CN110639835A - Online composite rod visual detection system - Google Patents
Online composite rod visual detection system Download PDFInfo
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- CN110639835A CN110639835A CN201910911019.4A CN201910911019A CN110639835A CN 110639835 A CN110639835 A CN 110639835A CN 201910911019 A CN201910911019 A CN 201910911019A CN 110639835 A CN110639835 A CN 110639835A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/34—Sorting according to other particular properties
Abstract
The invention belongs to the technical field of on-line visual detection systems, and relates to an on-line composite rod visual detection system. The system control execution module is used for executing the following actions: a, B, Z signals of a main shaft encoder are collected into a high-speed counter of the PLC, the output quantity respectively controls yellow, green, red and buzzing of an LED acousto-optic alarm lamp, and a high-speed electromagnetic valve guide vent valve of a removing port is used for removing the special-shaped composite rod; the input and output of the digital quantity and the analog quantity integrated by the PLC can be directly connected with a process signal; compared with other composite rod detection technologies, the online composite rod visual detection system has higher detection speed and accuracy, so that the production efficiency and the automation degree of the composite rod can be greatly improved. The on-line composite rod system adopts the modern optomechanical-electrical automation technology and the image processing technology, and has the advantages of rapidness, accuracy, high automation degree, simple operation, reliable quality and the like.
Description
Technical Field
The invention belongs to the technical field of on-line visual detection systems, and relates to an on-line composite rod visual detection system.
Background
The forming and composite production processes of the cigarette composite rod generally generate defective inferior-quality products, and the problems of inaccurate length, wrong arrangement, splicing gaps, material mixing and the like exist in the composite rod composite process, and screening and removing the inferior-quality products of the composite rod is an important production link for improving the quality of the cigarette composite rod product.
The traditional method for detecting inferior-quality products of composite rods adopts a manual sampling method, but the defects of low detection speed, high detection error rate and the like exist in the manual sampling detection, so that the requirements of high speed and accurate detection cannot be met at present. At present, the domestic common automatic detection and elimination methods for defective composite rods comprise a sensor detection method and a microwave detection method, the detection speed and the detection effect of the detection methods are improved compared with a manual sampling method, but the detection methods have the defects of higher equipment cost and poorer detection effect, so that the detection speed of the composite rod products needs to be further improved, and the false alarm rate of the defective composite rods needs to be reduced.
Disclosure of Invention
The invention aims to provide an online composite rod visual detection system suitable for a tobacco production line and capable of improving product quality detection of the production line. In order to achieve the purpose, the invention adopts the following technical scheme.
An online composite rod visual inspection system comprising a system control execution module for performing the following actions: a, B, Z signals of a main shaft encoder are collected into a high-speed counter of the PLC, yellow, green, red and buzzing of an LED acousto-optic alarm lamp are respectively controlled by output quantities, a high-speed electromagnetic valve of a removing port leads a vent valve to remove a special-shaped composite rod, and when the system stops detection, a red lamp flickers; when the device is connected with an upper computer, the red and green lamps twinkle; when the system starts to detect, the green light is always on; when the special-shaped composite rod exists, the yellow lamp is on and buzzes for 3S; when the special-shaped composite rod exists, the upper computer sends data to the PLC, and when the special-shaped composite rod is waited to move from the detection port to the removing port, the PLC outputs an electromagnetic valve to conduct an air valve to remove the special-shaped composite rod;
a logic control unit used by the online composite rod machine vision detection system selects a loose PLC, digital quantity and analog quantity input and output integrated by the PLC can be directly connected with a process signal, and the online composite rod machine vision detection system has ultra-high speed operation processing, specific parameters of the system are 0-3000 steps, ultra-high speed 80ns/ST instructions and support 8 digital quantity input/8 digital quantity output, the basic instruction speed of FP0 is 900ns, and FP0R is 1.5 times of the speed, namely 600 ns. The PLC has the characteristic that the production performance of the composite rod can be greatly improved. It uses the control unit of the RS232C port and corresponding serial communication.
