CN109490314B - Industrial machine vision system based on improved sensing detection device - Google Patents
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Abstract
The invention discloses an industrial machine vision system based on an improved sensing detection device, which comprises a sampling view finding system, a displacement device and a feedback linkage system, wherein the sampling view finding system, the displacement device and the feedback linkage system are mutually connected in a data transmission and control transmission manner; the view finding system comprises a top view finding component, a side view finding component, a top motion control device, a side motion control device and a high-precision measuring device based on illumination reflection; the displacement device comprises a horizontal telescopic cross rod, a vertical telescopic upright post, a rotary adjusting device and a position moving assembly; the feedback linkage system comprises a feedback linkage processing device and a feedback linkage control device. According to the invention, through the view finding assembly and the displacement device, the whole system moves along with the process sequence of the industrial processing production line to be detected, the process precision of the processing production line is monitored, the production line action is reversely warned or corrected, and the problems generated in the production process are adjusted.
Description
Technical Field
The invention discloses an industrial machine vision system based on an improved sensing detection device, and relates to the technical field of machine vision.
Background
Machine vision is a branch of rapid development of artificial intelligence. In brief, machine vision is to use a machine to take measurements and judgments instead of human eyes. The machine vision system converts the object to be shot into image signal through machine vision product (image shooting device, which is divided into CMOS and CCD), and transmits it to special image processing system, to obtain the form information of the object to be shot, and converts it into digital signal according to the information of pixel distribution, brightness and color, the image system carries out various operations to these signals to extract the characteristic of the object, and then controls the action of the equipment on site according to the result of discrimination. In the process of mass repetitive industrial production, the machine vision detection method can greatly improve the production efficiency and the automation degree.
Some methods for industrial inspection using machine vision techniques exist in the prior art, such as:
the invention patent of CN104971973B, a vehicle wheel cover binding system and its using method, mentions the application of the vision system, but it is limited to the positioning function of the vision system. In the field of the binding process, the application of the vision system is limited on the basis of positioning, detecting, track optimization and the like, so that the manufacturing quality of the binding process is improved, and the method still belongs to the blank.
In the invention patent CN201810264297, a rolling hemming track optimization method and system based on a vision system, it is mentioned that in three processing procedures of rolling hemming and flanging, pre-hemming and final hemming, the vision system collects images of a hemming part, molding parameters of a workpiece processed in each procedure are calculated respectively through the images, the quality of the hemming is judged through deviation analysis, problem diagnosis is carried out by means of a quality database, and the track optimization is carried out by feeding back the rolling hemming system. However, the technical scheme is limited to preset track optimization, and the problems that the conventional visual detection system based on a single camera cannot cover 360 degrees and defect detection cannot be realized in partial areas cannot be solved.
The technical scheme disclosed in the invention patent CN201810494716, namely a machine vision detection and screening device and a line scanning camera-based detection system, realizes multi-angle coverage detection, but the technical scheme needs to install a specific rotating mechanism on a production line to detect the defects around an object, but is inconvenient to use and low in working efficiency, so that the defects on the upper surface of the object cannot be detected, and the omnibearing defect detection cannot be really realized.
Besides, the application of the machine vision technology in the industrial system in the prior art has the following problems: with the development of science and technology, the structure of parts in the industrial field is increasingly complex, and various defects of micro pipelines or inner holes with small-size characteristics are difficult to observe due to detection precision and detection directions.
In the conventional detection of the micro-pore, a detection sensor is miniaturized and then the micro-pore is detected, for example, a micro endoscope or a CCD camera enters the micro-pore to collect an image of the inner surface, and a defect is identified through manual work or an image processing algorithm. Only the internal defect information of the pipe hole can be judged qualitatively, and the quantitative detection of the defects of the inner wall of the pipe hole cannot be realized.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: aiming at the defects of the prior art, the industrial machine vision system based on the improved sensing detection device is provided, a top view assembly, a side view assembly and a displacement device are arranged, a high-precision measuring device based on illumination reflection is embedded in the top view assembly or the side view assembly, the three-dimensional morphology of the micro-pipeline or the small-size characteristic inner hole is reconstructed according to images in different illumination modes, whether the product quality is influenced by the product defects or not is judged, the defect generation reason is deduced reversely, and the problems generated in the production process are adjusted.
