CN112683912A - Cloth cover defect visual detection method and device - Google Patents
Cloth cover defect visual detection method and device Download PDFInfo
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Abstract
The invention discloses a visual detection method and a device for cloth cover defects, which comprises the steps of adjusting a white light source to work at different brightness in sequence, and simultaneously utilizing an area-array camera to respectively capture a picture at each brightness; respectively calculating the mean difference of pixels in each picture; judging the display color of the multicolor light source according to the pixel average value difference of the picture; calculating according to the parameter values of the multicolor light source and the white light source to obtain the optimal brightness parameter value of the selected multicolor light source; obtaining a brightness control proportion value of the optimal light source according to the optimal brightness parameter value; adjusting the multicolor light source according to the display color and the optimal light source brightness control proportion value; and turning off the white light source; acquiring a picture under a set visual effect through a line camera; and analyzing the cloth cover defects of the acquired pictures under the set visual effect. The invention improves the adaptability of the automatic detection system in practical application and can effectively detect the cloth cover defects of different fabrics.
Description
Technical Field
The invention belongs to the technical field of cloth cover detection, and particularly relates to a cloth cover defect visual detection method and a device thereof.
Background
The detection of the textile production enterprise on the supplied materials of the cloth is an important link for ensuring the product quality. Along with the rapid progress of the technology, more and more enterprises adopt the automatic detection system to finish the cloth defect detection, thereby improving the detection efficiency, preventing the misjudgment caused by the eyestrain of people and avoiding damaging the health and eyesight of detection personnel.
Because the automatic detection equipment has higher technical requirements on operators, after debugging, fixed parameter configuration is usually adopted, and good effects can be obtained for partial fabrics and colors. However, in an actual production environment, the method is difficult to adapt to various fabrics and colors, so that a large number of enterprises still adopt a manual detection mode. Therefore, the existing cloth cover automatic detection equipment has poor adaptability in practical application, cannot detect different fabrics and has low detection precision.
Disclosure of Invention
In order to solve the problems, the invention provides a visual detection method and a device for cloth surface defects, which improve the adaptability of an automatic detection system in practical application and can effectively detect the cloth surface defects of different fabrics.
In order to achieve the purpose, the invention adopts the technical scheme that: a cloth cover defect visual detection method, the cloth cover checkout gear includes the detection assembly, detect the cloth cover through the detection assembly, the said detection assembly includes white light source, polychrome light source, area-array camera and line array camera, including the step:
s10, adjusting the white light source to work at different brightness in sequence, and simultaneously using the area-array camera to capture a picture at each brightness;
s20, respectively calculating the mean difference of the pixels in each picture;
s30, judging the display color of the multicolor light source according to the pixel average value difference of the picture;
s40, calculating according to the multicolor light source and white light source parameter values to obtain the optimal brightness parameter value of the selected multicolor light source;
s50, obtaining the brightness control proportion value of the optimal light source according to the optimal brightness parameter value;
s60, adjusting the multi-color light source according to the display color and the optimal light source brightness control ratio value; and turning off the white light source;
s70, acquiring pictures under a set visual effect through the line camera;
and S80, analyzing the cloth cover defects by using the obtained pictures with the set visual effect.
Further, the white ring light source is adjusted to work at 20%, 40%, 60%, 80% and 100% brightness in sequence, and simultaneously a picture is captured at each brightness by the area-array camera, so as to obtain a picture group [ P1, P2, P3, P4, P5 ].
Further, R, G, B mean values of each pixel of each picture are calculated respectively, and then the absolute value of the difference between every two mean values of each picture R, G, B is calculated to obtain the mean value difference of the pixels in the picture: PnRG, PnRB, PnGB;
wherein n is the number of the captured pictures 1-5, RG represents the absolute value of the difference between R and G, RB represents the absolute value of the difference between R and B, and GB represents the absolute value of the difference between G and B.
Further, the method for judging the display color of the multicolor light source according to the pixel average value difference of the picture comprises the following steps:
if the average value difference of at least 3 pictures is larger than the set threshold value and is the same average value difference, selecting the color with the largest average value of R, G, B as the display color of the multicolor light source;
if the average value difference of at least 3 pictures is larger than the set threshold value and is different, selecting the color with the largest average value difference ratio as the display color of the multicolor light source;
if the average value difference is not larger than the set threshold value, the display color of the multicolor light source is set to be red.