The system further comprises an online composite rod vision detection module, an upper camera collects images above the composite rod in real time, a lower camera collects images at the bottom of the composite rod in real time, the collected image data are transmitted to a lower computer at a detection end through an image collection card corresponding to each camera, a lower computer image processing system analyzes and processes the product images according to preset parameters, after the product defects are identified, all information such as the defect images, the defect types, the defect sizes and the defect positions are stored in a database, the defect images and the related information of the defects are displayed in real time through the upper computer, and an alarm signal and a rejection signal are output through the signal processing system.
Further improvements to the aforementioned online composite rod visual inspection system include, further comprising a system interface: the real-time image area is used for displaying the image of the product being monitored in real time, so that the detection parameters or hardware can be conveniently adjusted at any time; the defect type statistical graph area is used for displaying the number of defects in each type and counting the proportion of the defects in the total number of the defects, so that the production link can be adjusted in a targeted manner; the method comprises a defect picture wall area, the defect picture, the serial number, the time, the category and the like are displayed in real time, and the defect detection value and the defect deviation value can be compared, so that the method is clearer and more intuitive; the system comprises a menu area and a main control area, and various detection parameters are set for detected products.
Further improvements to the foregoing online composite rod visual inspection system include the following sampling process: the composite rods judged to be qualified by the online composite rod system are marked as T rods, the T rods take boxes as units, the composite rods judged to be unqualified are marked as F rods, 1000 composite rods are extracted from the F rods to be tested, the proportion of the qualified composite rods is determined, the error rate is the error detection rate of the detection system, the average value of the omission factor and the error detection rate of each sampling is the sampling error rate of the detection system and is marked as ER, and the average error rate after 10 times of manual sampling is marked as AER to detect the performance of the visual detection system.
The beneficial effects are that:
compared with other composite rod detection technologies, the online composite rod visual detection system has higher detection speed and accuracy, so that the production efficiency and the automation degree of the composite rod can be greatly improved. The on-line composite rod system adopts the modern optomechanical-electrical automation technology and the image processing technology, and has the advantages of rapidness, accuracy, high automation degree, simple operation, reliable quality and the like. Therefore, the production rate and the production quality of the cigarette composite rod are effectively improved for the tobacco company, and higher economic benefit and social benefit are created for the tobacco company.
Drawings
FIG. 1 is a schematic diagram of an on-line composite rod vision inspection system.
The reference numbers include: camera 1, light source 2, rejecting device 3.
Detailed Description
The invention is described in detail below with reference to specific embodiments.
The on-line composite rod vision detection system is shown in fig. 1, and comprises an LED light source, an optical lens, a CCD camera, an image acquisition card, an image processing module, an industrial personal computer, an encoder and the like. After the system is started and operated, a user inputs detection parameters required by detection, the system calculates delay counting triggered by frames according to the parameters and transmits the delay counting to the camera, the camera is ensured to accurately acquire composite rod images, the parameter setting is finished, a 'start' button of the system is clicked, and the system enters a detection state.
The online composite rod vision detection module collects images of a composite rod by using a double camera, the upper camera collects images above the composite rod in real time, and the lower camera collects images at the bottom of the composite rod in real time. The collected image data is transmitted to a lower computer at a detection end through an image acquisition card corresponding to each camera, the system carries out a series of analysis and processing on a product image according to preset parameters by an image processing system of the lower computer, after the product defect is identified, all information such as a defect image, a defect type, a defect size, a defect position and the like is stored in a database, the defect image and related information of the defect are displayed in real time through the upper computer, and an alarm signal, a rejection signal and the like are output through a signal processing system.
The light source selection of the online composite rod visual detection system accords with the hardware environment of composite rod production equipment and the product characteristics of the composite rod. The production line of the composite rod production equipment is high in speed, and the composite rod product is slender, so that a light source working in a narrow environment is needed. The LED illuminating light source is easy to customize and expand, so the LED light source is selected for the online composite rod visual detection system. The selected LED light source has high brightness and reflectivity, so that the interference of ambient light can be overcome, and the signal-to-noise ratio of the image is improved to ensure the quality of the acquired image. The LED linear light source is selected according to the slender physical characteristics of the composite rod, the service life of the LED linear light source can reach 10 ten thousand hours, and therefore the maintenance work of the light source in the later period can be reduced. When the LED linear light source is used, a proper sealed light source box is designed to prevent dust and the influence of the surrounding environment, and light attenuation caused by use and dust can be timely compensated.
