CN111311544A - Floor defect detection method based on deep learning - Google Patents

Floor defect detection method based on deep learning Download PDF

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CN111311544A
CN111311544A CN202010058893.0A CN202010058893A CN111311544A CN 111311544 A CN111311544 A CN 111311544A CN 202010058893 A CN202010058893 A CN 202010058893A CN 111311544 A CN111311544 A CN 111311544A
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CN111311544B (en
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邹逸
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Wuxi Sim Vision Technology Co ltd
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Abstract

The invention discloses a floor defect detection method based on deep learning, which comprises the following steps: 1) collecting a high-resolution image of a floor by using an industrial camera to establish a floor detection image library; 2) manually labeling the defect area of each defect image in the floor detection image library in the step 1) to form a floor detection image label library; 3) establishing a semantic segmentation model and an image classification model based on deep learning; 4) expanding the floor detection image library acquired in the step 1) by adopting a data enhancement technology; 5) carrying out deep learning training on the floor defect semantic segmentation model and the floor defect classification model on the image library expanded in the step 4); 6) and collecting floor surface images on line and carrying out defect detection on the floor surface based on the trained floor defect classification model. The invention achieves the precision of manual screening without manual interference, can reduce the production cost and promote the intellectualization of the floor industry.

Description

Floor defect detection method based on deep learning
The technical field is as follows:
the invention relates to the technical field of floor defect detection, in particular to a floor defect detection method based on deep learning.
Background art:
the defect detection of the floor is a key link of quality control in the production process of the floor. The existing defect detection mode is mainly completed by manual naked eye screening, and the existing method has the following defects: the detection speed is slow, the detection result is greatly influenced by the experience of quality inspection workers, the detection precision is uncontrollable, the cost of the quality inspection workers is high, and the like. With the appearance and development of scientific technologies such as computer technology, artificial intelligence and the like, the object surface defect detection technology based on the machine vision technology comes to the fore, so that the object surface defect detection effect is improved to a great extent, the object surface defect detection rate is increased, and the influence on the accuracy of the defect detection result caused by factors such as scene conditions, subjective judgment and the like is avoided.
Detection techniques based on conventional image processing recognition techniques still require manual extraction of features, and the design of these features requires a great deal of a priori knowledge and experience. In the flooring industry, the surface of the product is mainly irregular and has a large variety, and the traditional image algorithm is not satisfactory in the situation. Deep learning is an emerging research field, and has the advantages of automatic learning of useful characteristics, strong anti-interference capability and high robustness. The deep learning technology is applied to floor defect detection, so that the existing pain point problem can be well solved.
The information disclosed in this background section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.
The invention content is as follows:
the invention aims to provide a floor defect detection method based on deep learning, so that the defects in the prior art are overcome.
In order to achieve the above object, the present invention provides a floor defect detection method based on deep learning, comprising the following steps:
1) collecting a high-resolution image of a floor by using an industrial camera to establish a floor detection image library;
2) manually labeling the defect area of each defect image in the floor detection image library in the step 1) to form a floor detection image label library;
3) establishing a semantic segmentation model and an image classification model based on deep learning;
4) expanding the floor detection image library acquired in the step 1) by adopting a data enhancement technology;
5) carrying out deep learning training on the floor defect semantic segmentation model and the floor defect classification model on the image library expanded in the step 4);
6) and acquiring an image of the floor surface on line, detecting the defect of the floor surface based on the trained floor defect classification model, and positioning the specific position of the floor defect by using the floor defect semantic segmentation model if the defect exists.
The floor detection image library in the step 1) is composed of high-resolution images collected by an industrial camera, the resolution is more than 1024 × 1024, the ratio of the number of normal image samples to the number of defective image samples in the image library is close to 1:1, the total number of samples in the image library is N, and N is more than 1000.
The semantic segmentation model in the step 3) is composed of an Encoder Encoder and a Decoder Decoder, wherein the Encoder Encoder is a basic network and comprises a convolution layer, a batch normalization layer, a pooling layer and a linear activation layer and is used for automatically extracting depth features of an input image and outputting a group of feature maps; the Decoder comprises a convolution layer and an up-sampling layer and is used for screening a characteristic diagram and outputting a result image, wherein the resolution of the result image is the same as that of an input image.