Further, obtaining an optimal brightness parameter value of the selected multicolor light source according to calculation through the multicolor light source and the white light source, comprising the steps of:
according to the formula of the light source brightness change curve
Calculating the optimal brightness parameter value of the selected multicolor light source;
d is the contrast debugging of each strip light source to the white light source, and corresponding fixed parameters are configured; y is the maximum value of the average value of the snapshot picture, and x is the brightness control proportion value of the strip-shaped light source; a, b and c are coefficients of a light source brightness change curve formula;
and according to the selected 3 pictures with the largest mean difference, calculating the values of b and c through the formula to serve as the optimal brightness parameter value of the selected multicolor light source.
Further, the brightness control proportion value of the optimal light source is obtained according to the optimal brightness parameter value calculation, and the calculation formula is as follows:
the cloth cover detection device further comprises a cloth carrying device, the cloth carrying device drives the driving shaft to rotate through the motor, so that the carrying of the detected cloth is completed, and the cloth cover of the detected cloth sequentially passes through the detection assembly; and adjusting the synchronizer according to the motor operation data, and capturing images by the linear array camera in the detection assembly according to the pulse interval output by the synchronizer. The snapshot is triggered through the synchronizer, so that the snapshot frequency is related to the cloth moving speed, and the matching degree is improved.
On the other hand, the invention also provides a cloth cover defect visual detection device based on the cloth cover defect visual detection method, which comprises a rack, a cloth carrying device, a detection assembly, an industrial personal computer, a light source controller and an embedded controller, wherein the rack is provided with the cloth carrying device, and the detection assembly is arranged above the cloth carrying device;
the detection assembly comprises a white light source, a multicolor light source, an area-array camera and a linear array camera, wherein the white light source, the multicolor light source, the area-array camera and the linear array camera are adjacently arranged on the support frame and are opposite to the cloth cover passing on the cloth carrying device; the white light source and the multicolor light source are connected to the light source controller, the area array camera and the linear array camera are connected to the industrial personal computer, the light source controller and the industrial personal computer are electrically connected with the embedded controller, and the embedded controller is connected to the cloth carrying device.
Further, the cloth carrying device comprises an unwinding roller, a winding roller, a middle conducting roller group, a driving shaft, a motor and a driver, wherein the motor is connected with the driving shaft to drive the driving shaft to rotate; the driver is connected with the embedded controller and the motor, receives the instruction of the embedded controller and controls the motor to operate; the driving shaft drives the winding roller, the unwinding roller and the winding roller are arranged at two ends of the rack, the middle conducting roller group is arranged in the middle section of the rack, a cloth to be detected is placed on the unwinding roller and sequentially passes through the middle conducting roller group to the winding roller, and the winding roller rotates to drive the cloth to move, so that the cloth cover sequentially passes below the detection assembly.
Further, the white light source adopts a white annular light source, and the multicolor light source adopts a multicolor strip-shaped light source; the multi-color bar-shaped light source adopts a variable color light source, or the multi-color bar-shaped light source comprises a plurality of light sources with different colors, preferably a red bar-shaped light source, a green bar-shaped light source and a blue bar-shaped light source; and selecting the number of the linear cameras according to the width of the cloth cover by adopting at least one linear camera. The embedded controller also comprises a synchronizer which is connected to the embedded controller. The safety lamp, the switch box and the display are further included.
The beneficial effects of the technical scheme are as follows:
the invention can effectively improve the adaptability of cloth cover detection equipment in practical application, can effectively detect the cloth cover defects of different fabrics, and can effectively detect the cloth cover defects of the fabrics with surface glossiness, color and the like; the contrast of the acquired image is improved by automatically selecting the light source and the brightness with proper colors, so that the defect characteristics are more obvious, and the purposes of improving the visual detection accuracy and reducing the omission ratio are achieved.
Drawings
FIG. 1 is a schematic flow chart of a visual inspection method for cloth cover defects according to the present invention;
FIG. 2 is a schematic structural diagram of a cloth cover defect visual inspection apparatus according to the present invention;
FIG. 3 is a schematic structural diagram of a detecting assembly according to an embodiment of the present invention;
FIG. 4 is a schematic diagram of control circuit connections according to an embodiment of the present invention;
the system comprises a machine frame 1, a detection assembly 2, an industrial personal computer 3, a light source controller 4, an embedded controller 5, an unwinding roller 6, a winding roller 7, a middle conducting roller group 8, a driving shaft 9, a motor 10, a driver 11, a switch box 12 and a display 13, wherein the machine frame is a frame; 21 is a white light source, 22 is a multicolor light source, 23 is an area-array camera, 24 is a line-array camera, and 25 is a support.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described with reference to the accompanying drawings.
