CN112858321A - Steel plate surface defect detection system and method based on linear array CCD - Google Patents
Steel plate surface defect detection system and method based on linear array CCD Download PDFInfo
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- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 94
- 239000010959 steel Substances 0.000 title claims abstract description 94
- 230000007547 defect Effects 0.000 title claims abstract description 54
- 238000001514 detection method Methods 0.000 title claims abstract description 47
- 238000000034 method Methods 0.000 title claims abstract description 15
- 238000012545 processing Methods 0.000 claims abstract description 22
- 238000005286 illumination Methods 0.000 claims abstract description 15
- 230000005540 biological transmission Effects 0.000 claims abstract description 12
- 238000012937 correction Methods 0.000 claims description 13
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- 238000007781 pre-processing Methods 0.000 claims description 3
- 238000003708 edge detection Methods 0.000 claims description 2
- 238000001914 filtration Methods 0.000 claims description 2
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- 238000004519 manufacturing process Methods 0.000 abstract description 5
- 238000005516 engineering process Methods 0.000 description 7
- 206010039509 Scab Diseases 0.000 description 1
- 238000003705 background correction Methods 0.000 description 1
- 230000002457 bidirectional effect Effects 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 238000009749 continuous casting Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000013213 extrapolation Methods 0.000 description 1
- 238000003384 imaging method Methods 0.000 description 1
- 238000007373 indentation Methods 0.000 description 1
- 238000009776 industrial production Methods 0.000 description 1
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- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/8851—Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges
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- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
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- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/89—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/8851—Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges
- G01N2021/8887—Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges based on image processing techniques
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Abstract
The invention discloses a steel plate surface defect detection system and method based on a linear array CCD, wherein the system comprises the following steps: the transmission module is used for driving the steel plate to be tested to move along the horizontal direction; the illumination module is used for providing sufficient illumination for the image acquisition module to ensure the brightness of a view field; the image acquisition module is used for acquiring a high-resolution surface image of the steel plate to be detected by matching a linear array CCD camera with an image acquisition card; the exposure control module is used for measuring the movement speed of the steel plate to be measured, converting the movement speed into a pulse signal and inputting the pulse signal into the image acquisition card so as to control the exposure of the linear array CCD camera; and the image processing module is used for detecting and positioning the defects based on the collected surface image of the steel plate to be detected. The invention realizes the non-contact detection of the surface defects of the moving steel plate on the steel production line by adopting the linear array CCD camera, the acquired surface images of the steel plate have the characteristics of high resolution and high precision, and the detection and the positioning of the defects can be effectively and accurately realized.
Description
Technical Field
The invention belongs to the field of machine vision detection, particularly relates to the field of steel plate surface quality detection, and particularly relates to a steel plate surface defect detection system and method based on a linear array CCD.
Background
In the actual production process of the steel plate, different types of defects such as scabs, scratches, indentations, inclusions and the like are difficult to avoid under the influence of continuous casting of steel billets, rolling technology and production and processing level. These defects greatly reduce the wear and corrosion resistance of the steel sheet, which can have serious consequences if such a steel sheet with defects is used in some important applications. Therefore, the surface quality detection of the steel plate is an indispensable link in the steel production process.
In the steel plate surface detection technology, the traditional detection methods such as manual detection, infrared detection, ultrasonic detection, eddy current detection and the like have certain limitations. With the continuous development of computer image processing and machine vision technologies, a steel plate surface quality detection method based on machine vision is produced. The method utilizes the image sensor to collect the surface image of the steel plate, and then realizes the detection of the surface quality of the steel plate by matching with the image processing technology, and has the advantages of non-contact, high efficiency and the like. Common types of image capture devices include both linear and area-array cameras. In comparison, the linear array camera has higher precision and frame frequency in the one-dimensional direction, can meet the requirement of high resolution in industrial detection, and can finish the acquisition work of the surface image of the steel plate moving at high speed. Therefore, the linear array CCD camera is combined with the image processing technology to detect the surface quality of the steel plate, and the method has important research significance.
Disclosure of Invention
The invention aims to provide a steel plate defect detection system and method with the advantages of non-contact property, high detection efficiency, high detection precision and the like.