The optical lens is a high-definition industrial lens, the resolution ratio of the optical lens is 500 ten thousand pixels, the focal length is 50mm, the aperture range is F2.8-22, and the optical lens has the following advantages:
1. ultra-high resolution, high contrast: the 2/3 type CCD camera with the pixel pitch of 3.45 mu m and the resolution of 500 ten thousand pixels can realize the high resolution of 140lp/mm from the center to the edge. Even the periphery does not have great resolution reduction, and a clear and sharp image with high contrast can be obtained;
2. miniaturized design of Φ 43 mm: the outer diameter of the lens is limited to phi 43mm, so that the miniaturization is realized, and the lens is suitable for production equipment of composite rods;
3. minimal optical distortion: the optical distortion at the diagonal edge may not exceed 1%. For the field of image and image measurement with very small deformation, the method is suitable for the characteristics of a composite rod slender product;
4. lens bright until edge part acquisition: the lens can control the attenuation of the edge light as much as possible, and can obtain images which are bright until the edge and high in definition so as to facilitate later-stage image processing.
The online composite rod visual detection system adopts a high-performance multi-line scanning digital camera P4 series which has a special linear array CMOS sensor structure, high acquisition speed and excellent signal-to-noise ratio. The linear array camera has the resolution of 4k, the pixel size of 10.56 microns multiplied by 10.56 microns, the photosensitive performance is optimized, and the line frequency can reach 40KHz at most. The P4 color three-line CMOS sensor provides a single image capture area and outputs color information for each channel (red, green, blue) so that optimum color reduction performance can be obtained. Accurate sensor alignment can simplify the complexity of system-level multi-camera calibration. The Camera Link interface of the camera uses a high-level chip, so that the transmission distance can reach more than 15 meters. These characteristics of the P4 series can meet the high speed requirements of composite rod production equipment, and at the same time, can acquire excellent composite rod images and can quickly transmit to facilitate subsequent image processing operations, thereby meeting the requirements of high speed and high quality production of composite rods.
The image acquisition card can adopt X64, and X64 is a CameraLink image acquisition card based on a PCIExpressx1 interface. PCI-Express is a serial digital interface technology that provides dedicated bandwidth for each patch device while reducing the complexity of the PCB design. X64 supports up to two independent Base or one mediumcamera link color or black and white video cameras. The X64 image acquisition card supports a mature Trigger-to-image reliability framework of DALSA, the clock frequency of an acquisition pixel is as high as 85MHz, and the clock frequency can completely meet the high-speed requirement of composite rod production. Another advantage of the X64 image acquisition card is its extremely cost effective performance.
The logic control unit used by the on-line composite rod machine vision detection system selects the Panasonic PLC, and the PLC is suitable for being installed in an integrated structure, and has FP0R superior to a subminiature basic model, so that more excellent performance can be obtained, and the functional requirements of the system can be met. The PLC integrated digital quantity and analog quantity input and output can be directly connected with a process signal, and the PLC integrated digital quantity and analog quantity input and output device has ultra-high speed operation processing, and has the specific parameters of 0-3000 steps, ultra-high speed 80ns/(ST instruction) and support of 8 digital quantity input/8 digital quantity output. FP0 has a basic command speed of 900ns, while FP0R is 1.5 times that speed, 600 ns. The PLC has the characteristic that the production performance of the composite rod can be greatly improved. It uses the control unit of the RS232C port and corresponding serial communication.
The control execution module of the online composite rod machine vision detection system is mainly used for: a, B, Z signals of the main shaft encoder are collected to a high-speed counter of the PLC, yellow, green, red and buzzing of the LED acousto-optic alarm lamp are respectively controlled by output quantity, and the high-speed electromagnetic valve of the rejecting port conducts an air valve to reject the special-shaped composite rod. When the system stops detecting, the red light flickers; when the device is connected with an upper computer, the red and green lamps twinkle; when the system starts to detect, the green light is always on; when the special-shaped composite rod exists, the yellow lamp is turned on and buzzes (the buzzing function can be turned off on the upper computer) for 3S; when the special-shaped composite rod exists, the upper computer sends data to the PLC, and when the special-shaped composite rod is waited to move from the detection port to the removing port, the PLC outputs the electromagnetic valve to conduct the air valve to remove the special-shaped composite rod.
