CN111721229A - Wire section shape defect detection system and detection method thereof - Google Patents
Wire section shape defect detection system and detection method thereof Download PDFInfo
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- CN111721229A CN111721229A CN201910206706.6A CN201910206706A CN111721229A CN 111721229 A CN111721229 A CN 111721229A CN 201910206706 A CN201910206706 A CN 201910206706A CN 111721229 A CN111721229 A CN 111721229A
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- light source
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- wire rod
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
- G01B11/2433—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures for measuring outlines by shadow casting
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/08—Measuring arrangements characterised by the use of optical techniques for measuring diameters
Abstract
The invention discloses a wire cross-section shape defect detection system and a detection method thereof, wherein the detection system comprises: the light source unit is used for projecting light sources at different angles on the cross section of the wire rod; the projection area is used for receiving the image of the projection of the light source unit on the section diameter of the wire; the acquisition unit is used for acquiring an image of projection imaging formed by the projection area; and the computing unit is used for receiving and computing the image acquired by the acquisition unit. The invention not only can monitor the change of the size and the shape of the interface in the production process of the wire rod on line, but also can monitor the abnormal condition of the surface profile of the surface of the wire rod through the shape difference, thereby providing a quality accident prevention means for the online safe production of the wire rod.
Description
Technical Field
The invention relates to the field of monitoring and controlling of wire production quality, in particular to a wire section shape defect detection system and a detection method thereof.
Background
In the production process of wires such as steel wires and copper wires, the diameter of the wires is a key index for wire production, the diameter of the wires is measured, the diameter of a product can be monitored, an out-of-tolerance product is avoided, the defect of abnormal size generated on the surface of the wires is monitored, and the defects such as abrasion, inclusion, lead hanging and the like can be monitored. In the production process of the wire rod, not only the diameter size of the wire rod needs to be paid attention to, but also some surface defects can be generated in the processing process, wherein some surface defects are not smooth and appear on the difference of appearance colors, and the section size also has abnormal change.
The most common diameter measurement mode is a caliper measurement mode, and the method can only be used for sampling inspection and cannot form an online monitoring scheme in a production line. An automatic measuring device such as a diameter gauge can only complete the wire diameter measuring function and cannot directly perform the profile analysis function.
For example, patent application No. 201610102999.X provides an infrared laser wire rope diameter measurement system based on FPGA, utilizes infrared laser as a detection light source, is a non-contact measurement, does not need to rely on daily maintenance to maintain self inherent accuracy like traditional measuring tool, and inherent accuracy is high. Meanwhile, the FPGA is adopted to complete signal processing, and the integration degree and the measurement efficiency of the whole system are improved. This patent can only measure the cross-sectional diameter in one direction at the same time, and patents of the same principle are also a diameter measuring device for machine measurement of steel wire ropes, such as that provided in patent application No. 201620645276.
Disclosure of Invention
Aiming at the defects in the prior art, the invention aims to provide a system and a method for detecting the shape defects of the cross section of the wire rod, which can monitor the changes of the size and the shape of the interface in the production process of the wire rod on line, can monitor the abnormal conditions of the surface profile of the surface of the wire rod through the shape difference, and provide a quality accident prevention means for the online safe production of the wire rod.
In order to achieve the purpose, the invention adopts the following technical scheme:
in one aspect, a wire cross-sectional shape defect detection system includes:
the light source unit is used for projecting light sources at different angles on the cross section of the wire rod;
the projection area is used for receiving the image of the projection of the light source unit on the section diameter of the wire;
the acquisition unit is used for acquiring an image of projection imaging formed by the projection area;
and the computing unit is used for receiving and computing the image acquired by the acquisition unit.
The light source unit is a parallel light source group and comprises a first light source, a second light source and a third light source.
The projection area is the light curtain, the light curtain with the contained angle that first light source formed is 135, the light curtain with the contained angle that the second light source formed is 90, the light curtain with the contained angle that the third light source formed is 45.
The acquisition unit is an image sensor.
The computing unit is a computer, and the computer is connected with the image sensor.
On the other hand, the method for detecting the shape defects of the cross section of the wire rod comprises the following steps:
1) finishing the arrangement of the parallel light source group, the light curtain, the image sensor and the computer;
2) the wire rod passes through the position of the crossed light source of the parallel light source group, so that the diameter of the cross section of the wire rod forms projection imaging in different directions on the light curtain, and an image sensor acquires the diameter boundary projection of the wire rod in different circumferential directions;
3) the computer detects a target boundary in the image according to the image acquired by the image sensor;
4) detecting the linearity and parallelism of the diameter boundary of the wire rod, judging once and calculating the diameter;
5) and the computer outputs the detection result.