The technical solution for realizing the purpose of the invention is as follows: a steel plate surface defect detection system based on a linear array CCD comprises a transmission module, an illumination module, an image acquisition module, an exposure control module and an image processing module;
the transmission module is used for driving the steel plate to be tested to move along the horizontal direction;
the illumination module is used for providing sufficient illumination for the image acquisition module to ensure the brightness of a view field;
the image acquisition module is used for acquiring a high-resolution surface image of the steel plate to be detected by matching a linear array CCD camera with an image acquisition card;
the exposure control module is used for measuring the movement speed of the steel plate to be measured, converting the movement speed into a pulse signal and inputting the pulse signal into the image acquisition card to control the exposure of the linear array CCD camera;
and the image processing module is used for detecting and positioning defects based on the collected surface image of the steel plate to be detected.
The steel plate surface defect detection method based on the linear array CCD comprises the following steps:
step 1, calibrating a linear array CCD camera in an image acquisition module to obtain an internal parameter matrix and a distortion parameter matrix of the linear array CCD camera;
step 2, measuring the movement speed of the steel plate to be measured by using a photoelectric encoder, and converting the movement speed of the steel plate into a pulse signal;
step 3, processing and counting the pulse signals by using the FPGA to obtain camera exposure control signals and the movement mileage of the steel plate;
step 4, the exposure control module controls the image acquisition module to acquire the surface image of the steel plate to be detected, and the images acquired by the two linear array CCD cameras are recorded as A respectively1And A2；
Step 5, utilizing the internal reference matrix and the distortion parameter matrix obtained in the step 1 to carry out comparison on the steel plate surface image A acquired in the step 41And A2Carrying out distortion correction to obtain a steel plate surface image B after distortion correction1And B2；
Step 6, the image B after distortion correction1And B2Carrying out pretreatment;
step 7, splicing the two preprocessed images to obtain a large-size steel plate surface image C;
step 8, carrying out defect detection and positioning on the spliced steel plate surface image C, dividing a defect area, and acquiring and storing position and size information of the defect
Compared with the prior art, the invention has the following remarkable advantages: 1) the machine vision and the image processing technology are combined to realize non-contact automatic defect detection of the moving steel plate on the production line; 2) an exposure control signal is generated by adopting a speed measuring method of a photoelectric encoder, and the advance distortion caused by the mismatching of the steel plate movement speed and the camera acquisition speed is corrected; 3) the high-speed linear array camera is matched with an image acquisition card to acquire the image of the surface of the steel plate, so that the high-precision image can be quickly acquired; 4) the method for splicing and imaging by adopting two linear array CCD cameras gives consideration to the requirements of large field of view and high resolution in industrial detection.
The present invention is described in further detail below with reference to the attached drawing figures.
Drawings
FIG. 1 is a schematic structural diagram of a linear array CCD-based steel plate surface defect detection system of the present invention.
FIG. 2 is an overall flow chart of the linear array CCD-based steel plate surface defect detection system of the present invention.
FIG. 3 is an image processing flow chart of the steel plate surface defect detection method based on the linear array CCD of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present application more apparent, the present application is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present application and are not intended to limit the present application.
With reference to fig. 1, the present invention provides a linear array CCD-based steel plate surface defect detection system, which includes a transmission module, an illumination module, an image acquisition module, an exposure control module and an image processing module;
the transmission module is used for driving the steel plate to be tested to move along the horizontal direction;
the illumination module is used for providing sufficient illumination for the image acquisition module to ensure the brightness of a view field;
the image acquisition module is used for acquiring a high-resolution surface image of the steel plate to be detected by matching a linear array CCD camera with an image acquisition card; the whole image acquisition module is arranged at a certain height above the steel plate to be detected, the image acquisition module is fixed, and the steel plate moves at a constant speed on the transmission module along the horizontal direction;
the exposure control module is used for measuring the movement speed of the steel plate to be measured, converting the movement speed into a pulse signal and inputting the pulse signal into the image acquisition card to control the exposure of the linear array CCD camera;
and the image processing module is used for detecting and positioning defects based on the collected surface image of the steel plate to be detected.
Further, in one embodiment, the illumination module uses a linear LED light source and uses dark field illumination.
Further, in one embodiment, the image acquisition module acquires images of the steel plate to be measured by using two line CCD cameras, and the model of the used line CCD camera is a DALSA V3-CC-04K009 color industrial camera.
Further, in one embodiment, the control of the image acquisition module is realized by an image acquisition card, the model of the image acquisition card is Xtium-CL MX4, and the image acquisition card is connected with the line CCD camera by a camera link data cable.
