CN113237889A - Multi-scale ceramic detection method and system - Google Patents
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Abstract
The invention provides a multi-scale ceramic detection method and system. When the flaw does not exist, the detection is finished, the flaw-free conclusion is given, and when the flaw exists, the accurate detection including a three-dimensional reconstruction technology, a track planning technology and the like is adopted, so that the quantitative flaw index is given. Compared with the traditional method, the multi-scale detection method combining rapid detection and accurate detection greatly reduces the influence of environmental factors on the detection result, effectively improves the detection precision, and does not need to spend a large amount of time and cost to complete the acquisition of the required data set.
Description
Technical Field
The invention relates to the field of image processing, in particular to a multi-scale ceramic detection method and system.
Background
The ceramic industry is an important part of national economy in China. The ceramic industry scale of China is the first global, has the highest global ceramic product production, export and consumption, and has very great market prospect. In recent years, the production technology, the mechanization degree and the automation degree of the ceramic industry are gradually improved, a large amount of automatic production equipment and production lines are introduced, semi-automatic production from mud refining, blank drawing, blank benefiting, blank drying, glazing and kiln burning is realized, but the quality detection and grading evaluation process is not yet automated, detection and evaluation are performed mainly by means of human eye observation and auxiliary touch, the detection efficiency is low, the detection requirements of batch production are difficult to meet, the detection is easy to be influenced by various factors, the detection omission, wrong detection and wrong evaluation are caused, and the product quality control is not guaranteed. Along with the social progress and the improvement of the life quality of people, people pay more and more attention to the appearance quality of products, and the quality control and public praise of the products directly influence the development prospect of enterprises.
The existing ceramic defect detection methods are mainly divided into two types, namely a ceramic defect detection method based on a traditional method and a ceramic defect detection method based on a neural network. The ceramic flaw detection method based on the traditional method mainly uses a camera to shoot a target object to finish obtaining color and depth information of the target object, and then adopts a visual algorithm to identify and mark flaws, so that the method has the defect of being greatly influenced by external environment factors, and the reliability of obtained results is not high; compared with the traditional method, the ceramic flaw detection method based on the neural network has higher accuracy, but needs a large amount of data sets to train the corresponding network, consumes too long time and has too high cost.
Disclosure of Invention
In view of the above, the present invention provides a multi-scale ceramic detection method and system, which first perform a fast detection on a target object, place a workpiece on a workbench, and take a picture of the workpiece and detect the workpiece by using a fast detection system. When the flaw does not exist, the detection is finished, the flaw-free conclusion is given, and when the flaw exists, the accurate detection including a three-dimensional reconstruction technology, a track planning technology and the like is adopted, so that the quantitative flaw index is given.
Compared with the traditional method, the multi-scale detection method combining rapid detection and accurate detection greatly reduces the influence of environmental factors on the detection result, effectively improves the detection precision, and does not need to spend a large amount of time and cost to complete the acquisition of the required data set.
The invention provides a multi-scale ceramic detection method and a system, wherein the system specifically comprises the following steps:
a rapid detection subsystem and a precise detection subsystem;
the rapid detection subsystem comprises a workbench, a bracket and an RGB color camera; the bracket is fixedly arranged on the workbench; the RGB color camera is fixedly arranged on the bracket;
the accurate detection subsystem includes: the system comprises a six-degree-of-freedom industrial mechanical arm, a seven-degree-of-freedom flexible arm, a detection table, an RGBD camera and a short-focus camera;
the six-degree-of-freedom industrial mechanical arm and the seven-degree-of-freedom flexible arm are fixedly arranged on the left side and the right side of the detection table respectively through a base; the RGBD camera is arranged at the tail end of the six-degree-of-freedom industrial mechanical arm; the short-focus camera is arranged at the tail end of the seven-degree-of-freedom flexible arm.
Further, the detection table is provided with a turnover device for turning over the ceramic article.