In this embodiment, referring to fig. 1 and 2, the present invention provides a visual inspection method for cloth surface defects, where a cloth surface inspection apparatus includes an inspection component 2, the cloth surface is inspected by the inspection component 2, the inspection component 2 includes a white light source 21, a multi-color light source 22, an area-array camera 23 and a line-array camera 24, and the method includes the steps of:
s10, adjusting the white light source 21 to work at different brightness in sequence, and simultaneously using the area-array camera 23 to capture a picture at each brightness;
s20, respectively calculating the mean difference of the pixels in each picture;
s30, determining the display color of the multicolor light source 22 according to the pixel average value difference of the picture;
s40, calculating according to the multicolor light source 22 and the white light source 21 to obtain the optimal brightness parameter value of the selected multicolor light source 22;
s50, obtaining the brightness control proportion value of the optimal light source according to the optimal brightness parameter value;
s60, adjusting the multi-color light source 22 according to the display color and the optimal light source brightness control ratio value; and turns off the white light source 21;
s70, acquiring pictures under the set visual effect through the linear array camera 24;
and S80, analyzing the cloth cover defects by using the obtained pictures with the set visual effect.
As an optimization of the above embodiment, in step S10, the white ring light source is adjusted to operate at 20%, 40%, 60%, 80%, and 100% brightness in sequence, and simultaneously a picture is captured by the area-array camera 23 at each brightness to obtain a group of pictures [ P1, P2, P3, P4, and P5 ].
In step S20, the mean value R, G, B of each pixel of each picture is calculated, and then the absolute value of the difference between every two mean values of R, G, B of each picture is calculated to obtain the mean value difference of the pixels in the picture: PnRG, PnRB, PnGB;
wherein n is the number of the captured pictures 1-5, RG represents the absolute value of the difference between R and G, RB represents the absolute value of the difference between R and B, and GB represents the absolute value of the difference between G and B.
In step S30, the method for determining the display color of the multicolor light source 22 based on the pixel average value difference of the picture comprises the steps of:
if the average value difference of at least 3 pictures is larger than the set threshold value and is the same average value difference, selecting the color with the largest average value of R, G, B as the display color of the multicolor light source 22;
if the average value difference of at least 3 pictures is larger than the set threshold value and is different, selecting the color with the largest average value difference ratio as the display color of the multicolor light source 22;
if there is no mean difference > the set threshold, the display color of the multicolor light source 22 is set to red.
In step S40, obtaining the optimum brightness parameter value of the selected multicolor light source 22 according to the calculation by the multicolor light source 22 and the white light source 21 comprises the steps of:
according to the formula of the light source brightness change curve
Calculating an optimal brightness parameter value for the selected multicolor light source 22;
d is the contrast debugging of each strip light source to the white light source 21, and corresponding fixed parameters are configured; y is the maximum value of the average value of the snapshot picture, and x is the brightness control proportion value of the strip-shaped light source; a, b and c are coefficients of a light source brightness change curve formula;
and according to the selected 3 pictures with the largest average difference, calculating the values of b and c through the formula to be used as the optimal brightness parameter value of the selected multicolor light source 22.
In step S50, a brightness control ratio value of the optimal light source is obtained according to the optimal brightness parameter value calculation, and the calculation formula is:
the cloth surface detection device also comprises a cloth carrying device, the cloth carrying device drives a driving shaft 9 to rotate through a motor 10, so that the carrying of the detection cloth is completed, and the cloth surface of the detection cloth sequentially passes through the detection assembly 2; the synchronizer is adjusted according to the operation data of the motor 10, and the linear array camera 24 in the detection assembly 2 carries out image capturing according to the pulse interval output by the synchronizer.