The image classification model in the step 3) and the semantic segmentation model share parameters of an Encoder Encoder, and a convolution layer and a full connection layer are added on the basis of the Encoder Encoder to form the image classification model.
The data enhancement method in the step 4) comprises image horizontal turning, image vertical turning, image random brightness adjustment, random Gaussian noise disturbance and image random rotation, wherein the range of the image random rotation angle is between-10 degrees and 10 degrees.
When the defect detection is carried out on the floor surface in the step 6), cutting the floor surface image into a plurality of images with 1024 × 1024 resolution, inputting the images into the deep learning image classification model in the step 3), and if one slice is a defect image, judging that the whole image is a defect image; and (3) inputting the floor surface image, wherein the whole image is directly input when the deep learning semantic segmentation model is input in the step 3).
When the floor surface is detected in the step 6), the floor surface image is firstly classified by the floor defect classification model after deep learning training, if the floor surface image is not defective, the floor surface image is judged to be a normal product, and if the floor surface image is defective, the floor surface image is positioned at a specific defect position by the floor semantic segmentation model after deep learning training.
The step 5) of deep learning training of the floor defect semantic segmentation model and the floor defect classification model is carried out according to the following steps:
s1: randomly sampling the image library enhanced in the step 4) according to a ratio of 4:1 to divide the image library into a training set and a verification set;
s2: iterating the deep learning semantic segmentation model in the step 3) on a training set for 150 rounds at most, stopping training if the loss value is converged in the training process, and selecting the model which best appears on a verification set as a final semantic segmentation model;
s3: and 3) reading part of parameters of an Encoder of a trained deep learning semantic segmentation model Encoder by a deep learning image classification model, freezing the part of parameters, iterating on a training set for 150 rounds at most, only finely adjusting a convolution layer and a full connection layer except the Encoder in the image classification model, stopping training if the loss value is converged in the training process, and selecting the model which best appears on a verification set as a final classification model.
The step 4) of S1) cutting the enhanced image into a plurality of 1024 × 1024 resolution image inputs.
During the training, the deep learning semantic segmentation model takes DICELoss as an optimization target; during training, the deep learning classification model takes crossEntropyLoss as an optimization target.
And the floor defect classification model and the floor defect semantic segmentation model trained in the step 6 are pth files derived by solidifying the model trained in the step 5.
Compared with the prior art, the invention has the following beneficial effects:
the floor defect classification model and the floor defect semantic segmentation model are trained by adopting an image classification technology and a semantic segmentation technology based on deep learning, and a newly acquired image is detected in real time by taking the models as a basis, so that the high-precision defect classification and defect positioning can be carried out on the floor in real time; compared with the traditional image identification method, the method has the advantages that the key features in the floor image are automatically extracted, the complicated manual feature extraction link is omitted, and the detection speed and precision can be improved; the invention achieves the precision of manual screening without manual interference, can reduce the production cost and promote the intellectualization of the floor industry.
Description of the drawings:
FIG. 1 is a schematic diagram of a deep learning-based floor defect detection method of the present invention;
the specific implementation mode is as follows:
the following detailed description of specific embodiments of the invention is provided, but it should be understood that the scope of the invention is not limited to the specific embodiments.
Throughout the specification and claims, unless explicitly stated otherwise, the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element or component but not the exclusion of any other element or component.
As shown in fig. 1, a method for detecting a floor defect based on deep learning includes the following steps:
1) collecting a high-resolution image of a floor by using an industrial camera to establish a floor detection image library;
2) manually labeling the defect area of each defect image in the floor detection image library in the step 1) to form a floor detection image label library;
3) establishing a semantic segmentation model and an image classification model based on deep learning;
4) expanding the floor detection image library acquired in the step 1) by adopting a data enhancement technology;
5) carrying out deep learning training on the floor defect semantic segmentation model and the floor defect classification model on the image library expanded in the step 4);
6) and acquiring an image of the floor surface on line, detecting the defect of the floor surface based on the trained floor defect classification model, and positioning the specific position of the floor defect by using the floor defect semantic segmentation model if the defect exists.
The floor detection image library in the step 1) is composed of high-resolution images collected by an industrial camera, the resolution is more than 1024 × 1024, the ratio of the number of normal image samples to the number of defective image samples in the image library is close to 1:1, the total number of samples in the image library is N, and N is more than 1000.