A multi-scale ceramic detection method is applied to a multi-scale ceramic detection system and comprises the following steps:
s101: placing a workpiece to be detected on the workbench, and acquiring an original RGB image of the workpiece to be detected by using an RGB color camera;
s102: carrying out image preprocessing on the original RGB image to obtain a preprocessed image;
s103: adopting a flaw detection method for the preprocessed image to obtain a primary flaw of the workpiece to be detected;
s104: placing the bow and the arrow to be detected on the detection table, and rotating by using a turnover device of the detection table; the RGBD camera at the tail end of the six-degree-of-freedom industrial mechanical arm is used for shooting a to-be-detected workpiece at multiple angles to obtain a group of to-be-detected workpiece images at different angles;
s105: performing three-dimensional reconstruction by using the multi-angle workpiece image to be detected to obtain a three-dimensional model of the workpiece to be detected;
s106: adding bounding boxes to the three-dimensional model, and checking the size information of the bounding boxes and the size information of the standard workpiece to obtain an area with inconsistent size;
s107: acquiring a flaw area of the workpiece to be detected according to the area with inconsistent sizes and the initial flaw obtained in the step S103;
s108: and (4) performing close-range image acquisition on the flaw area by using a short-focus camera arranged at the tail end of the seven-degree-of-freedom flexible arm, and performing accurate flaw detection by using the flaw detection method in the step S103 to obtain the accurate flaw of the workpiece to be detected.
The image preprocessing method in step S102 specifically includes the following operations performed in sequence: grayscale, erosion, gradient calculation, and dilation.
The beneficial effects provided by the invention are as follows: 1. a rapid detection system for ceramic products is set up, and primary flaw detection of target workpieces can be realized within 1 s; 2. a precise detection system for the ceramic product is set up; 3. by using the multi-scale detection method combining rapid detection and accurate detection, the accuracy of the detection result is greatly improved; 4. the form of adding the bounding box in the three-dimensional reconstruction result is adopted, so that the size of the detected workpiece can be checked more conveniently and rapidly in a relatively precise cutting mode. The invention applies the technology of eye model, image processing, camera calibration, three-dimensional reconstruction, mechanical arm track planning and the like formed by a mechanical arm and an RGBD camera, and most importantly, the invention provides a new detection idea.
Drawings
FIG. 1 is a schematic diagram of a rapid detection subsystem of a multi-scale ceramic detection system of the present invention;
FIG. 2 is a schematic view of a precision detection subsystem of a multi-scale ceramic detection system of the present invention;
FIG. 3 is a flow chart of a multi-scale ceramic detection method of the present invention;
fig. 4 is an image acquired by the camera 1 of the present invention;
FIG. 5 is an image after the etching operation of the present invention;
FIG. 6 is an image after gradient calculation according to the present invention;
FIG. 7 is an image of the present invention after the dilation operation;
FIG. 8 is a diagram illustrating the rapid assay results of the present invention;
FIG. 9 is a three-dimensional reconstruction model effect diagram of the present invention;
fig. 10 is a diagram of the AABB bounding box effect of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, embodiments of the present invention will be further described with reference to the accompanying drawings.
A multi-scale ceramic detection system comprising the following:
a rapid detection subsystem and a precise detection subsystem;
referring to fig. 1, fig. 1 is a schematic diagram of a fast detection subsystem of a multi-scale ceramic detection system according to the present invention;
the rapid detection subsystem comprises a workbench, a bracket and an RGB color camera; the bracket is fixedly arranged on the workbench; the RGB color camera is fixedly arranged on the bracket;
in fig. 1, the camera 1 is an RGB color camera; the camera 1 is fixed right above the workpiece and can move by adjusting the bracket structure; the rapid detection subsystem can rapidly detect the workpiece to be detected.
Referring to FIG. 2, FIG. 2 is a schematic diagram of a precise detection subsystem of a multi-scale ceramic detection system according to the present invention;
the accurate detection subsystem includes: the system comprises a six-degree-of-freedom industrial mechanical arm, a seven-degree-of-freedom flexible arm, a detection table, an RGBD camera and a short-focus camera;
the six-degree-of-freedom industrial mechanical arm and the seven-degree-of-freedom flexible arm are fixedly arranged on the left side and the right side of the detection table respectively through a base; the RGBD camera is arranged at the tail end of the six-degree-of-freedom industrial mechanical arm; the short-focus camera is arranged at the tail end of the seven-degree-of-freedom flexible arm.