In order to match the realization of the method of the invention, based on the same inventive concept, as shown in fig. 2-4, the invention also provides a cloth surface defect visual detection device, which comprises a frame 1, a cloth carrying device, a detection assembly 2, an industrial personal computer 3, a light source controller 4 and an embedded controller 5, wherein the frame 1 is provided with the cloth carrying device, and the detection assembly 2 is arranged above the cloth carrying device;
the detection assembly 2 comprises a white light source 21, a multicolor light source 22, an area-array camera 23 and a line-array camera 24, wherein the white light source 21, the multicolor light source 22, the area-array camera 23 and the line-array camera 24 are adjacently arranged on a support frame 25 and face the cloth cover passing on the cloth carrying device; the white light source 21 and the multicolor light source 22 are connected to the light source controller 4, the area array camera 23 and the line array camera 24 are connected to the industrial personal computer 3, the light source controller 4 and the industrial personal computer 3 are electrically connected with the embedded controller 5, and the embedded controller 5 is connected to the cloth carrying device.
As an optimized scheme of the above embodiment, the cloth carrying device comprises an unwinding roller 6, a winding roller 7, a middle conducting roller group 8, a driving shaft 9, a motor 10 and a driver 11, wherein the motor 10 is connected with the driving shaft 9 to drive the driving shaft to rotate; the driver 11 is connected with the embedded controller 5 and the motor 10, and the driver 11 receives an instruction of the embedded controller 5 and controls the motor 10 to operate; the driving shaft 9 drives the winding roller 7, the unwinding roller 6 and the winding roller 7 are arranged at two ends of the rack 1, the middle conducting roller group 8 is arranged in the middle section of the rack 1, a cloth to be detected is placed on the unwinding roller 6 and sequentially passes through the middle conducting roller group 8 to the winding roller 7, the winding roller 7 rotates to drive the cloth to move, and the cloth cover sequentially passes below the detection assembly 2.
As a preferable solution of the above embodiment, the white light source 21 is a white annular light source, and the multicolor light source 22 is a multicolor strip light source; the multi-color bar light source adopts a variable color light source, or the multi-color bar light source comprises a plurality of light sources with different colors, preferably a red bar light source, a green bar light source and a blue bar light source.
At least one line camera 24 is adopted, and the number of the line cameras 24 is selected according to the width of the cloth cover.
It also comprises a synchronizer, which is connected to the embedded controller 5.
Also included are safety lights, switch box 12 and display 13.
The foregoing shows and describes the general principles and broad features of the present invention and advantages thereof. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are described in the specification and illustrated only to illustrate the principle of the present invention, but that various changes and modifications may be made therein without departing from the spirit and scope of the present invention, which fall within the scope of the invention as claimed. The scope of the invention is defined by the appended claims and equivalents thereof.
Claims (10)
1. The visual detection method for the cloth cover defects is characterized in that a cloth cover detection device comprises a detection assembly (2), the cloth cover is detected through the detection assembly (2), the detection assembly (2) comprises a white light source (21), a multicolor light source (22), an area-array camera (23) and a line-array camera (24), and the visual detection method comprises the following steps:
s10, adjusting the white light source (21) to work at different brightness in sequence, and simultaneously using the area-array camera (23) to capture a picture at each brightness;
s20, respectively calculating the mean difference of the pixels in each picture;
s30, judging the display color of the multicolor light source (22) according to the pixel average value difference of the picture;
s40, calculating according to the parameter values of the multicolor light source (22) and the white light source (21), and acquiring the optimal brightness parameter value of the selected multicolor light source (22);
s50, obtaining the brightness control proportion value of the optimal light source according to the optimal brightness parameter value;
s60, adjusting the multi-color light source (22) according to the display color and the optimal light source brightness control proportion value; and turning off the white light source (21);
s70, acquiring pictures under the set visual effect through the line camera (24);
and S80, analyzing the cloth cover defects by using the obtained pictures with the set visual effect.
2. The visual inspection method of cloth cover defects according to claim 1, characterized in that the white ring light source is adjusted to work at 20%, 40%, 60%, 80%, 100% brightness in turn, and simultaneously a picture is captured by the area-array camera (23) at each brightness to obtain a picture group [ P1, P2, P3, P4, P5 ].
3. The visual inspection method of cloth cover defects according to claim 2, characterized in that R, G, B mean values of each pixel of each picture are calculated respectively, and then absolute values of differences between every two mean values of each picture R, G, B are calculated to obtain mean value differences of pixels in the pictures: PnRG, PnRB, PnGB;
wherein n is the number of the captured pictures 1-5, RG represents the absolute value of the difference between R and G, RB represents the absolute value of the difference between R and B, and GB represents the absolute value of the difference between G and B.