The invention adopts the following technical scheme for solving the technical problems:
an industrial machine vision system based on improved sensing detection device, the system comprises a sampling view finding system, a displacement device and a feedback linkage system which are mutually connected by data transmission and control transmission, wherein:
the view finding system comprises a top view finding component, a side view finding component, a top motion control device, a side motion control device and a high-precision measuring device based on illumination reflection; the displacement device comprises a horizontal telescopic cross rod, a vertical telescopic upright post, a rotary adjusting device and a position moving assembly; the feedback linkage system comprises a feedback linkage processing device and a feedback linkage control device;
the front ends of the top view finding assembly and the side view finding assembly are provided with high-precision measuring devices based on illumination reflection, and the top view finding assembly and the side view finding assembly are connected with the horizontal telescopic cross rod through a top motion control device and a side motion control device respectively; the horizontal telescopic cross rod is connected with the vertical telescopic upright post through the rotary adjusting device, and the vertical telescopic upright post is arranged on the position moving assembly; the feedback linkage control device is arranged in the displacement device, and the feedback linkage processing device is arranged at the control end of the industrial production line.
As a further preferred scheme of the invention, the high-precision measuring device based on illumination reflection comprises a plurality of light source modules, a framing imaging module, a CCD splicing gathering reflector and a light source reflector; the plurality of light source modules are uniformly arranged around the framing imaging module, the framing imaging module is respectively connected with the CCD splicing gathering reflector and the light source reflector through the first support frame and the second support frame, light rays projected by the light source modules are irradiated to the inside of an object to be detected through the light source reflector, and light rays reflected by the object to be detected are gathered and reflected by the CCD splicing gathering reflector and then are projected to the framing imaging module.
As a further preferable scheme of the present invention, the view finding imaging module includes a plurality of CCD devices, and the effective pixels of the plurality of CCD devices are overlapped end to assemble a double-row staggered focal plane form, that is, the second row of CCD devices is used to fill the gap formed by the first row of CCD devices on the same plane, and the head and tail pixels of the adjacent CCD devices are aligned or overlapped for a certain distance, and a clear wide-width large-field image is generated by integration delay processing.
As a further preferable scheme of the present invention, the top motion control device, the side motion control device, the horizontal telescopic cross bar, the vertical telescopic vertical column, the rotation adjusting device and the position moving assembly are controlled and controlled by a servo motor and a PLC control main board, wherein the top motion control device, the side motion control device, the horizontal telescopic cross bar, the vertical telescopic vertical column and the rotation adjusting device are driven by a hydraulic module, and the position moving assembly is driven by a motor and an electric roller.
The invention also discloses a working method of the industrial machine vision system based on the improved sensing detection device, which comprises the following steps:
the industrial machine vision system integrally moves along with the process sequence of the industrial processing production line to be detected through the arranged displacement device, image acquisition and comparison are carried out through the sampling viewing system, the processing precision of the processing production line is monitored, and the production line action is reversely warned or corrected; the displacement device moves according to the process sequence of the industrial processing production line to be detected, and the given image is fed back to a specific processing and manufacturing flow; when the image detection result is matched with a preset standard image, judging that the production process reaches the standard; when the image detection result is not matched with the preset standard image, the occurrence of a product flaw or an industrial process design problem is judged, and the system sends out an early warning alarm or suspends the production activity of a production line.
Furthermore, the high-precision measuring device based on illumination reflection detects according to the feedback of the collected high-precision image, and the specific detection and judgment steps comprise:
the method comprises the following steps of firstly, sequentially carrying out image acquisition, image correction, edge extraction, target identification, gray comparison, traversing and searching template features and outputting a comparison result;
step two, comparing the gray level of the collected image with a set threshold value to judge whether flaws exist or not;
and step three, positioning the flaw position through image edge extraction.
As a preferable scheme of the invention, the servo motor is a three-phase permanent magnet alternating current servo motor, and the specific model is Siemens 6SC61 series.
As a preferable scheme of the invention, the specific model of the PLC control main board is a SmCo permanent magnet alternating current servo motor controller.
As a preferred scheme of the present invention, the specific types of the CCD device are: sony EXVIEW HAD CCD.