In fig. 2, the camera 2 is an RGBD camera, and the camera 3 is a short-focus camera; when the subsystem works normally, an RGBD camera is used for collecting images of a target, an area with flaws is found preliminarily, three-dimensional reconstruction is carried out on a workpiece, and then a short-focus camera is used for detecting the parts with flaws in a close range, so that the detection work of ceramic products is completed. The detection table is provided with a turnover device for turning over the ceramic articles.
Referring to fig. 3, fig. 3 is a flow chart of a multi-scale ceramic detection method; the method is applied to a multi-scale ceramic detection system and comprises the following steps:
s101: placing a workpiece to be detected on the workbench, and acquiring an original RGB image of the workpiece to be detected by using an RGB color camera;
s102: carrying out image preprocessing on the original RGB image to obtain a preprocessed image;
s103: adopting a flaw detection method for the preprocessed image to obtain a primary flaw of the workpiece to be detected;
s104: placing the bow and the arrow to be detected on the detection table, and rotating by using a turnover device of the detection table; the RGBD camera at the tail end of the six-degree-of-freedom industrial mechanical arm is used for shooting a to-be-detected workpiece at multiple angles to obtain a group of to-be-detected workpiece images at different angles;
s105: performing three-dimensional reconstruction by using the multi-angle workpiece image to be detected to obtain a three-dimensional model of the workpiece to be detected;
s106: adding bounding boxes to the three-dimensional model, and checking the size information of the bounding boxes and the size information of the standard workpiece to obtain an area with inconsistent size;
s107: acquiring a flaw area of the workpiece to be detected according to the area with inconsistent sizes and the initial flaw obtained in the step S103;
s108: and (4) performing close-range image acquisition on the flaw area by using a short-focus camera arranged at the tail end of the seven-degree-of-freedom flexible arm, and performing accurate flaw detection by using the flaw detection method in the step S103 to obtain the accurate flaw of the workpiece to be detected.
The invention is exemplified below by using a squatting pan as an example;
firstly, image acquisition is carried out by using a camera 1; the image of the workpiece to be detected is acquired by a camera fixed on the bracket, wherein the area mainly having the flaw is circled in the image, please refer to fig. 4, fig. 4 is an acquired physical image of the squatting pan, the original image is an RGB color image, and a corresponding gray scale image is shown.
And next, preprocessing the image, and completing preprocessing of the original image by performing graying, corrosion, gradient calculation and expansion operations on the acquired color image so as to better perform the next defect detection. The erosion operation is to convolute the grayed picture with a kernel B (usually square or circular) of any shape, where the kernel B has a definable anchor point, usually defined as the kernel center point. And during corrosion operation, drawing the kernel B through the image, extracting the minimum pixel value of the coverage area of the kernel B, and replacing the pixel at the anchor point position. Therefore, after this operation, the area of the picture with small pixels is enlarged and the area of the picture with large pixels is reduced. Whereas the dilation operation is the opposite, which reduces the area of small pixels and enlarges the area of large pixels. Therefore, firstly, the gray-scale image is etched to make the defect (pixel is smaller) more obvious, as shown in fig. 5, and then the gray-scale image is used to make the difference with the etched image through the gradient calculation, so that the area with the defect is white, and at the moment, some areas which are not the defect are also white, as shown in fig. 6. Then, the expansion operation is performed, so that the defect appearing white becomes more obvious, as shown in fig. 7.
And detecting the defects. The image after the preprocessing operation is detected for the first time by using the packaged function getContourBox, and the steps are as follows: 1. the search for all contours in fig. 7 is done using findContours functions in the OpenCV vision library. 2. The contourArea function is used to calculate the area of each contour and remove contours with too large or too small area. 3. And (3) obtaining the minimum circumscribed rectangle of each outline by using a boundingRec function, and removing the outline of the circumscribed rectangle frame beyond the range of the original image (since the target ceramic product and the flaw are both in the area with the eccentric center of the image, the false detection rate can be reduced by using the step) 4. detecting RGB three channel values of the centers of all the outlines in the color image, and removing the outline with higher three channel values (namely removing the interference of brighter areas such as light spots). 5. All remaining contours are circled. The result after inspection is shown in fig. 8, and it can be seen that most defects have been detected.
The image is acquired with the camera 2 of the precision detection subsystem. And the color depth camera fixed at the tail end of the six-degree-of-freedom industrial arm shoots the workpiece at multiple angles to obtain a group of pictures at multiple angles.
