CN110599450A - LED light source position correction method and system - Google Patents

LED light source position correction method and system Download PDF

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Publication number
CN110599450A
CN110599450A CN201910712322.1A CN201910712322A CN110599450A CN 110599450 A CN110599450 A CN 110599450A CN 201910712322 A CN201910712322 A CN 201910712322A CN 110599450 A CN110599450 A CN 110599450A
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image
led
lamp cup
led lamp
lamp panel
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CN110599450B (en
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苏睿
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Huizhou Shengshi Lighting Co Ltd
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Huizhou Shengshi Lighting Co Ltd
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    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T7/00—Image analysis
    • G06T7/0002—Inspection of images, e.g. flaw detection
    • G06T7/0004—Industrial image inspection
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T7/00—Image analysis
    • G06T7/30—Determination of transform parameters for the alignment of images, i.e. image registration
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06V—IMAGE OR VIDEO RECOGNITION OR UNDERSTANDING
    • G06V10/00—Arrangements for image or video recognition or understanding
    • G06V10/10—Image acquisition
    • G06V10/12—Details of acquisition arrangements; Constructional details thereof
    • G06V10/14—Optical characteristics of the device performing the acquisition or on the illumination arrangements
    • G06V10/141—Control of illumination
    • 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
    • G06T2207/20—Special algorithmic details
    • G06T2207/20081—Training; Learning
    • 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
    • G06T2207/20—Special algorithmic details
    • G06T2207/20084—Artificial neural networks [ANN]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B20/00—Energy efficient lighting technologies, e.g. halogen lamps or gas discharge lamps
    • Y02B20/40—Control techniques providing energy savings, e.g. smart controller or presence detection

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Theoretical Computer Science (AREA)
  • Computer Vision & Pattern Recognition (AREA)
  • Quality & Reliability (AREA)
  • Multimedia (AREA)
  • Image Input (AREA)
  • Length Measuring Devices By Optical Means (AREA)

Abstract

The invention discloses a method and a system for correcting the position of an LED light source.A standard image of a through hole area of a lamp cup is stored, and before an LED lamp panel and the lamp cup are installed, the collected current lamp cup image is compared with the standard image, so that the accuracy of the installation of the LED lamp panel and the lamp cup is ensured, and the installation efficiency is improved; through carrying out primary correction and secondary correction to lamp cup and LED lamp plate to can avoid the tolerance of lamp cup or LED lamp plate self to cause the central axis of lamp cup and the central axis of LED lamp plate probably not to overlap or not in qualified precision range, guarantee the uniformity of the precision and the luminance of LED product. Simultaneously, through once proofreaying and correct twice, can improve the central axis of lamp cup and the central axis's of LED lamp plate overlapping precision.

Description

LED light source position correction method and system
Technical Field
The invention relates to the field of visual detection, in particular to a method and a system for correcting the position of an LED light source.
Background
At present, the vision inspection is to use a robot to replace human eyes for measurement and judgment. The visual detection is that a machine vision product, namely an image shooting device, is divided into a CMOS (complementary metal oxide semiconductor) and a CCD (charge coupled device), a shot target is converted into an image signal and is transmitted to a special image processing system, and the image signal is converted into a digital signal according to information such as pixel distribution, brightness, color and the like; the image system performs various calculations on these signals to extract the features of the target, and then controls the operation of the on-site equipment according to the result of the discrimination. Is a valuable mechanism for production, assembly or packaging. It has immeasurable value in terms of the ability to detect defects and prevent defective products from being distributed to consumers. Defective products are detected by a vision device and corrected by a correction mechanism.
However, at the present stage, when the lamp cup and the LED lamp panel are assembled, the bottom hole of the lamp cup and the LED lamp panel are mostly installed and corrected manually, which results in inaccurate installation precision and low installation efficiency. Meanwhile, whether the central axis of the lamp cup and the central axis of the LED lamp panel in the LED product are in a qualified range or not is detected at the present stage, tolerance can occur in the production or assembly process of the LED product, such as flatness tolerance of the light cup, diameter tolerance of an opening of the light cup and the like, and then the positions of the lamp cup and the LED lamp panel can be adjusted according to the tolerance by a correction mechanism when the correction is carried out, so that the central axis of the lamp cup and the central axis of the LED lamp panel are not overlapped or in the qualified precision range, the precision of each LED product is not uniform, the brightness of each LED product is not uniform, and the defective product rate is greatly increased.
Disclosure of Invention
The invention aims to overcome the defects in the prior art, and provides an LED light source position correction method and system which can ensure that the assembly precision of a lamp cup and a light-emitting chip is high, the central axis of the lamp cup and the central axis of the light-emitting chip are coincided or in a qualified range, and the coincidence precision of the central axis of the lamp cup and the central axis of the light-emitting chip is improved.