In the step 1), determining the relative position relationship among the parallel light source group, the light curtain and the image sensor to obtain fixed parameter information, wherein the fixed parameter information includes the included angle between each of the first light source, the second light source and the third light source and the light curtain, and the illumination area of each light source on the light curtain.
In the step 4), under normal conditions, the two diameter boundaries of the wire are straight and parallel, and if abnormal, the two diameter boundaries of the wire are not parallel or the diameter boundaries are bent.
The computer performs straight line fitting on the straight line boundary and calculates the maximum value of the distance difference between the boundary point and the fitted straight line;
when the maximum value of the distance difference exceeds a set threshold value, the straight line is bent, the surface of the wire rod is judged to have abnormal contour, otherwise, the diameter boundary of the wire rod is judged to be a straight line boundary;
if the boundaries of one diameter of the wire are all straight lines, calculating the included angle of the boundaries of the straight lines, judging that the wire has abnormal profile if the included angle is larger than a set threshold value, judging that the wire is normal if the included angle is smaller than the set threshold value, and calculating that the two straight lines are the boundary lines of the diameters of the normal wires;
and calculating the diameter D of the wire according to different light source irradiation angles theta of the first light source, the second light source and the third light source, setting the distance between the central points of the two boundary straight lines as D, and comparing the diameters of the wire at a plurality of angles with a standard value, and giving an alarm when the diameter error is larger than a set value.
In the step 5), outputting the detection result according to the result of the step 4), wherein the boundary is bent, the boundary is not parallel or the diameter of the wire rod is output; and judging diameter values in different directions, and outputting abnormity if the deviation exceeds a set value.
In the technical scheme, the system and the method for detecting the defects of the section shape of the wire rod provided by the invention firstly design a set of automatic wire rod section size measuring device and the defects of the surface contour shape of the wire rod, and can replace manual detection, thereby bringing higher precision and efficiency; secondly, compared with a simple automatic dimension measuring device, the design scheme provided by the invention has the advantages that dimension measurement and shape measurement are taken into consideration, and the dimension and shape defects of the section of the wire rod can be more accurately detected and judged. The dimension comparison in different directions on the same section is realized in principle, the interference of jitter factors in the wire production process can be ignored, and therefore the principle is simple and reliable, and the method is easier to apply to the field and obtain stable measurement effect.
Drawings
FIG. 1 is a schematic diagram of a wire cross-sectional shape defect detection system of the present invention in situ;
FIG. 2 is a schematic diagram of a parallel light illumination area and a wire projection area in the wire cross-sectional shape defect detection system of the present invention;
FIG. 3 is a flow chart of the method for detecting defects in the cross-sectional shape of a wire rod according to the present invention.
Detailed Description
The technical scheme of the invention is further explained by combining the drawings and the embodiment.
Referring to fig. 1, a system for detecting defects in a cross-sectional shape of a wire rod provided by the present invention includes:
and the light source unit is used for projecting light sources at different angles on the cross section of the wire rod, and placing the wire rod 1 at the intersection position of the light source projections at different angles.
The projection area is used for receiving the image of the projection of the light source unit on the section diameter of the wire;
the acquisition unit is used for acquiring an image of projection imaging formed by the projection area;
and the calculating unit is used for receiving and calculating and processing the image acquired by the acquiring unit so as to analyze the cross-sectional size and the shape of the wire 1.
Preferably, the light source unit adopts a parallel light source group, which includes a plurality of parallel light sources, such as a first light source 2, a second light source 3, a third light source 4, and the like, the light ray 5 emitting direction of each light source is in one plane, and the optical axis center intersects at a point, that is, the plurality of light sources irradiate a point at different angles, and the point is used for placing the position of the measured object (wire 1).
Preferably, the projection area adopts the light curtain 6, and a plane where the emitting direction of each light source light 5 is located is perpendicular to the light curtain 6, that is, each light source has an illumination area in the light curtain 6, and each illumination area is independent and does not overlap with each other.
Preferably, the collecting unit adopts an image sensor 7, can image the light curtain 6, and covers each illumination area of the parallel light source group.
Preferably, the computing unit adopts a computer 8, the computer 8 is connected with the image sensor 7, and the image sensor 7 collects images and transmits the images to the computer 8 for processing.
Taking the parallel light source group composed of the three parallel light sources (the first light source 2, the second light source 3 and the third light source 4) in fig. 1 as an example, the image effect collected by the image sensor 7 is as shown in fig. 2, and each light source forms an illumination area on the light curtain 6 and forms a projection of the cross-sectional diameter of the wire rod.