And performing high-precision three-dimensional reconstruction on the target ceramic product by using the multi-angle RGBD image, wherein the result is shown in FIG. 9, a bounding box is added to the reconstructed result, and the size information of the bounding box is compared with the size of the bounding box of the standard component, so that the size check between the detected workpiece and the standard component is realized. Common bounding box algorithms are AABB bounding boxes, bounding spheres, directional bounding boxes OBB, and fixed directional convex hull FDH, the current choice is to generate AABB bounding boxes on the reconstruction model, and the result of adding bounding boxes is shown in fig. 10.
The steps above respectively obtain the primary flaw and the approximate area where the primary flaw exists; then, a short-focus camera is used for carrying out close-range image acquisition and flaw detection according to the rough detection area, and accurate flaws can be obtained;
the invention has the beneficial effects that: 1. a rapid detection system for ceramic products is set up, and primary flaw detection of target workpieces can be realized within 1 s; 2. a precise detection system for the ceramic product is set up; 3. by using the multi-scale detection method combining rapid detection and accurate detection, the accuracy of the detection result is greatly improved; 4. the form of adding the bounding box in the three-dimensional reconstruction result is adopted, so that the size of the detected workpiece can be checked more conveniently and rapidly in a relatively precise cutting mode. The invention applies the technology of eye model, image processing, camera calibration, three-dimensional reconstruction, mechanical arm track planning and the like formed by a mechanical arm and an RGBD camera, and most importantly, the invention provides a new detection idea.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.
Claims (4)
1. A multi-scale ceramic detection system, comprising:
a rapid detection subsystem and a precise detection subsystem;
the rapid detection subsystem comprises a workbench, a bracket and an RGB color camera; the bracket is fixedly arranged on the workbench; the RGB color camera is fixedly arranged on the bracket;
the accurate detection subsystem includes: the system comprises a six-degree-of-freedom industrial mechanical arm, a seven-degree-of-freedom flexible arm, a detection table, an RGBD camera and a short-focus camera;
the six-degree-of-freedom industrial mechanical arm and the seven-degree-of-freedom flexible arm are fixedly arranged on the left side and the right side of the detection table respectively through a base; the RGBD camera is arranged at the tail end of the six-degree-of-freedom industrial mechanical arm; the short-focus camera is arranged at the tail end of the seven-degree-of-freedom flexible arm.
2. A multi-scale ceramic detection system as claimed in claim 1 wherein: the detection table is provided with a turnover device for turning over the ceramic articles.
3. A multi-scale ceramic detection method applied to any one of the multi-scale ceramic detection systems of claims 1-2, wherein: the method specifically comprises the following steps:
s101: placing a workpiece to be detected on the workbench, and acquiring an original RGB image of the workpiece to be detected by using an RGB color camera;
s102: carrying out image preprocessing on the original RGB image to obtain a preprocessed image;
s103: adopting a flaw detection method for the preprocessed image to obtain a primary flaw of the workpiece to be detected;
s104: placing the bow and the arrow to be detected on the detection table, and rotating by using a turnover device of the detection table; the RGBD camera at the tail end of the six-degree-of-freedom industrial mechanical arm is used for shooting a to-be-detected workpiece at multiple angles to obtain a group of to-be-detected workpiece images at different angles;
s105: performing three-dimensional reconstruction by using the multi-angle workpiece image to be detected to obtain a three-dimensional model of the workpiece to be detected;
s106: adding bounding boxes to the three-dimensional model, and checking the size information of the bounding boxes and the size information of the standard workpiece to obtain an area with inconsistent size;
s107: acquiring a flaw area of the workpiece to be detected according to the area with inconsistent sizes and the initial flaw obtained in the step S103;
s108: and (4) performing close-range image acquisition on the flaw area by using a short-focus camera arranged at the tail end of the seven-degree-of-freedom flexible arm, and performing accurate flaw detection by using the flaw detection method in the step S103 to obtain the accurate flaw of the workpiece to be detected.
4. A multi-scale ceramic detection method as claimed in claim 3, characterized in that: the image preprocessing method in step S102 specifically includes the following operations performed in sequence: grayscale, erosion, gradient calculation, and dilation.
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