The purpose of the invention is realized by the following technical scheme:
a method for correcting the position of an LED light source comprises a lamp cup and an LED lamp panel, wherein a through hole area is arranged at the bottom of the lamp cup, and a plurality of through holes are formed in the through hole area, and the method comprises the following steps:
storing a standard image of the via region;
correspondingly acquiring a current image of the through hole area aiming at the current lamp cup, and comparing the current image with the standard image to obtain a deflection angle of the current lamp cup;
performing rotation operation of the deflection angle on the lamp cup;
installing the LED lamp panel on the lamp cup;
lighting the LED lamp panel, and enabling the brightness value of the LED lamp panel to reach a primary brightness calibration value;
when the LED light source is lighted under the condition of the primary brightness calibration value, respectively acquiring a lighted image of the lamp cup, a lighted image of the LED lamp panel and a light spot image of the LED light source, and respectively performing image preprocessing operation on the lighted image of the lamp cup, the lighted image of the LED lamp panel and the light spot image of the LED light source to respectively obtain a lamp cup processing image, an LED lamp panel processing image and a light spot processing image;
obtaining a central coordinate value of the lamp cup processing image, a central coordinate value of the LED lamp panel processing image and a light spot data value according to the lamp cup processing image, the LED lamp panel processing image and the light spot processing image respectively;
calculating a difference value between the central coordinate value of the lamp cup processing image and the central coordinate value of the LED lamp panel processing image, generating a primary correction path, and controlling the driving module to execute the primary correction path;
comparing the light spot data value with a preset light spot threshold, if the light spot data value is different from the preset light spot threshold, calculating to generate a difference value between the light spot data value and the preset light spot threshold, generating a secondary correction path, and controlling the driving module to execute the secondary correction path.
In one embodiment, when the LED light source is turned on under the condition of the initial brightness calibration value in the step, acquiring a turned-on image of the lamp cup, a turned-on image of the LED lamp panel, and a light spot image of the LED light source, respectively, and performing image preprocessing on the turned-on image of the lamp cup, the turned-on image of the LED lamp panel, and the light spot image of the LED light source, to obtain a lamp cup processed image, an LED lamp panel processed image, and a light spot processed image, respectively, specifically includes:
respectively carrying out thresholding on the lighting image of the lamp cup, the lighting image of the LED lamp panel and the light spot image of the LED light source to generate a lamp cup binary image, an LED lamp panel binary image and a light spot binary image;
respectively carrying out recognition operation on the lamp cup binary image and the LED lamp panel binary image and a preset LED light source outline condition to generate a lamp cup outline analysis diagram and an LED lamp panel outline analysis diagram;
splicing and synthesizing the lamp cup outer contour analysis diagram and the LED lamp panel outer contour analysis diagram to generate an LED light source outer contour analysis diagram;
and carrying out partitioning processing operation according to the inscribed circle and the circumscribed rectangle of the LED light source outline analysis diagram, and generating a plurality of independent LED light source outline diagrams.
In one embodiment, the step of splicing the lamp cup outer contour analysis diagram with the LED lamp panel outer contour analysis diagram to generate an LED light source outer contour analysis diagram specifically includes:
and carrying out contrast enhancement operation on the LED light source outline picture and the light spot binary picture.
In one embodiment, thresholding is performed on the real-time image of the lamp cup and the real-time image of the LED lamp panel to generate a lamp cup binary picture and an LED lamp panel binary picture, specifically including:
and acquiring saturation parameters in HSV color models of the lamp cup binary picture, the LED lamp panel binary picture and the facula binary picture.
In one embodiment, in the step, calculating a difference between a central coordinate value of the lamp cup processed image and a central coordinate value of the LED lamp panel processed image to generate a primary correction path, and controlling the driving module to execute the primary correction path specifically includes:
marking the lighting image of the lamp cup and the lighting image of the LED lamp panel respectively, and performing normalization processing to generate a lamp cup outer contour training image, an LED lamp panel outer contour training image and a light spot training image;
and respectively carrying out convolutional neural network training operation on the lamp cup outer contour training image, the LED lamp panel outer contour training image and the light spot training image.
In one embodiment, the preset light spot threshold includes roundness of a light spot threshold, concentricity of an isocandela intensity threshold of a light spot, size of the light spot threshold, and peripheral smear of the light spot.
In one embodiment, after the step of calculating and generating the central coordinate value of the lamp cup processed image, the central coordinate value of the LED lamp panel processed image, and the light spot data value according to a preset calculation condition, the method further includes:
and lightening the brightness value of the LED lamp panel to a secondary brightness calibration value.
An LED light source position correction system comprising:
the image storage module is used for storing a standard image of the through hole area;
the image acquisition module is used for collecting the current image of the through hole area, and is also used for acquiring the lighting image of the lamp cup, the lighting image of the LED lamp panel and the light spot image of the LED light source;
the image processing module is used for respectively carrying out image preprocessing operation on the lighting image of the lamp cup, the lighting image of the LED lamp panel and the light spot image of the LED light source to respectively obtain a lamp cup processing image, an LED lamp panel processing image and a light spot processing image;
the calculation module is used for calculating a difference value between a central coordinate value of the lamp cup processed image and a central coordinate value of the LED lamp panel processed image and calculating and generating a difference value between the light spot data value and the preset light spot threshold value;
the control module is used for controlling the driving module to execute the primary correction path and controlling the driving module to execute the secondary correction path;
a drive module to execute the primary correction path and to execute the secondary correction path.
In one embodiment, the image processing module is further configured to perform recognition operations on the lamp cup binary image and the LED lamp panel binary image and a preset LED light source outline condition, respectively, so as to generate a lamp cup outline analysis diagram and an LED lamp panel outline analysis diagram.
In one embodiment, the image processing module is further configured to perform a marking operation on the lighting image of the lamp cup and the lighting image of the LED lamp panel, and perform normalization processing to generate a lamp cup outer contour training image, an LED lamp panel outer contour training image, and a light spot training image.