As shown in fig. 2, illumination areas i, ii, and iii are defined in the image of the light curtain 6, respectively, corresponding to the first light source 2, the second light source 3, and the third light source 4. The light curtain 6 with the contained angle that first light source 2 formed is 135, light curtain 6 with the contained angle that second light source 3 formed is 90, light curtain 6 with the contained angle that third light source 4 formed is 45. Each light source illumination area is provided with four boundaries, and the boundaries defining the illumination areas I, II and III are respectively defined as I from left to rightA、ⅠB、ⅠC、ⅠD、ⅡA、ⅡB、ⅡC、ⅡD、ⅢA、ⅢB、ⅢC、ⅢD. Wherein IA、ⅠD、ⅡA、ⅡD、ⅢA、ⅢDThe left and right boundaries of the illumination area, respectively, of the light source are influenced by the positional arrangement of the light source and the light curtain 6, and once the spatial arrangement is fixed, the boundaries are fixed. IB、ⅠC、ⅡB、ⅡC、ⅢB、ⅢCRespectively the left and right imaged boundaries of the diameter of the wire 1.
Referring to fig. 3, the present invention further provides a method for detecting defects in the cross-sectional shape of a wire rod, including the following steps:
1) and finishing the arrangement of the parallel light source group, the light curtain 6, the image sensor 7 and the computer 8, determining the relative position relationship of the parallel light source group, the light curtain 6 and the image sensor 7, and obtaining fixed parameter information, wherein the fixed parameter information comprises the included angle angles of the first light source 2, the second light source 3 and the third light source 4 with the light curtain 6 and the illumination area of each light source on the light curtain 6.
2) The wire 1 is passed through the position of the crossed light source of the parallel light source group, the cross section diameter of the wire forms projection images in different directions on the light curtain 6, and the image sensor 7 collects the diameter boundary projections in different circumferential directions of the wire.
3) The computer 8 detects the boundary of the object in the image from the image acquired by the image sensor 7. As shown in fig. 2, there are A, B, C and D in four boundaries in different illumination areas, where boundary a and boundary B are fixed in position, and boundary B and boundary C vary following the position and diameter variation of the wire 1. Thus detection may search for boundary B and boundary C within boundary a and boundary D, respectively, within different regions.
4) And detecting the linearity and the parallelism of the diameter boundary of the wire rod, judging once and calculating the diameter. Normally, the two diametric boundaries of the wire are straight and parallel, and if abnormal, the two diametric boundaries of the wire are not parallel or appear to bend.
Therefore, the computer 8 fits a straight line to the straight boundary and calculates the maximum value of the distance difference between the boundary point and the fitted straight line;
when the maximum value of the distance difference exceeds a set threshold value, the straight line is bent, the surface of the wire rod is judged to have abnormal contour, otherwise, the diameter boundary of the wire rod is judged to be a straight line boundary;
if the boundaries of one diameter of the wire are all straight lines, calculating the included angle of the boundaries of the straight lines, judging that the wire has abnormal profile if the included angle is larger than a set threshold value, judging that the wire is normal if the included angle is smaller than the set threshold value, and calculating that the two straight lines are the boundary lines of the diameters of the normal wires;
and calculating the diameter D of the wire according to different light source irradiation angles theta of the first light source, the second light source and the third light source, setting the distance between the central points of the two boundary straight lines as D, and comparing the diameters of the wire at a plurality of angles with a standard value, and giving an alarm when the diameter error is larger than a set value.
5) The computer 8 outputs the detection result. Outputting the detection result according to the result of the step 4) to obtain the bent boundary, the unparallel boundary or the diameter of the wire; and judging diameter values in different directions, and outputting abnormity if the deviation exceeds a set value.
The method for detecting the defects of the cross section shape of the wire rod can simultaneously obtain the projections of the diameter boundaries of the wire rod 1 in three directions in one image, and analyze the shape and the position of the projection boundaries:
1) and analyzing the linear relation of the projection boundary data, and if the boundary has a curve, indicating that the surface of the wire rod has concave-convex.
2) And comparing the parallelism of the two boundaries of the diameter of the wire rod, and judging that the wire rod has a shape error if the parallel error is greater than a set value.
3) If the two boundaries of the wire diameter are parallel, the distance D between the two boundaries is calculated, and since the parallel light projection direction forms a certain angle θ with the light curtain 6, the wire diameter D has a conversion relationship with the wire projection boundary D, where D is D × sin θ. Defining three projection direction diameters d135, d90 and d45, respectively; and if the difference value between the maximum value and the minimum value of the diameter exceeds a fixed value, the shape error exists, the diameter values in different directions are compared with the standard diameter d, and if the difference value exceeds a set value, the diameter out-of-tolerance alarm is carried out.
At this point, by analyzing and comparing the shape and position of the boundary, it can be determined whether the wire has a shape error, and if the shape is normal, the diameter value of the wire is calculated.