Compared with the prior art, the invention adopting the technical scheme has the following technical effects: according to the technical scheme disclosed by the invention, the top view assembly and the side view assembly are designed, and the number and the positions of the assemblies can be allocated according to actual requirements; arranging a displacement device, moving the whole system along with the process sequence of the industrial processing production line to be detected, monitoring the process precision of the processing production line through image acquisition and comparison, and carrying out reverse early warning or correcting the action of the production line; embedding a high-precision measuring device based on illumination reflection in the top or side view finding assembly, and finding whether a product flaw exists in a micro pipeline or a small-size characteristic inner hole or not according to the feedback of the acquired high-precision image; reconstructing the three-dimensional morphology of the micro-pipeline or the small-size characteristic inner hole according to images of the micro-pipeline or the small-size characteristic inner hole under different illumination modes, judging whether the product quality is influenced by the product flaws or not, reversely deducing the causes of the flaws and adjusting the problems generated in the production process.
Drawings
Fig. 1 is a schematic diagram of the system structure of the present invention.
Fig. 2 is a schematic diagram illustrating control of connection between functional modules according to the present invention.
FIG. 3 is a schematic diagram of the structural imaging principle of the high-precision measuring device based on light reflection in the present invention.
FIG. 4 is a schematic diagram of the image processing steps in the present invention.
Wherein: 1. the device comprises a top view finding assembly, 2 a side view finding assembly, 3 a high-precision measuring device based on illumination reflection, 4 a top motion control device, 5 a side motion control device, 6 a horizontal telescopic cross rod, 7 a vertical telescopic upright column, 8 a rotation adjusting device, 9 a position moving assembly, 10 a feedback linkage processing device, 11 and a feedback linkage control device;
301. the device comprises a light source module 302, a framing imaging module 303, a CCD splicing gathering reflector 304, a light source reflector 305 and an object to be detected.
Detailed Description
Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary only for explaining the present invention and are not construed as limiting the present invention.
The technical scheme of the invention is further explained in detail by combining the drawings as follows:
the system structure diagram of the invention is shown in fig. 1, the industrial machine vision system based on the improved sensing detection device comprises a sampling view finding system, a displacement device and a feedback linkage system which are mutually connected by data transmission and control transmission, wherein: the view finding system comprises a top view finding assembly, a side view finding assembly, a top motion control device, a side motion control device and a high-precision measuring device based on illumination reflection; the displacement device comprises a horizontal telescopic cross rod, a vertical telescopic upright post, a rotary adjusting device and a position moving assembly; the feedback linkage system comprises a feedback linkage processing device and a feedback linkage control device; the front ends of the top view finding assembly and the side view finding assembly are provided with high-precision measuring devices based on illumination reflection, and the top view finding assembly and the side view finding assembly are respectively connected with the horizontal telescopic cross rod through a top motion control device and a side motion control device; the horizontal telescopic cross rod is connected with the vertical telescopic upright post through a rotary adjusting device, and the vertical telescopic upright post is arranged on the position moving assembly; the feedback linkage control device is arranged in the displacement device, and the feedback linkage processing device is arranged at the control end of the industrial production line.
The invention designs the top view finding component and the side view finding component, the number and the position of the components can be allocated according to the actual requirement, and the movement of the view finding component in the actual image acquisition process is automatically controlled by a programmable device.
The top and side view components are added with a high-precision measuring device based on illumination reflection at one or more positions according to actual needs, and flaws or defects which are fine or hidden in the tubular product are found by utilizing the illumination view result. A plurality of light sources are arranged in the high-precision measuring device based on illumination reflection, and the three-dimensional appearance of a flaw product is reconstructed through images in different illumination modes. The motion control device of the top view finding group and the side view finding group presets control program control according to different product detection production lines, and improves control precision.
In a specific embodiment of the invention, the top motion control device, the side motion control device, the horizontal telescopic cross bar, the vertical telescopic upright post, the rotation adjusting device and the position moving assembly are controlled and controlled in motion through a servo motor and a PLC control main board, wherein the top motion control device, the side motion control device, the horizontal telescopic cross bar, the vertical telescopic upright post and the rotation adjusting device are driven by a hydraulic module, and the position moving assembly is driven by a motor and an electric roller.