Compared with the prior art, the invention has the following advantages and beneficial effects:
the invention relates to a method and a system for correcting the position of an LED light source.A standard image of a through hole area of a lamp cup is stored, and before an LED lamp panel and the lamp cup are installed, the collected current lamp cup image is compared with the standard image, so that the accuracy of the installation of the LED lamp panel and the lamp cup is ensured, and the installation efficiency is improved; through carrying out primary correction and secondary correction to lamp cup and LED lamp plate to can avoid the tolerance of lamp cup or LED lamp plate self to cause the central axis of lamp cup and the central axis of LED lamp plate probably not to overlap or not in qualified precision range, thereby guarantee the precision of LED product and the unity of luminance. Simultaneously, through once proofreaying and correct twice, can improve the central axis of lamp cup and the central axis's of LED lamp plate overlapping precision.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the embodiments will be briefly described below, it should be understood that the following drawings only illustrate some embodiments of the present invention and therefore should not be considered as limiting the scope, and for those skilled in the art, other related drawings can be obtained according to the drawings without inventive efforts.
FIG. 1 is a flowchart illustrating steps of a method for correcting a position of an LED light source according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of a current image of a via region according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of a standard image of a via region according to an embodiment of the present invention;
fig. 4 is a schematic structural diagram of a lamp cup processing image and an LED lamp panel processing image according to an embodiment of the present invention;
FIG. 5 is a schematic diagram of a structure of a spot processing image according to an embodiment of the present invention;
FIG. 6 is a functional block diagram of an LED light source position correction system according to an embodiment of the present invention;
FIG. 7 is a schematic structural diagram of an LED light source position calibration device according to another embodiment of the present invention;
FIG. 8 is a schematic view of the structure shown in FIG. 7 from another perspective;
FIG. 9 is a schematic view of the structure shown in FIG. 7 from yet another perspective;
fig. 10 is a schematic structural diagram of an LED light source position correction device according to yet another embodiment of the present invention.
Detailed Description
To facilitate an understanding of the invention, the invention will now be described more fully with reference to the accompanying drawings. Preferred embodiments of the present invention are shown in the drawings. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete.
It will be understood that when an element is referred to as being "secured to" another element, it can be directly on the other element or intervening elements may also be present. When an element is referred to as being "connected" to another element, it can be directly connected to the other element or intervening elements may also be present. The terms "vertical," "horizontal," "left," "right," and the like as used herein are for illustrative purposes only and do not represent the only embodiments.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.
Referring to fig. 1, a method for correcting a position of an LED light source, the LED light source including a lamp cup and an LED lamp panel, the bottom of the lamp cup being provided with a through hole region, the through hole region being provided with a plurality of through holes, includes the following steps:
s110, storing a standard image of the through hole area;
s120, correspondingly acquiring a current image of the through hole area aiming at the current lamp cup, and comparing the current image with a standard image to obtain a deflection angle of the current lamp cup;
s130, rotating the lamp cup by a deflection angle;
s140, mounting the LED lamp panel on the lamp cup;
s150, lighting the LED lamp panel, and enabling the brightness value of the LED lamp panel to reach the primary brightness calibration value;
s160, when the LED light source is lighted under the condition of the initial brightness calibration value, respectively acquiring a lighted image of the lamp cup, a lighted image of the LED lamp panel and a light spot image of the LED light source, respectively performing image preprocessing operation on the lighted image of the lamp cup, the lighted image of the LED lamp panel and the light spot image of the LED light source to respectively obtain a lamp cup processing image, an LED lamp panel processing image and a light spot processing image, and respectively processing the lamp cup processing image, the LED lamp panel processing image and the light spot processing image;
s170, obtaining a central coordinate value of the lamp cup processing image, a central coordinate value of the LED lamp panel processing image and a light spot data value according to the lamp cup processing image, the LED lamp panel processing image and the light spot processing image;
s180, calculating a difference value between the central coordinate value of the lamp cup processing image and the central coordinate value of the LED lamp panel processing image, generating a primary correction path, and controlling a driving module to execute the primary correction path;
s190, comparing the light spot data value with a preset light spot threshold value, if the light spot data value is different from the preset light spot threshold value, calculating a difference value between the generated light spot data value and the preset light spot threshold value, generating a secondary correction path, and controlling a driving module to execute the secondary correction path.
Referring to fig. 1 again, specifically, when the LED light source is turned on under the condition of the initial brightness calibration value in the step, the step of respectively acquiring the turned-on image of the lamp cup, the turned-on image of the LED lamp panel, and the light spot image of the LED light source, and respectively performing image preprocessing on the turned-on image of the lamp cup, the turned-on image of the LED lamp panel, and the light spot image of the LED light source to respectively obtain the lamp cup processed image, the LED lamp panel processed image, and the light spot processed image specifically includes:
respectively carrying out thresholding on the lighting image of the lamp cup, the lighting image of the LED lamp panel and the light spot image of the LED light source to generate a lamp cup binary image, an LED lamp panel binary image and a light spot binary image;
respectively carrying out recognition operation on the lamp cup binary image and the LED lamp panel binary image and a preset LED light source outline condition to generate a lamp cup outline analysis diagram and an LED lamp panel outline analysis diagram;
splicing and synthesizing the lamp cup outline analysis diagram and the LED lamp panel outline analysis diagram to generate an LED light source outline analysis diagram;
and carrying out partitioning processing operation according to the inscribed circle and the circumscribed rectangle of the outline analysis diagram of the LED light source to generate a plurality of independent outline diagrams of the LED light source.