Further, in one embodiment, the exposure control module comprises a photoelectric encoder part and an FPGA signal processing part. The photoelectric encoder is fixed on a transmission shaft of the transmission module to coaxially rotate. The FPGA processes the pulse signal output by the photoelectric encoder to generate an exposure control signal which can be recognized by a camera, and counts the pulses for calculating the moving mileage of the steel plate.
Further, in one embodiment, the exposure control module uses a photoelectric encoder to measure the speed of the transmission module for transmitting the steel plate, and the generated pulse signal is processed by the FPGA and then output to the image acquisition card as the exposure control signal of the linear array CCD camera.
Further, in one embodiment, the photoelectric encoder is E6B2-CWZ1X, and the pulse signal is transmitted to the image acquisition card by adopting a 27-core special cable of DH 27M-DLS-IDTS.
Further, in one embodiment, with reference to fig. 3, the image processing module is configured to perform defect detection and positioning based on the collected surface image of the steel plate to be detected, and includes the following steps:
step 1, preprocessing acquired images, including distortion correction, blind pixel compensation, brightness non-uniformity correction, region-of-interest detection and filtering denoising;
detecting failure sensor elements based on a scene bidirectional linear extrapolation method, and interpolating by adopting the correlation of adjacent row and column sensor elements to realize blind element compensation;
here, a two-point method is adopted to carry out flat field correction, so that the problem of uneven brightness is solved;
step 2, image splicing is carried out through an SURF feature point matching algorithm and a pixel weighted average fusion method;
step 3, extracting a block image containing defects from the spliced image by adopting a method of combining an average gray difference and a gray value threshold;
here, the blocks including defects are extracted first, so that the amount of calculation in the system can be reduced.
Step 4, performing morphological processing on the block image;
step 5, adopting an edge detection algorithm based on a Canny operator to segment defects from the image;
and 6, acquiring the minimum circumscribed rectangle of the outline of the defect area, thereby extracting the size and position information of the defect.
With reference to fig. 2, the invention provides a steel plate surface defect detection method based on a linear array CCD, which comprises the following steps:
step 1, calibrating a linear array CCD camera in an image acquisition module to obtain an internal parameter matrix and a distortion parameter matrix of the linear array CCD camera;
step 2, measuring the movement speed of the steel plate to be measured by using a photoelectric encoder, and converting the movement speed of the steel plate into a pulse signal;
step 3, processing and counting the pulse signals by using the FPGA to obtain camera exposure control signals and the movement mileage of the steel plate;
step 4, the exposure control module controls the image acquisition module to acquire the surface image of the steel plate to be detected, and the images acquired by the two linear array CCD cameras are recorded as A respectively1And A2；
Step 5, utilizing the internal reference matrix and distortion parameter matrix pair obtained in the step 1The steel plate surface image A collected in the step 41And A2Carrying out distortion correction to obtain a steel plate surface image B after distortion correction1And B2；
Step 6, the image B after distortion correction1And B2Carrying out pretreatment;
step 7, splicing the two preprocessed images to obtain a large-size steel plate surface image C;
and 8, carrying out defect detection and positioning on the spliced steel plate surface image C, segmenting a defect area, and acquiring and storing position and size information of the defect.
For specific limitations of the steel plate surface defect detection method based on the linear array CCD, see the above limitations on the steel plate surface defect detection system based on the linear array CCD, which are not described herein again.
The system and the method for detecting the surface defects of the steel plate based on the linear array CCD are realized based on machine vision and image processing technologies. Two linear array CCD cameras are adopted to be matched with an image acquisition card to acquire the surface image of the steel plate; measuring the movement speed of the steel plate by a photoelectric encoder, and generating an exposure control signal after the steel plate is processed by an FPGA (field programmable gate array); and finally, performing image preprocessing, image splicing, defect detection and positioning in the upper computer. The system has the characteristics of non-contact, high acquisition speed and consideration of both large view field and high resolution requirements, can meet the requirements of industrial production, and has wide application prospect.
The technical features of the above embodiments can be arbitrarily combined, and for the sake of brevity, all possible combinations of the technical features in the above embodiments are not described, but should be considered as the scope of the present specification as long as there is no contradiction between the combinations of the technical features.
The above-mentioned embodiments only express several embodiments of the present application, and the description thereof is more specific and detailed, but not construed as limiting the scope of the invention. It should be noted that, for a person skilled in the art, several variations and modifications can be made without departing from the concept of the present application, which falls within the scope of protection of the present application.
