting rod vertically arranged on the movable displacement table, and the strip-shaped light source is arranged at the top end of the second supporting rod.
8. The surface damage defect inspection device of claim 7, wherein the first support mechanism further comprises an angle adjustment adapter and an adapter rod;
one end of the adapter rod is fixed on the first support rod through the angle adjusting adapter piece, and the other end of the adapter rod is used for placing a camera; the angle adjustment adaptor is used for finely adjusting the shooting angle of the camera.
9. A surface defect detection method based on side view camera shooting is characterized by comprising the following steps:
s1: placing a camera and a bar-shaped light source on the same side of a display screen to be detected, wherein the bar-shaped light source is horizontally placed, and the setting position of the camera is higher than that of the bar-shaped light source;
s2: acquiring parameter information of a display screen to be detected and a camera lens, wherein the parameter information comprises the size of the display screen to be detected, the size of a target surface of the camera and the focal length of the camera lens;
s3: calculating to obtain the working distance between the camera and the center of the display screen according to the parameter information; calculating the height of the camera and the distance between the camera and the side edge of the display screen according to the working distance and the set shooting angle;
s4: generating a first adjusting signal according to the height of the camera and the distance from the side edge of the display screen, and adjusting the position of the camera according to the first adjusting signal so that the real-time position of the camera is matched with the position information in the step S3;
s5: generating a collection signal and acquiring a surface image of a display screen shot by a camera under the indication of the collection signal;
s6: dividing the surface image into a plurality of areas, respectively calculating the brightness value of each area, calculating the average brightness value of the surface image according to the brightness value of each area, respectively calculating the deviation between the brightness value of each area and the average brightness value, and judging whether the deviation is not greater than a set deviation threshold value; if yes, generating correct information, and proceeding to step S8; if not, calculating coordinate information of the area with uneven brightness and generating position adjusting information of the strip-shaped light source according to the coordinate information;
s7: generating a second adjusting signal according to the position adjusting information; adjusting the position of the bar-shaped light source according to the second adjusting signal, and executing the steps S5-S6 until the brightness of the image on the surface of the display screen shot by the camera is uniform;
s8: and acquiring a surface image of the display screen according to the correct information and detecting the defects to obtain the number of the surface defects and the corresponding coordinate position information.
10. The surface defect detection method of claim 9, further comprising the steps of:
s9: visually presenting the surface image, the number of the defects and the coordinate positions corresponding to the defects;
s10: and (5) transferring the next display screen to the designated position, and repeating the steps S2-S9 to detect the defects.
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