It should be noted that the LED lamp panel includes a chip and a circuit board. Firstly, a plurality of lamp cups on a receiving tray are collected, the bottom of each lamp cup is provided with a through hole area, a plurality of through holes are contained in the through hole area, a correction server clamps the lamp cups on the receiving tray to an industrial camera for taking a picture by controlling an LED light source position correction device, the purpose is to collect and store the current image of the through hole area, as shown in figure 2, and comparing the acquired current image with a standard image of the through hole area prestored in the correction server, wherein the prestored standard image of the through hole area is shown as figure 3, that is, comparing whether the hole position of the current image of the through hole area is consistent with the position of the middle hole position of the pre-stored standard image of the through hole area, if not, the correction server calculates the deviation angle through the built-in function, and sending an instruction to the LED light source position correction device to rotate according to the deviation angle so as to enable the hole site position of the current image to be the same as the hole site position of the standard image. So, through the aforesaid correction, can improve the installation accuracy of lamp cup and LED lamp plate, and then improve the efficiency of installation. And then, assembling the lamp cup after the correction with the LED lamp panel, and performing next correction operation after the assembly is completed. Further, the correction server sends an instruction for lighting the LED lamp panel to an external power supply, so that the brightness of the LED lamp panel is the same as the brightness of a preset primary brightness calibration value in the correction server, and the aim of obtaining images of the LED lamp panel, the lamp cup and the light spot more clearly is achieved; then, by setting a target area, an industrial camera is used for collecting a lighting image of the lamp cup, a lighting image of the LED lamp panel and a light spot image of the LED light source, respectively thresholding the collected lighting image of the lamp cup, the lighting image of the LED lamp panel and the light spot image of the LED light source to generate a lamp cup binary image, an LED lamp panel binary image and a light spot binary image, filtering out a part of binary pictures which are not in accordance with the information in the blob file through blob analysis in the correction server, wherein the blob is a large file, the blob file is a picture or a sound file, in the application, the outline condition of the LED light source is preset as a bold file, the blob file stores characteristic information such as area, length, width, angle, circle center degree and the like, and the light cup contour analysis graph and the LED lamp panel contour analysis graph are obtained by comparing the light cup binary picture, the LED lamp panel binary picture and the light spot binary picture. The correction server splices and synthesizes the lamp cup outline analysis chart and the LED lamp panel outline analysis chart to generate an LED light source outline analysis chart; then, aiming at an LED light source outline analysis diagram, calculating to obtain a minimum inscribed circle of the outline of the opening of the lamp cup, a minimum inscribed circle of the arc of the lamp cup and a minimum circumscribed rectangle of the chip, and cutting the pictures by adopting a sub-pixel point cutting method, so that each small picture comprises a current image of the through hole area of the lamp cup, a processing image of the LED lamp panel and a processing image of a light spot, namely the outline diagram of the LED light source comprises the current image of the through hole area of the lamp cup, the processing image of the LED lamp panel and the processing image of the light spot.
Further, please refer to fig. 5, the correction server obtains the central coordinate value of the lamp cup processed image, the central coordinate value of the LED lamp panel processed image and the light spot data value through a built-in calculation function according to the lamp cup processed image, the LED lamp panel processed image and the light spot processed image shown in fig. 4, and the light spot processed image shown in fig. 5, designs an initial correction path according to the difference between the central coordinate value of the lamp cup processed image and the central coordinate value of the LED lamp panel processed image, and sends an instruction to the LED light source position correction device to perform correction according to the initial correction path. After the primary correction is completed, comparing the light spot data value with a preset light spot threshold value, wherein the preset light spot threshold value comprises light spot threshold value roundness, light spot isocandela threshold value concentricity, light spot threshold value size and light spot peripheral smear, setting the preset light spot threshold value in a correction server manually, if the light spot data value is different from the preset light spot threshold value, calculating a difference value between the generated light spot data value and the preset light spot threshold value by a built-in calculation function, designing and generating a secondary correction path, and sending an instruction to an LED light source position correction device to correct according to the secondary correction path, so that the overlapping precision of the central axis of the lamp cup and the central axis of the LED lamp panel can reach +/-0.01 mm.
Referring to fig. 1 again, in a further embodiment, the step of splicing the lamp cup outer contour analysis diagram with the LED lamp panel outer contour analysis diagram to generate the LED light source outer contour analysis diagram specifically includes:
and carrying out contrast enhancement operation on the LED light source outline picture and the light spot binary picture.
It should be noted that, in the application, the retinex image enhancement algorithm is used to enhance the contrast of the image processed by one lamp cup, the image processed by one LED lamp panel and the image processed by one light spot, so that the features of the image are clearer.
Referring to fig. 1 again, in an embodiment, the thresholding the real-time image of the lamp cup and the real-time image of the LED lamp panel to generate the lamp cup binary picture and the LED lamp panel binary picture respectively specifically includes:
and acquiring saturation parameters in HSV color models of the lamp cup binary image, the LED lamp panel binary image and the facula binary image.