In summary, the system and the method for detecting the shape defect of the cross section of the wire rod of the present invention adopt the machine vision technology, obtain the dimensions of the same cross section of the wire rod in different directions at the same time by a group of parallel light sources, and measure the diameter of the wire rod and judge the abnormal condition of the diameter distribution by analyzing the shape and the position of the boundary of the wire rod.
It should be understood by those skilled in the art that the above embodiments are only for illustrating the present invention and are not to be used as a limitation of the present invention, and that changes and modifications to the above described embodiments are within the scope of the claims of the present invention as long as they are within the spirit and scope of the present invention.
Claims (10)
1. A wire sectional shape defect detection system, comprising:
the light source unit is used for projecting light sources at different angles on the cross section of the wire rod;
the projection area is used for receiving the image of the projection of the light source unit on the section diameter of the wire;
the acquisition unit is used for acquiring an image of projection imaging formed by the projection area;
and the computing unit is used for receiving and computing the image acquired by the acquisition unit.
2. A wire sectional shape defect detecting system as claimed in claim 1, wherein: the light source unit is a parallel light source group and comprises a first light source, a second light source and a third light source.
3. A wire sectional shape defect detecting system as claimed in claim 2, wherein: the projection area is the light curtain, the light curtain with the contained angle that first light source formed is 135, the light curtain with the contained angle that the second light source formed is 90, the light curtain with the contained angle that the third light source formed is 45.
4. A wire sectional shape defect detecting system as claimed in claim 1, wherein: the acquisition unit is an image sensor.
5. A wire sectional shape defect detecting system as claimed in claim 1, wherein: the computing unit is a computer, and the computer is connected with the image sensor.
6. A method for detecting defects in the cross-sectional shape of a wire rod according to any one of claims 1 to 5, comprising the steps of:
1) finishing the arrangement of the parallel light source group, the light curtain, the image sensor and the computer;
2) the wire rod passes through the position of the crossed light source of the parallel light source group, so that the diameter of the cross section of the wire rod forms projection imaging in different directions on the light curtain, and an image sensor acquires the diameter boundary projection of the wire rod in different circumferential directions;
3) the computer detects a target boundary in the image according to the image acquired by the image sensor;
4) detecting the linearity and parallelism of the diameter boundary of the wire rod, judging once and calculating the diameter;
5) and the computer outputs the detection result.
7. The method for detecting the shape defect of the cross section of the wire rod as claimed in claim 6, wherein: in the step 1), determining the relative position relationship among the parallel light source group, the light curtain and the image sensor to obtain fixed parameter information, wherein the fixed parameter information includes the included angle between each of the first light source, the second light source and the third light source and the light curtain, and the illumination area of each light source on the light curtain.
8. The method for detecting the shape defect of the cross section of the wire rod as claimed in claim 6, wherein: in the step 4), under normal conditions, the two diameter boundaries of the wire are straight and parallel, and if abnormal, the two diameter boundaries of the wire are not parallel or the diameter boundaries are bent.
9. The method for detecting defects in the cross-sectional shape of a wire as claimed in claim 7, wherein: the computer performs straight line fitting on the straight line boundary and calculates the maximum value of the distance difference between the boundary point and the fitted straight line;
when the maximum value of the distance difference exceeds a set threshold value, the straight line is bent, the surface of the wire rod is judged to have abnormal contour, otherwise, the diameter boundary of the wire rod is judged to be a straight line boundary;
if the boundaries of one diameter of the wire are all straight lines, calculating the included angle of the boundaries of the straight lines, judging that the wire has abnormal profile if the included angle is larger than a set threshold value, judging that the wire is normal if the included angle is smaller than the set threshold value, and calculating that the two straight lines are the boundary lines of the diameters of the normal wires;
and calculating the diameter D of the wire according to different light source irradiation angles theta of the first light source, the second light source and the third light source, setting the distance between the central points of the two boundary straight lines as D, and comparing the diameters of the wire at a plurality of angles with a standard value, and giving an alarm when the diameter error is larger than a set value.
10. The method for detecting the shape defect of the cross section of the wire rod as claimed in claim 6, wherein: in the step 5), outputting the detection result according to the result of the step 4), wherein the boundary is bent, the boundary is not parallel or the diameter of the wire rod is output; and judging diameter values in different directions, and outputting abnormity if the deviation exceeds a set value.
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Cited By (2)
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| CN112381800A (en) * | 2020-11-16 | 2021-02-19 | 广东电网有限责任公司肇庆供电局 | Wire diameter abnormity identification method and device, electronic equipment and computer readable storage medium |
| CN112577445A (en) * | 2020-12-18 | 2021-03-30 | 深圳市泽峰光电科技有限公司 | Log end face profile extraction method of rotary grating |
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