The semantic segmentation model in the step 3) is composed of an Encoder Encoder and a Decoder Decoder, wherein the Encoder Encoder is a basic network and comprises a convolution layer, a batch normalization layer, a pooling layer and a linear activation layer and is used for automatically extracting depth features of an input image and outputting a group of feature maps; the Decoder comprises a convolution layer and an up-sampling layer and is used for screening a characteristic diagram and outputting a result image, wherein the resolution of the result image is the same as that of an input image.
The image classification model in the step 3) and the semantic segmentation model share parameters of an Encoder Encoder, and a convolution layer and a full connection layer are added on the basis of the Encoder Encoder to form the image classification model.
The data enhancement method in the step 4) comprises image horizontal turning, image vertical turning, image random brightness adjustment, random Gaussian noise disturbance and image random rotation, wherein the range of the image random rotation angle is between-10 degrees and 10 degrees.
When the defect detection is carried out on the floor surface in the step 6), cutting the floor surface image into a plurality of images with 1024 × 1024 resolution, inputting the images into the deep learning image classification model in the step 3), and if one slice is a defect image, judging that the whole image is a defect image; and (3) inputting the floor surface image, wherein the whole image is directly input when the deep learning semantic segmentation model is input in the step 3).
When the floor surface is detected in the step 6), the floor surface image is firstly classified by the floor defect classification model after deep learning training, if the floor surface image is not defective, the floor surface image is judged to be a normal product, and if the floor surface image is defective, the floor surface image is positioned at a specific defect position by the floor semantic segmentation model after deep learning training.
The step 5) of deep learning training of the floor defect semantic segmentation model and the floor defect classification model is carried out according to the following steps:
s1: randomly sampling the image library enhanced in the step 4) according to a ratio of 4:1 to divide the image library into a training set and a verification set;
s2: iterating the deep learning semantic segmentation model in the step 3) on a training set for 150 rounds at most, stopping training if the loss value is converged in the training process, and selecting the model which best appears on a verification set as a final semantic segmentation model;
s3: and 3) reading part of parameters of an Encoder of a trained deep learning semantic segmentation model Encoder by a deep learning image classification model, freezing the part of parameters, iterating on a training set for 150 rounds at most, only finely adjusting a convolution layer and a full connection layer except the Encoder in the image classification model, stopping training if the loss value is converged in the training process, and selecting the model which best appears on a verification set as a final classification model.
The step 4) of S1) cutting the enhanced image into a plurality of 1024 × 1024 resolution image inputs.
During the training, the deep learning semantic segmentation model takes DICELoss as an optimization target; during training, the deep learning classification model takes crossEntropyLoss as an optimization target.
And the floor defect classification model and the floor defect semantic segmentation model trained in the step 6 are pth files derived by solidifying the model trained in the step 5.
In the training process, only data in the training set can perform data enhancement operation during iteration, the verification set does not perform data enhancement, the loss value of the model on the verification set can be calculated after each iteration is finished, and the model with the minimum loss value is stored as a Pythrch pth file. The initialization parameters used by the model during training are model parameters obtained by training on the ImageNet classification data set; during training, the parameter updating mode is Adam, the initial learning rate is 0.001, and the batch size is 8.
The floor defect classification model and the floor defect semantic segmentation model are trained by adopting an image classification technology and a semantic segmentation technology based on deep learning, and a newly acquired image is detected in real time by taking the models as a basis, so that the high-precision defect classification and defect positioning can be carried out on the floor in real time; compared with the traditional image identification method, the method has the advantages that the key features in the floor image are automatically extracted, the complicated manual feature extraction link is omitted, and the detection speed and precision can be improved; the invention achieves the precision of manual screening without manual interference, can reduce the production cost and promote the intellectualization of the floor industry.
The foregoing descriptions of specific exemplary embodiments of the present invention have been presented for purposes of illustration and description. It is not intended to limit the invention to the precise form disclosed, and obviously many modifications and variations are possible in light of the above teaching. The exemplary embodiments were chosen and described in order to explain certain principles of the invention and its practical application to enable one skilled in the art to make and use various exemplary embodiments of the invention and various alternatives and modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims and their equivalents.