Referring to fig. 1 again, in a further embodiment, in the step of calculating a difference value between a central coordinate value of the lamp cup processed image and a central coordinate value of the LED lamp panel processed image to generate a primary correction path, the controlling the driving module to execute the primary correction path specifically includes:
respectively marking the lighting image of the lamp cup and the lighting image of the LED lamp panel, and performing normalization processing to generate a lamp cup outer contour training image, an LED lamp panel outer contour training image and a light spot training image;
and respectively carrying out convolutional neural network training operation on the lamp cup outer contour training image, the LED lamp panel outer contour training image and the light spot training image.
The convolutional neural network is based on a residual neural network and a full convolutional network architecture, comprises a plurality of convolutional layers, and has the advantages of accurate positioning, small calculated amount, high speed, easiness in training and the like through optimization.
Referring to fig. 1 again, in one embodiment, before the step of calculating and generating the central coordinate value of the lamp cup processed image, the central coordinate value of the LED lamp panel processed image and the light spot data value according to the preset calculation condition, the method further includes:
and lightening the brightness value of the LED lamp panel to a secondary brightness calibration value.
It should be noted that the secondary brightness calibration value is larger than the primary brightness calibration value, and since the secondary brightness calibration value needs to acquire a clear spot processing image, a more enhanced brightness is needed.
Further, in another embodiment, a method for correcting the position of an LED light source includes the steps of:
s101, mounting an LED lamp panel on a lamp cup;
s102, lighting the LED lamp panel, and enabling the brightness value of the LED lamp panel to reach a primary brightness calibration value;
s103, respectively collecting a lighting image of the lamp cup, a lighting image of the LED lamp panel and a light spot image of the LED light source when the LED light source is lighted under the condition of the initial brightness calibration value;
s104, storing the lighting image of the lamp cup, the lighting image of the LED lamp panel and the light spot image of the LED light source;
s105, calculating a central coordinate value of a lighting image of the lamp cup and a central coordinate value of a lighting image of the LED lamp panel according to the light spot lighting image of the LED light source;
s106, calculating a difference value between the central coordinate value of the lighting image of the lamp cup and the central coordinate value of the lighting image of the LED lamp panel, generating a correction path, and controlling the driving module to execute the correction path.
In step S104, after storing the lighting image of the lamp cup, the lighting image of the LED lamp panel, and the spot image of the LED light source, the method further includes the steps of: s104a, respectively marking the lighting image of the lamp cup and the lighting image of the LED lamp panel, and carrying out normalization processing to generate a lamp cup outer contour training image, an LED lamp panel outer contour training image and a light spot training image; s104b, establishing a matching label, binding the lamp cup outer contour training image, the LED lamp panel outer contour training image and the light spot training image, and storing the matching label. After the LED lamp panel is installed in the lamp cup, the correction server collects and stores the current lighting image of the lamp cup, the lighting image of the LED lamp panel and the light spot image of the LED light source, performs normalization processing, and binds the lamp cup outline training image, the LED lamp panel outline training image and the light spot training image by establishing matching labels, thereby ensuring that each lamp cup and the training image of the LED lamp panel are correspondingly matched with one light spot training image, so that the correction server forms a convolutional neural network by collecting and storing a large number of matching labels, so that the correction server can directly calculate the difference value between the central coordinate value of the lighting image of the lamp cup and the central coordinate value of the lighting image of the LED lamp panel by directly obtaining the lighting image of the LED light spot, and then directly controls the driving module to execute a correction path, thereby reach the central axis that makes the central axis of lamp cup and the central axis of LED lamp plate overlap or overlap to qualified scope. The mode not only simplifies the correction process, but also greatly saves time, improves the working efficiency and ensures that the adjustment precision is more accurate.
Therefore, according to the LED light source position correction method, the standard image of the through hole area of the lamp cup is stored, and before the LED lamp panel and the lamp cup are installed, the collected current lamp cup image is compared with the standard image, so that the accuracy of the installation of the LED lamp panel and the lamp cup is ensured, and the installation efficiency is improved; through carrying out primary correction and secondary correction to lamp cup and LED lamp plate to can avoid the tolerance of lamp cup or LED lamp plate self to cause the central axis of lamp cup and the central axis of LED lamp plate probably not to overlap or not in qualified precision range, thereby guarantee the precision of LED product and the unity of luminance. Simultaneously, through once proofreaying and correct twice, can improve the central axis of lamp cup and the central axis's of LED lamp plate overlapping precision.
Referring to fig. 6, an LED light source position correction system 10 includes an image storage module 100, an image acquisition module 200, an image processing module 300, a calculation module 400, a control module 500, and a driving module 600.
The image storage module 100 is used for storing a standard image of the through hole area; the image acquisition module 200 is used for collecting a current image of the through hole area, and the image acquisition module 200 is also used for acquiring a lighting image of the lamp cup, a lighting image of the LED lamp panel and a light spot image of the LED light source; the image processing module 300 is configured to perform image preprocessing operations on the lighting image of the lamp cup, the lighting image of the LED lamp panel, and the light spot image of the LED light source, respectively to obtain a lamp cup processing image, an LED lamp panel processing image, and a light spot processing image; the calculation module 400 is configured to calculate a difference between a central coordinate value of the lamp cup processed image and a central coordinate value of the LED lamp panel processed image, and calculate a difference between the generated light spot data value and a preset light spot threshold; the control module 500 is configured to control the driving module to execute a primary calibration path and control the driving module to execute a secondary calibration path; the driving module 600 is configured to perform a primary correction path and a secondary correction path, and it should be noted that the driving module 600 is an LED light source position correction device.