4. A visual inspection method for cloth cover defects according to claim 3, wherein the display color of the multi-color light source (22) is determined according to the pixel average value difference of the picture, comprising the steps of:
if the average value difference of at least 3 pictures is larger than the set threshold value and is the same, selecting the color with the largest average value of R, G, B as the display color of the multicolor light source (22);
if the average value difference of at least 3 pictures is larger than the set threshold value and is different, selecting the color with the largest average value difference ratio as the display color of the multicolor light source (22);
if the average value difference is not larger than the set threshold value, the display color of the multicolor light source (22) is set to be red.
5. A visual inspection method of cloth cover defects according to claim 4, characterized in that, the optimal brightness parameter value of the selected multicolor light source (22) is obtained according to the calculation through the multicolor light source (22) and the white light source (21), comprising the steps of:
according to the formula of the light source brightness change curve
Calculating an optimum brightness parameter value for the selected polychromatic light source (22);
d is the contrast debugging of each strip-shaped light source to the white light source (21), and corresponding fixed parameters are configured; y is the maximum value of the average value of the snapshot picture, and x is the brightness control proportion value of the strip-shaped light source; a, b and c are coefficients of a light source brightness change curve formula;
and according to the selected 3 pictures with the largest mean difference, calculating the values of b and c through the formula to be used as the optimal brightness parameter value of the selected multicolor light source (22).
6. The visual inspection method of cloth cover defects according to claim 5, characterized in that the brightness control ratio value of the optimal light source is obtained according to the optimal brightness parameter value calculation, and the calculation formula is:
7. the visual detection method of cloth cover defects according to claim 1, characterized in that the cloth cover detection device further comprises a cloth carrying device, the cloth carrying device drives a driving shaft (9) to rotate through a motor (10), so that carrying of the detected cloth is completed, and the cloth cover of the detected cloth passes through the detection assembly (2) in sequence; and the synchronizer is adjusted according to the running data of the motor (10), and the linear array camera (24) in the detection assembly (2) carries out image snapshot according to the pulse interval output by the synchronizer.
8. A cloth cover defect visual detection device based on the cloth cover defect visual detection method of claim 1 is characterized by comprising a rack (1), a cloth carrying device, a detection assembly (2), an industrial personal computer (3), a light source controller (4) and an embedded controller (5), wherein the rack (1) is provided with the cloth carrying device, and the detection assembly (2) is arranged above the cloth carrying device;
the detection assembly (2) comprises a white light source (21), a multicolor light source (22), an area-array camera (23) and a linear array camera (24), wherein the white light source (21), the multicolor light source (22), the area-array camera (23) and the linear array camera (24) are adjacently arranged on a support frame (25) and face the cloth cover passing on the cloth carrying device; white light source (21) and polychrome light source (22) are connected to light source controller (4), area array camera (23) and linear array camera (24) are connected to industrial computer (3), light source controller (4) and industrial computer (3) are connected with embedded controller (5) electricity, embedded controller (5) are connected to cloth carrying device.
9. The visual cloth cover defect detection device of claim 8, wherein the cloth carrying device comprises an unwinding roller (6), a winding roller (7), a middle conducting roller group (8), a driving shaft (9), a motor (10) and a driver (11), and the motor (10) is connected with the driving shaft (9) to drive the driving shaft (9) to rotate; the driver (11) is connected with the embedded controller (5) and the motor (10), and the driver (11) receives an instruction of the embedded controller (5) and controls the motor (10) to operate; drive shaft (9) drive wind-up roll (7), unreel roller (6) and wind-up roll (7) and set up at the both ends of frame (1), middle part conduction roller set (8) set up in frame (1) middle section, wait to detect the cloth and put on unreeling roller (6) to in proper order through middle part conduction roller set (8) to wind-up roll (7), rotate through wind-up roll (7) and drive the cloth and remove, make the cloth cover pass through determine module (2) below in proper order.
10. The visual inspection device for cloth cover defects of claim 8, wherein a white annular light source is adopted as the white light source (21), and a multicolor strip light source is adopted as the multicolor light source (22); the multi-color bar-shaped light source adopts a variable color light source, or the multi-color bar-shaped light source comprises a plurality of light sources with different colors; selecting the number of the linear cameras (24) according to the cloth cover width by adopting at least one linear camera (24); also included is a synchronizer connected to the embedded controller (5).
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| CN114878587A (en) * | 2022-07-04 | 2022-08-09 | 南通市通州区磊香利纺织品有限公司 | A two-sided flaw cloth inspection machine for weaving cloth |
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