Claims (10)

1. A floor defect detection method based on deep learning is characterized in that: the following steps:
1) collecting a high-resolution image of a floor by using an industrial camera to establish a floor detection image library;
2) manually labeling the defect area of each defect image in the floor detection image library in the step 1) to form a floor detection image label library;
3) establishing a semantic segmentation model and an image classification model based on deep learning;
4) expanding the floor detection image library acquired in the step 1) by adopting a data enhancement technology;
5) carrying out deep learning training on the floor defect semantic segmentation model and the floor defect classification model on the image library expanded in the step 4);
6) and acquiring an image of the floor surface on line, detecting the defect of the floor surface based on the trained floor defect classification model, and positioning the specific position of the floor defect by using the floor defect semantic segmentation model if the defect exists.
2. The floor defect detection method based on deep learning as claimed in claim 1, wherein: the floor detection image library in the step 1) is composed of high-resolution images collected by an industrial camera, the resolution is more than 1024 × 1024, the ratio of the number of normal image samples to the number of defective image samples in the image library is close to 1:1, the total number of samples in the image library is N, and N is more than 1000.
3. The floor defect detection method based on deep learning as claimed in claim 1, wherein: the semantic segmentation model in the step 3) is composed of an Encoder Encoder and a Decoder Decoder, wherein the Encoder Encoder is a basic network and comprises a convolution layer, a batch normalization layer, a pooling layer and a linear activation layer and is used for automatically extracting depth features of an input image and outputting a group of feature maps; the Decoder comprises a convolution layer and an up-sampling layer and is used for screening a characteristic diagram and outputting a result image, wherein the resolution of the result image is the same as that of an input image.
4. The floor defect detection method based on deep learning as claimed in claim 1, wherein: the image classification model in the step 3) and the semantic segmentation model share parameters of an Encoder Encoder, and a convolution layer and a full connection layer are added on the basis of the Encoder Encoder to form the image classification model.
5. The floor defect detection method based on deep learning as claimed in claim 1, wherein: the data enhancement method in the step 4) comprises image horizontal turning, image vertical turning, image random brightness adjustment, random Gaussian noise disturbance and image random rotation, wherein the range of the image random rotation angle is between-10 degrees and 10 degrees.
6. The floor defect detection method based on deep learning as claimed in claim 1, wherein: when the defect detection is carried out on the floor surface in the step 6), cutting the floor surface image into a plurality of images with 1024 × 1024 resolution, inputting the images into the deep learning image classification model in the step 3), and if one slice is a defect image, judging that the whole image is a defect image; and (3) inputting the floor surface image, wherein the whole image is directly input when the deep learning semantic segmentation model is input in the step 3).
7. The floor defect detection method based on deep learning as claimed in claim 1, wherein: when the floor surface is detected in the step 6), the floor surface image is firstly classified by the floor defect classification model after deep learning training, if the floor surface image is not defective, the floor surface image is judged to be a normal product, and if the floor surface image is defective, the floor surface image is positioned at a specific defect position by the floor semantic segmentation model after deep learning training.
8. The floor defect detection method based on deep learning as claimed in claim 1, wherein: the step 5) of deep learning training of the floor defect semantic segmentation model and the floor defect classification model is carried out according to the following steps:
s1: randomly sampling the image library enhanced in the step 4) according to a ratio of 4:1 to divide the image library into a training set and a verification set;
s2: iterating the deep learning semantic segmentation model in the step 3) on a training set for 150 rounds at most, stopping training if the loss value is converged in the training process, and selecting the model which best appears on a verification set as a final semantic segmentation model;
s3: and 3) reading part of parameters of an Encoder of a trained deep learning semantic segmentation model Encoder by a deep learning image classification model, freezing the part of parameters, iterating on a training set for 150 rounds at most, only finely adjusting a convolution layer and a full connection layer except the Encoder in the image classification model, stopping training if the loss value is converged in the training process, and selecting the model which best appears on a verification set as a final classification model.
9. The floor defect detection method based on deep learning as claimed in claim 7, wherein: the step 4) of S1) cutting the enhanced image into a plurality of 1024 × 1024 resolution image inputs.
10. The floor defect detection method based on deep learning as claimed in claim 7, wherein: during the training, the deep learning semantic segmentation model takes DICELoss as an optimization target; during training, the deep learning classification model takes crossEntropyLoss as an optimization target.
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CN113837209A (en) * 2020-06-23 2021-12-24 乐达创意科技股份有限公司 Method and system for improved machine learning using data for training
CN112132784A (en) * 2020-08-22 2020-12-25 安徽大学 Method for classifying and segmenting industrial magnetic tile defect image based on small sample deep convolution neural network
CN111986199A (en) * 2020-09-11 2020-11-24 征图新视(江苏)科技股份有限公司 Unsupervised deep learning-based wood floor surface flaw detection method
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CN112365443A (en) * 2020-10-16 2021-02-12 珠海市奥德维科技有限公司 Hexahedron defect detection method and medium based on deep learning
CN112990392A (en) * 2021-05-20 2021-06-18 四川大学 New material floor defect target detection system based on improved YOLOv5 algorithm
CN113283541A (en) * 2021-06-15 2021-08-20 无锡锤头鲨智能科技有限公司 Automatic floor sorting method
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CN113344888A (en) * 2021-06-17 2021-09-03 四川启睿克科技有限公司 Surface defect detection method and device based on combined model
CN113627315A (en) * 2021-08-06 2021-11-09 上海华测导航技术股份有限公司 Method for preprocessing data from edge-end camera to algorithmic reasoning process
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