Referring to fig. 4 again, in an embodiment, the image processing module 300 is further configured to perform an identification operation on the lamp cup binary image and the LED lamp panel binary image and a preset LED light source outline condition, so as to generate a lamp cup outline analysis diagram and an LED lamp panel outline analysis diagram.
Referring to fig. 4 again, in an embodiment, the image processing module 300 is further configured to perform a marking operation on the lighting image of the lamp cup and the lighting image of the LED lamp panel, and perform a normalization process to generate a lamp cup outer contour training image, an LED lamp panel outer contour training image, and a light spot training image.
Thus, in the LED light source position correction system 10, the standard image of the through hole region of the lamp cup is stored by the image storage module 100, and before the LED lamp panel and the lamp cup are installed, the collected current lamp cup image is compared with the standard image, so that the accuracy of the installation of the LED lamp panel and the lamp cup is ensured, and the installation efficiency is improved; through image processing module 300, calculation module 400, control module 500 and drive module 600 carry out primary correction and secondary correction to lamp cup and LED lamp plate to can avoid the tolerance of lamp cup or LED lamp plate self to cause the central axis of lamp cup and the central axis of LED lamp plate probably not to overlap or not in qualified precision range, thereby guarantee the uniformity of the precision and the luminance of LED product, simultaneously, through once proofreading and secondary correction, can improve the overlapping precision of the central axis of lamp cup and the central axis of LED lamp plate.
Referring to fig. 7, in another embodiment, the LED light source position calibration apparatus 20 includes a machine 30, a backlight unit 40, a photographing unit 50 and a reflection unit 60, wherein the machine 30 is used for mounting the components, the backlight unit 40 is used for providing illumination, the photographing unit 50 is used for photographing the LED light source, and the reflection unit 60 is used for reflecting light spots.
Referring to fig. 8, a machine 30 is provided with a via hole; the backlight module 40 includes a power-on module 41 and a lamp ring 42, the power-on module 41 is disposed on the machine 30, the lamp ring 42 is disposed on the machine 30, and the lamp ring 42 is electrically connected to the power-on module 41; the photographing component 50 comprises a mounting seat 51, a first industrial camera 52, a second industrial camera 53 and a box body 54, wherein the mounting seat 51 is arranged on the machine table 30, the first industrial camera 52 is arranged on the mounting seat 51, the second industrial camera 53 is arranged on the mounting seat 51, a gap is arranged between the first industrial camera 52 and the second industrial camera 53, a lens of the first industrial camera 51 is aligned with the conduction hole, the box body 54 is arranged on the machine table 30, a light spot projection area is arranged on the box body 54, and the second industrial camera 53 is used for photographing the light spot projection area; the reflection assembly 60 includes a horizontal cylinder 61 and a reflection mirror 62, the horizontal cylinder 61 is disposed on the machine table 30, and the reflection mirror 62 is connected to the horizontal cylinder 61.
Please refer to fig. 2 again, the power-on module 41 is electrically connected to an external power supply, the first industrial camera 52 and the second industrial camera 53 are respectively in communication with an external calibration server, the light spot projection area is a light spot imaging area of the LED light source, and the lens of the second industrial camera 53 is used for capturing the light spots of the LED light source in the light spot imaging area. Further, the reflecting mirror 62 is disposed at an angle of 45 ° with respect to the horizontal ground, and the reflecting mirror 62 is disposed at an angle of 90 ° with respect to the lens of the second industrial camera 53, so as to ensure that the light spot in the light spot imaging area is not distorted. Still further, through setting up box 54, can seal whole facula projection path, and then reduce the scattering of light for the facula is more clearly projected on the facula projection area.
The working process is as follows: when the lamp cup and the LED chip are assembled and placed in the via hole by the rotating device, the power module 41 is powered on to light the lamp ring 42, so as to provide sufficient brightness for the first industrial camera 52 and the second industrial camera 53 to take a picture; next, the first industrial camera 52 takes a picture of the lamp cup and the LED chip, and transmits the picture to the calibration server, and the calibration server controls the rotating device to complete the primary calibration; then, the energizing module 41 lights up the LED chip in the LED light source, the horizontal cylinder 61 drives the reflector 62 to move in the direction approaching the box 54, and the light emitted from the LED light source is reflected to the spot projection area in the box 54 by the reflector 62; finally, the light spot of the light spot projection area is photographed by the lens of the second industrial camera 53, the image is transmitted to the correction server, and the correction server controls the rotating device to complete secondary correction. In this way, the lens of the first industrial camera 52 is aligned with the via hole on the machine table 30, so as to clearly shoot real-time images of the lamp cup and the LED chip, and perform primary correction on the central axis position of the lamp cup and the central axis position of the LED chip; shooting the light spot projection area through a second industrial camera 53 to obtain a light spot image of the LED light source, further performing secondary correction on the central axis position of the lamp cup and the central axis position of the LED chip, and clamping the lamp cup and the LED chip to the next station through a rotating device after the secondary correction is completed; furthermore, through the primary correction and the secondary correction, the correction precision can be more accurate, the precision of each LED product is uniform, and the problem that the correction precision of each LED product is inaccurate due to tolerance in the production or assembly process of the LED products can be avoided by shooting and analyzing the light spot images of the LED light sources.