Claims (8)
1. A steel plate surface defect detection system based on a linear array CCD is characterized by comprising a transmission module, an illumination module, an image acquisition module, an exposure control module and an image processing module;
the transmission module is used for driving the steel plate to be tested to move along the horizontal direction;
the illumination module is used for providing sufficient illumination for the image acquisition module to ensure the brightness of a view field;
the image acquisition module is used for acquiring a high-resolution surface image of the steel plate to be detected by matching a linear array CCD camera with an image acquisition card;
the exposure control module is used for measuring the movement speed of the steel plate to be measured, converting the movement speed into a pulse signal and inputting the pulse signal into the image acquisition card to control the exposure of the linear array CCD camera;
and the image processing module is used for detecting and positioning defects based on the collected surface image of the steel plate to be detected.
2. The linear array CCD-based steel plate surface defect detection system as claimed in claim 1, wherein the illumination module adopts a linear LED light source and adopts a dark field illumination mode.
3. The linear CCD-based steel plate surface defect detection system of claim 1 or 2, wherein the image acquisition module adopts two linear CCD cameras to acquire images of the steel plate to be detected, and the model of the linear CCD camera is DALSA V3-CC-04K009 color industrial camera.
4. The linear array CCD-based steel plate surface defect detection system as claimed in claim 3, wherein the control of the image acquisition module is realized by an image acquisition card of type Xtium-CL MX4, and the image acquisition card is connected with the linear array CCD camera by a camera link data cable.
5. The linear array CCD-based steel plate surface defect detection system as claimed in claim 4, wherein the exposure control module adopts a photoelectric encoder to measure the speed of the transmission module for transmitting the steel plate, and the generated pulse signal is processed by FPGA and then output to the image acquisition card as the exposure control signal of the linear array CCD camera.
6. The linear array CCD-based steel plate surface defect detection system of claim 5, wherein the photoelectric encoder is E6B2-CWZ1X, and the photoelectric encoder adopts a 27-core special cable of DH27M-DLS-IDTS to transmit pulse signals to an image acquisition card.
7. The linear array CCD-based steel plate surface defect detection system as claimed in claim 6, wherein the image processing module is used for detecting and positioning defects based on the collected steel plate surface image to be detected, and comprises the following steps:
step 1, preprocessing acquired images, including distortion correction, blind pixel compensation, brightness non-uniformity correction, region-of-interest detection and filtering denoising;
step 2, image splicing is carried out through an SURF feature point matching algorithm and a pixel weighted average fusion method;
step 3, extracting a block image containing defects from the spliced image by adopting a method of combining an average gray difference and a gray value threshold;
step 4, performing morphological processing on the block image;
step 5, adopting an edge detection algorithm based on a Canny operator to segment defects from the image;
and 6, acquiring the minimum circumscribed rectangle of the outline of the defect area, thereby extracting the size and position information of the defect.
8. The linear array CCD-based steel plate surface defect detection method based on the system of any one of claims 1 to 7, which is characterized by comprising the following steps:
step 1, calibrating a linear array CCD camera in an image acquisition module to obtain an internal parameter matrix and a distortion parameter matrix of the linear array CCD camera;
step 2, measuring the movement speed of the steel plate to be measured by using a photoelectric encoder, and converting the movement speed of the steel plate into a pulse signal;
step 3, processing and counting the pulse signals by using the FPGA to obtain camera exposure control signals and the movement mileage of the steel plate;
step 4, the exposure control module controls the image acquisition module to acquire the surface image of the steel plate to be detected, and the images acquired by the two linear array CCD cameras are recorded as A respectively1And A2；
Step 5, utilizing the internal reference matrix and the distortion parameter matrix obtained in the step 1 to carry out comparison on the steel plate surface image A acquired in the step 41And A2Carrying out distortion correction to obtain a steel plate surface image B after distortion correction1And B2；
Step 6, the image B after distortion correction1And B2Carrying out pretreatment;
step 7, splicing the two preprocessed images to obtain a large-size steel plate surface image C;
and 8, carrying out defect detection and positioning on the spliced steel plate surface image C, segmenting a defect area, and acquiring and storing position and size information of the defect.
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| CN113884502A (en) * | 2021-12-07 | 2022-01-04 | 武汉华工激光工程有限责任公司 | Linear array camera-based carrier plate detection and laser marking system and method |
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| CN114280083B (en) * | 2021-12-16 | 2023-11-07 | 重庆日联科技有限公司 | Detection method for realizing industrial X-ray nondestructive detection of large-size flat castings based on automatic CNC programming of linear array camera |
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