As a preferred scheme of the invention, the servo motor is a three-phase permanent magnet alternating current servo motor, and the specific model is Siemens 6SC61 series; the specific model of the PLC control main board is a SmCo permanent magnet alternating current servo motor controller; the specific types of the CCD device are as follows: sony EXVIEW HAD CCD.
The above-described device is preferred and any other existing servo motor and controller that fulfill similar functions, if used in accordance with the method disclosed herein, shall also pertain to the use of the method disclosed herein.
In the invention, a connection control schematic diagram among functional modules is shown in fig. 2, an industrial machine vision system integrally moves along with the process sequence of an industrial processing production line to be detected through a set displacement device, image acquisition and comparison are carried out through a sampling viewing system, the processing precision of the processing production line is monitored, and the production line action is reversely warned or corrected; the displacement device moves according to the process sequence of the industrial processing production line to be detected, and the given image is fed back to a specific processing and manufacturing flow; when the image detection result is matched with a preset standard image, judging that the production process reaches the standard; when the image detection result is not matched with the preset standard image, the occurrence of a product flaw or an industrial process design problem is judged, and the system sends out an early warning alarm or suspends the production activity of a production line.
In the invention, a schematic diagram of a structural imaging principle of a high-precision measuring device based on illumination reflection is shown in fig. 3, and as a further preferable scheme of the invention, the high-precision measuring device based on illumination reflection comprises a plurality of light source modules, a view-finding imaging module, a CCD splicing gathering reflector and a light source reflector; the plurality of light source modules are uniformly arranged around the framing imaging module, the framing imaging module is respectively connected with the CCD splicing gathering reflector and the light source reflector through the first support frame and the second support frame, light projected by the light source modules irradiates the inside of an object to be detected through the light source reflector, and light reflected by the object to be detected is gathered and reflected through the CCD splicing gathering reflector and then projected to the framing imaging module.
As a further preferable scheme of the present invention, the view finding imaging module includes a plurality of CCD devices, and the effective pixels of the plurality of CCD devices are overlapped end to assemble a double-row staggered focal plane form, that is, the second row of CCD devices is used to fill the gap formed by the first row of CCD devices on the same plane, and the head and tail pixels of the adjacent CCD devices are aligned or overlapped for a certain distance, and a clear wide-width large-field image is generated by integration delay processing.
In the invention, the schematic diagram of the image processing steps is shown in fig. 4, the high-precision measuring device based on illumination reflection performs detection according to the feedback of the acquired high-precision image, and the specific detection and judgment steps comprise:
the method comprises the following steps of firstly, sequentially carrying out image acquisition, image correction, edge extraction, target identification, gray level comparison, traversal searching template characteristics and outputting comparison results;
step two, comparing the gray level of the collected image with a set threshold value to judge whether flaws exist or not;
and step three, positioning the flaw position through image edge extraction.
The technical scheme disclosed by the invention solves the following problems existing in the existing industrial machine vision system:
1. the traditional vision detection system based on a single camera cannot cover 360 degrees, and defect detection cannot be realized in partial areas. The detection system based on the line scanning camera can detect the defects around the object only by installing a specific rotating mechanism on a production line, but is inconvenient to use, low in working efficiency, incapable of detecting the defects on the upper surface of the object and incapable of realizing multi-angle and all-directional defect detection.
2. In the prior art, the application of the industrial mechanical vision system is limited on the basis of positioning, detection and the like, and the mechanical vision system is applied to track optimization through design, so that the detection of the production industry and the manufacturing quality of detected products can be further realized.
3. With the development of science and technology, the part structure in the industrial field is increasingly complex, and various defects of a micro pipeline or an inner hole with small-size characteristics are difficult to observe due to detection precision and detection direction.
4. In the conventional detection of the micro-pore, a detection sensor is miniaturized and then the micro-pore is detected, for example, a micro endoscope or a CCD camera enters the micro-pore to collect an image of the inner surface, and a defect is identified through manual work or an image processing algorithm. Only the internal defect information of the pipe hole can be judged qualitatively, and the quantitative detection of the defects of the inner wall of the pipe hole cannot be realized.