Referring to fig. 9, in one embodiment, the backlight assembly 40 further includes a fixing plate 43 and a guide rail 44, the guide rail 44 is disposed on the fixing plate 43, and the fixing plate 43 is disposed on the machine 30. Specifically, the backlight module 40 further includes a support 45 and a lifting cylinder 46, the support 45 is slidably disposed on the guide rail 44, the support 45 is connected to the lifting cylinder 46, the lifting cylinder 46 is used for driving the support 45 to perform reciprocating motion in a direction close to or away from the via hole, the lifting cylinder 46 is disposed on the fixing plate 43, and the power-on module 41 is disposed on the support 45. More specifically, the backlight module 40 further includes a supporting plate 47 and a connecting column 48, one end of the connecting column 48 is disposed on the supporting base 45, the other end of the connecting column 48 is disposed on the supporting plate 47, and the lamp ring 42 is disposed on the supporting plate 47. Thus, by arranging the lifting cylinder 46 and the guide rail 47, the support 45 can have a larger moving range, and the lamp ring 42 can better provide the photographing brightness for the first industrial camera 52 and the second industrial camera 53.
Referring to fig. 9 again, in one embodiment, the backlight module 40 further includes a rib 49, and the rib 49 is disposed on the fixing plate 430. In this way, by providing the reinforcing rib 49, the mechanical strength of the fixing plate 43 can be enhanced, and the stability of the entire mechanical structure can be improved.
Referring to fig. 8 again, in an embodiment, the photographing assembly 500 further includes a supporting leg 55, the supporting leg 55 is disposed on the mounting base 51, and the second industrial camera 53 is disposed on the supporting leg 55. Because can produce great vibrations in the middle of the whole mechanism operation, through setting up supporting legs 55, can make second industry camera 53 stabilize and set up on supporting legs 55, and then make the camera lens of second industry camera 53 rock when shooing.
Referring to fig. 7 again, in an embodiment, the LED light source position calibration device 20 further includes a plurality of protrusions, and each protrusion is disposed on an inner sidewall of the via hole at an interval. So, through setting up a plurality of archs, can play the bearing effect to the lamp cup for the lamp cup can not drop.
Referring to fig. 9 again, in an embodiment, the photographing assembly 500 further includes a clamping block 56, and the clamping block 56 is disposed on the mounting base 51. So, through setting up joint piece 56, can make first industry camera 52 firmly block on board 30, can not drop, guaranteed the stability of shooing.
Referring to fig. 7 again, in an embodiment, the LED light source position calibration device 20 further includes a plurality of supporting blocks 70, and each supporting block 70 is disposed on the machine 30. Further, referring to fig. 3 again, the photographing assembly 300 further includes a plurality of bearing blocks 57, and each of the bearing blocks 57 is disposed on the mounting base 54 at intervals. This application is provided with 4 bearing blocks 57 altogether, can guarantee the firm joint of mount pad 51 on board 30 through setting up bearing block 57.
In order to further improve the moving range and the moving accuracy of the backlight unit 40a, as shown in fig. 10, the LED light source position correcting device 80 is a structural diagram of another embodiment of the LED light source position correcting device, and includes: the driving structure of the machine table 30a, the backlight assembly 40a and the backlight assembly 40a adopts an air cylinder, a guide rail and a drag chain, and by adopting the mode, the connecting wire harness with the backlight assembly 40a can be protected, and meanwhile, the movement precision of the air cylinder can be improved.
Compared with the prior art, the invention has the following advantages:
according to the method and the system for correcting the position of the LED light source, the standard image of the through hole area of the lamp cup is stored, and the collected current lamp cup image is compared with the standard image before the LED lamp panel and the lamp cup are installed, so that the accuracy of the installation of the LED lamp panel and the lamp cup is ensured, and the installation efficiency is improved; through carrying out primary correction and secondary correction to lamp cup and LED lamp plate to can avoid the tolerance of lamp cup or LED lamp plate self to cause the central axis of lamp cup and the central axis of LED lamp plate probably not to overlap or not in qualified precision range, thereby guarantee the uniformity of the precision and the luminance of LED product, simultaneously, through once proofreading and secondary correction, can improve the central axis of lamp cup and the central axis's of LED lamp plate overlapping precision.
The above embodiments only express several embodiments of the present invention, and the description thereof is more specific and detailed, but not construed as limiting the scope of the present invention. It should be noted that, for a person skilled in the art, several variations and modifications can be made without departing from the inventive concept, which falls within the scope of the present invention. Therefore, the protection scope of the present patent shall be subject to the appended claims.