Finally, it should be noted that the above embodiments are only used for illustrating the technical solutions of the present invention, and not for limiting the protection scope of the present invention, although the present invention has been described in detail with reference to the preferred embodiments, it should be understood by those skilled in the art that modifications or equivalent substitutions can be made on the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.
Claims (4)
1. An online composite rod visual inspection system, comprising a system control execution module, wherein the system control execution module is configured to perform the following actions: a, B, Z signals of a main shaft encoder are collected into a high-speed counter of the PLC, yellow, green, red and buzzing of an LED acousto-optic alarm lamp are respectively controlled by output quantities, a high-speed electromagnetic valve of a removing port leads a vent valve to remove a special-shaped composite rod, and when the system stops detection, a red lamp flickers; when the device is connected with an upper computer, the red and green lamps twinkle; when the system starts to detect, the green light is always on; when the special-shaped composite rod exists, the yellow lamp is on and buzzes for 3S; when the special-shaped composite rod exists, the upper computer sends data to the PLC, and when the special-shaped composite rod is waited to move from the detection port to the removing port, the PLC outputs an electromagnetic valve to conduct an air valve to remove the special-shaped composite rod;
a logic control unit used by the online composite rod machine vision detection system selects a loose PLC, digital quantity and analog quantity input and output integrated by the PLC can be directly connected with a process signal, and the online composite rod machine vision detection system has ultra-high speed operation processing, specific parameters of the system are 0-3000 steps, ultra-high speed 80ns/ST instructions and support 8 digital quantity input/8 digital quantity output, the basic instruction speed of FP0 is 900ns, and FP0R is 1.5 times of the speed, namely 600 ns.
2. The on-line composite rod vision inspection system of claim 1, wherein the on-line composite rod vision inspection module uses two cameras to collect images of the composite rod, the upper camera collects images of the upper part of the composite rod in real time, the lower camera collects images of the bottom part of the composite rod in real time, the collected image data are transmitted to the lower computer at the inspection end through an image collection card corresponding to each camera, the system further carries out a series of analysis and processing on the product images through an image processing system at the lower computer according to preset parameters, after the product defects are identified, all information such as the defect images, defect types, defect sizes, defect positions and the like are stored in a database, the defect images and related information of the defects are displayed in real time through the upper computer, and meanwhile, an alarm signal and a rejection signal are output through the signal processing system.
3. The on-line composite rod visual inspection system of claim 1, further comprising a system interface: the real-time image area is used for displaying the image of the product being monitored in real time, so that the detection parameters or hardware can be conveniently adjusted at any time; the defect type statistical graph area is used for displaying the number of defects in each type and counting the proportion of the defects in the total number of the defects, so that the production link can be adjusted in a targeted manner; the method comprises a defect picture wall area, the defect picture, the serial number, the time, the category and the like are displayed in real time, and the defect detection value and the defect deviation value can be compared, so that the method is clearer and more intuitive; the system comprises a menu area and a main control area, and various detection parameters are set for detected products.
4. The on-line composite rod vision inspection system of claim 1, wherein the sampling process is as follows: the composite rods judged to be qualified by the online composite rod system are marked as T rods, the T rods take boxes as units, the composite rods judged to be unqualified are marked as F rods, 1000 composite rods are extracted from the F rods to be tested, the proportion of the qualified composite rods is determined, the error rate is the error detection rate of the detection system, the average value of the omission factor and the error detection rate of each sampling is the sampling error rate of the detection system and is marked as ER, and the average error rate after 10 times of manual sampling is marked as AER to detect the performance of the visual detection system.
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| CN201910911019.4A CN110639835A (en) | 2019-09-25 | 2019-09-25 | Online composite rod visual detection system |
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| CN201910911019.4A CN110639835A (en) | 2019-09-25 | 2019-09-25 | Online composite rod visual detection system |
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| CN113092479A (en) * | 2021-04-28 | 2021-07-09 | 北京安道拓汽车部件有限公司 | General vision mistake-proofing system for automotive interior |
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Application publication date: 20200103 |