The embodiments of the present invention have been described in detail with reference to the drawings, but the present invention is not limited to the above embodiments, and various changes can be made within the knowledge of those skilled in the art without departing from the gist of the present invention. Although the present invention has been described with reference to a preferred embodiment, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (5)
1. The utility model provides an industrial machine vision system based on improved generation sensing detection device which characterized in that, the system is including mutual setting data transmission and control transmission connected's sampling framing system, displacement device and feedback linked system, wherein:
the view finding system comprises a top view finding assembly, a side view finding assembly, a top motion control device, a side motion control device and a high-precision measuring device based on illumination reflection;
the displacement device comprises a horizontal telescopic cross rod, a vertical telescopic upright post, a rotary adjusting device and a position moving assembly;
the feedback linkage system comprises a feedback linkage processing device and a feedback linkage control device;
the front ends of the top view finding assembly and the side view finding assembly are provided with high-precision measuring devices based on illumination reflection, and the top view finding assembly and the side view finding assembly are connected with the horizontal telescopic cross rod through a top motion control device and a side motion control device respectively;
the high-precision measuring device based on illumination reflection comprises a plurality of light source modules, a view finding imaging module, a CCD assembly and a light source reflector;
the plurality of light source modules are uniformly arranged around the framing imaging module, the framing imaging module is respectively connected with the CCD assembly and the light source reflector through the first support frame and the second support frame, light rays projected by the light source modules are irradiated to the interior of an object to be detected through the light source reflector, and light rays reflected by the object to be detected are gathered and reflected by the CCD assembly and then projected to the framing imaging module;
the view finding imaging module comprises a plurality of CCD devices, effective pixels of the CCD devices are overlapped end to be assembled into a double-row staggered focal plane form, namely, gaps formed by a first row of CCD devices are filled up by a second row of CCD devices on the same plane, the head and tail pixels of adjacent CCD devices are aligned or overlapped for a certain distance, and clear wide and large view field images are generated through integral delay processing;
the horizontal telescopic cross rod is connected with the vertical telescopic upright post through a rotary adjusting device, and the vertical telescopic upright post is arranged on the position moving assembly;
the feedback linkage control device is arranged in the displacement device, and the feedback linkage processing device is arranged at the control end of the industrial production line;
the top motion control device, the side motion control device, the horizontal telescopic cross rod, the vertical telescopic upright post, the rotation adjusting device and the position moving assembly are controlled and controlled in motion through a servo motor and a PLC control main board, wherein the top motion control device, the side motion control device, the horizontal telescopic cross rod, the vertical telescopic upright post and the rotation adjusting device are driven through a hydraulic module, and the position moving assembly is driven through a motor and an electric roller;
the working method of the system comprises the following steps:
the industrial machine vision system integrally moves along with the process sequence of the industrial processing production line to be detected through the arranged displacement device, image acquisition and comparison are carried out through the sampling viewing system, the processing precision of the processing production line is monitored, and the production line action is reversely warned or corrected;
the displacement device moves according to the process sequence of the industrial processing production line to be detected, and the given image is fed back to a specific processing and manufacturing flow;
when the image detection result is matched with a preset standard image, judging that the production process reaches the standard;
when the image detection result is not matched with the preset standard image, the occurrence of a product flaw or an industrial process design problem is judged, and the system sends out an early warning alarm or suspends the production activity of a production line.
2. The industrial machine vision system based on the improved sensing detection device, as claimed in claim 1, wherein the high-precision measuring device based on the illumination reflection performs detection according to the feedback of the collected high-precision image, and the specific detection determining step includes:
the method comprises the following steps of firstly, sequentially carrying out image acquisition, image correction, edge extraction, target identification, gray level comparison, traversal searching template characteristics and outputting comparison results;
step two, comparing the gray level of the collected image with a set threshold value to judge whether flaws exist or not;
and step three, positioning the flaw position through image edge extraction.
3. The industrial machine vision system based on the improved sensing detection device as claimed in claim 1, wherein: the servo motor is a three-phase permanent magnet alternating current servo motor, and the specific model is Siemens 6SC61 series.
4. The industrial machine vision system based on the improved sensing detection device as claimed in claim 1, wherein: the specific model of the PLC control main board is a SmCo permanent magnet alternating current servo motor controller.
5. The industrial machine vision system based on the improved sensing detection device as claimed in claim 1, wherein: the specific models of the CCD device are as follows: sony EXVIEW HAD CCD.
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