Claims (10)

1. The method for correcting the position of the LED light source comprises a lamp cup and an LED lamp panel, wherein a through hole area is arranged at the bottom of the lamp cup, and a plurality of through holes are formed in the through hole area, and is characterized by comprising the following steps of:
storing a standard image of the via region;
correspondingly acquiring a current image of the through hole area aiming at the current lamp cup, and comparing the current image with the standard image to obtain a deflection angle of the current lamp cup;
performing rotation operation of the deflection angle on the lamp cup;
installing the LED lamp panel on the lamp cup;
lighting the LED lamp panel, and enabling the brightness value of the LED lamp panel to reach a primary brightness calibration value;
when the LED light source is lighted under the condition of the primary brightness calibration value, respectively acquiring a lighted image of the lamp cup, a lighted image of the LED lamp panel and a light spot image of the LED light source, and respectively performing image preprocessing operation on the lighted image of the lamp cup, the lighted image of the LED lamp panel and the light spot image of the LED light source to respectively obtain a lamp cup processing image, an LED lamp panel processing image and a light spot processing image;
obtaining a central coordinate value of the lamp cup processing image, a central coordinate value of the LED lamp panel processing image and a light spot data value according to the lamp cup processing image, the LED lamp panel processing image and the light spot processing image respectively;
calculating a difference value between the central coordinate value of the lamp cup processing image and the central coordinate value of the LED lamp panel processing image, generating a primary correction path, and controlling the driving module to execute the primary correction path;
comparing the light spot data value with a preset light spot threshold, if the light spot data value is different from the preset light spot threshold, calculating to generate a difference value between the light spot data value and the preset light spot threshold, generating a secondary correction path, and controlling the driving module to execute the secondary correction path.
2. The LED light source position correction method according to claim 1, wherein, when the LED light source is lit at the initial brightness calibration value in the step, the step of collecting the lit image of the lamp cup, the lit image of the LED lamp panel, and the light spot image of the LED light source, respectively, and performing image preprocessing on the lit image of the lamp cup, the lit image of the LED lamp panel, and the light spot image of the LED light source, respectively, to obtain the lamp cup processed image, the LED lamp panel processed image, and the light spot processed image, specifically includes:
respectively carrying out thresholding on the lighting image of the lamp cup, the lighting image of the LED lamp panel and the light spot image of the LED light source to generate a lamp cup binary image, an LED lamp panel binary image and a light spot binary image;
respectively carrying out recognition operation on the lamp cup binary image and the LED lamp panel binary image and a preset LED light source outline condition to generate a lamp cup outline analysis diagram and an LED lamp panel outline analysis diagram;
splicing and synthesizing the lamp cup outer contour analysis diagram and the LED lamp panel outer contour analysis diagram to generate an LED light source outer contour analysis diagram;
and carrying out partitioning processing operation according to the inscribed circle and the circumscribed rectangle of the LED light source outline analysis diagram, and generating a plurality of independent LED light source outline diagrams.
3. The LED light source position correction method according to claim 2, wherein the step of generating the LED light source outer contour analysis diagram by splicing the lamp cup outer contour analysis diagram with the LED lamp panel outer contour analysis diagram specifically includes:
and carrying out contrast enhancement operation on the LED light source outline picture and the light spot binary picture.
4. The method for correcting the position of the LED light source according to claim 2, wherein thresholding the real-time image of the lamp cup and the real-time image of the LED lamp panel to generate a lamp cup binary picture and an LED lamp panel binary picture respectively comprises:
and acquiring saturation parameters in HSV color models of the lamp cup binary picture, the LED lamp panel binary picture and the facula binary picture.
5. The LED light source position correction method according to claim 1, wherein the step of calculating a difference between a central coordinate value of the lamp cup processed image and a central coordinate value of the LED lamp panel processed image to generate a primary correction path, and the step of controlling the driving module to execute the primary correction path specifically includes:
marking the lighting image of the lamp cup and the lighting image of the LED lamp panel respectively, and performing normalization processing to generate a lamp cup outer contour training image, an LED lamp panel outer contour training image and a light spot training image;
and respectively carrying out convolutional neural network training operation on the lamp cup outer contour training image, the LED lamp panel outer contour training image and the light spot training image.
6. The method according to claim 1, wherein the predetermined spot threshold includes a roundness of a spot threshold, a concentricity of an isocandela threshold of a spot, a size of the spot threshold, and a peripheral smear of the spot.
7. The method according to claim 1, wherein after the step of calculating and generating the center coordinate value of the lamp cup processed image, the center coordinate value of the LED lamp panel processed image, and the light spot data value according to a preset calculation condition, the method further comprises:
and lightening the brightness value of the LED lamp panel to a secondary brightness calibration value.
8. An LED light source position correction system, comprising:
the image storage module is used for storing a standard image of the through hole area;
the image acquisition module is used for collecting the current image of the through hole area, and is also used for acquiring the lighting image of the lamp cup, the lighting image of the LED lamp panel and the light spot image of the LED light source;
the image processing module is used for respectively carrying out image preprocessing operation on the lighting image of the lamp cup, the lighting image of the LED lamp panel and the light spot image of the LED light source to respectively obtain a lamp cup processing image, an LED lamp panel processing image and a light spot processing image;
the calculation module is used for calculating a difference value between a central coordinate value of the lamp cup processed image and a central coordinate value of the LED lamp panel processed image and calculating and generating a difference value between the light spot data value and the preset light spot threshold value;
the control module is used for controlling the driving module to execute the primary correction path and controlling the driving module to execute the secondary correction path;
a drive module to execute the primary correction path and to execute the secondary correction path.
9. The LED light source position correction system of claim 8, wherein the image processing module is further configured to perform recognition operations on the lamp cup binary image and the LED lamp panel binary image and a preset LED light source outline condition, respectively, so as to generate a lamp cup outline analysis map and an LED lamp panel outline analysis map.
10. The system of claim 8, wherein the image processing module is further configured to perform a labeling operation on the lit image of the lamp cup and the lit image of the LED lamp panel, perform a normalization process, and generate a lamp cup outer contour training image, an LED lamp panel outer contour training image, and a light spot training image.
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