CN113390879A - Coating measurement, correction and flaw detection method and system - Google Patents
Coating measurement, correction and flaw detection method and system Download PDFInfo
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- 238000001514 detection method Methods 0.000 title claims abstract description 370
- 238000000576 coating method Methods 0.000 title claims abstract description 138
- 239000011248 coating agent Substances 0.000 title claims abstract description 133
- 238000012937 correction Methods 0.000 title claims abstract description 72
- 238000005259 measurement Methods 0.000 title claims abstract description 54
- 238000004519 manufacturing process Methods 0.000 claims abstract description 26
- 230000007547 defect Effects 0.000 claims description 68
- 238000012545 processing Methods 0.000 claims description 48
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- 206010027146 Melanoderma Diseases 0.000 claims description 3
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- 238000005261 decarburization Methods 0.000 claims description 3
- 238000001914 filtration Methods 0.000 claims description 3
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- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 238000013528 artificial neural network Methods 0.000 description 1
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- 239000011889 copper foil Substances 0.000 description 1
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- 238000004513 sizing Methods 0.000 description 1
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- 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
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- 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 coating measurement, deviation correction and flaw detection method, which comprises the steps that a photographing pulse signal sent by an encoder triggers a first A-surface video detection device to acquire a first A-surface image so as to carry out first detection; and acquiring a second A-side image by the second A-side video detection device and acquiring a first B-side image by the first B-side video detection device so as to perform second detection, and acquiring a third A-side image acquired by the third A-side video detection device and a third B-side image acquired by the second B-side video detection device so as to perform third detection. Meanwhile, the invention also provides a coating measurement, correction and flaw detection system. According to the technical scheme provided by the invention, the size detection, the deviation correction detection and the flaw detection in the coating production process are realized, the ink-jet printer is automatically triggered to perform bad ink-jet printing, and the deviation correction assembly automatically corrects the deviation, so that unmanned automatic production is realized, the production efficiency and the detection efficiency of defective products are greatly improved, and the coating production quality is improved.
Description
Technical Field
The invention relates to the technical field of coating measurement, deviation correction and flaw detection, in particular to a coating measurement, deviation correction and flaw detection method and system.
Background
At present, the coating process is to coat the coating material on the surface of the substrate extremely uniformly to form a thin film on the surface of the substrate, which is very easy to cause the problems of slurry leakage, bubble, wrinkle and the like in the actual production process, and the coating is continuously carried out on the production line at a certain speed and is very easy to deviate in the process of running. However, it is difficult to find and correct the problems manually, and the uniformity of coating determines the quality of the coating process, so it is also necessary to detect the position and size of the coating in real time during the coating process, and to find the problems in time and deal with them.
Disclosure of Invention
The invention provides a coating measurement, deviation correction and flaw detection method and system, aiming at realizing timely problem finding and timely processing in a coating process and improving the production efficiency and the coating quality.
In order to achieve the above object, the present invention provides a method for measuring, correcting and detecting defects of a coating, the method for measuring, correcting and detecting defects of a coating comprises:
the photographing pulse signal sent by the encoder triggers the first A-side video detection device to acquire a first A-side image and sends the first A-side image to the main control equipment;
the main control equipment performs image processing on the first A-surface image and performs first detection; the first inspection comprises identifying a coating size inspection and a wet film flaw inspection;
acquiring a second A-plane image acquired by a second A-plane video detection device and a first B-plane image acquired by a first B-plane video detection device according to the acquisition time point of the first A-plane image and the device speed, and sending the second A-plane image and the first B-plane image to a main control device; the equipment speed is the traveling speed of the coating on the production equipment;
the master control equipment performs image processing on a second A-plane image and a first B-plane image at the same acquisition time point and performs second detection; the second detection comprises coating size detection, deviation correction detection and dry film defect detection;
acquiring a third A-plane image acquired by a third A-plane video detection device and a third B-plane image acquired by a second B-plane video detection device according to the acquisition time point and the device speed of the second A-plane image and the first B-plane image, and sending the third A-plane image and the third B-plane image to a main control device;
the master control equipment performs image processing on a third A-plane image and a third B-plane image at the same acquisition time point and performs third detection; the third inspection includes tail flaw inspection.
Further, the wet film defect detection comprises any one or more of metal leakage detection, slurry dripping detection, slurry black line detection and slurry metal leakage detection.
Further, the dry film defect detection includes any one or more of metal leakage detection, tape splicing detection, decarburization detection, bubbling detection, scratch detection, streak detection, bubble detection, black spot detection, bright spot detection, size detection, and smear detection.
Further, the coating measurement, correction and defect detection method further comprises, before the first detection step:
and the main control equipment calibrates the detection area according to preset product model parameters.
Further, the image processing includes:
discarding the image of the image beyond the calibrated detection area to ensure that the images of the A surface and the B surface are aligned;
carrying out binarization processing on the image to obtain the position location of the detected object;
filtering out interference elements in the image;
and setting edge detection points at the coating edge, and fitting the edge detection points to form the coating edge by utilizing an interpolation algorithm.
Further, after the third detection, the method further includes:
and triggering the ink-jet printer to automatically spray the bad marks when any detection result is judged to be a bad result according to the detection results of the first detection, the second detection and the third detection.
Meanwhile, the invention also provides a coating measurement, correction and flaw detection system, which comprises an encoder, a plurality of sets of video detection devices, a main control device, an ink-jet printer and a correction assembly; the encoder is pressed on the pole piece before coating to trigger the video detection device to acquire an image; the video detection device, the ink-jet printer and the deviation rectifying assembly are connected with the main control equipment; the video detection device is used for acquiring images and sending the acquired images to the main control equipment; the main control equipment is used for carrying out image processing and detection processing and sending a control signal to the ink-jet printer and the deviation rectifying assembly according to a detection result; the code spraying machine is used for spraying a poor coating mark for poor detection according to the control signal; the deviation rectifying assembly is used for rectifying the coating with deviation according to the control signal.
Preferably, the video detection device includes a first a-side video detection device, a second a-side video detection device, a first B-side video detection device, a third a-side video detection device, and a second B-side video detection device, where the second a-side video detection device and the first B-side video detection device are disposed opposite to each other, and the third a-side video detection device and the second B-side video detection device are disposed opposite to each other.
Preferably, the video detection device is a high-speed black and white line scanning 16K camera, the single camera view size is 750mm, and the pixels are 750mm/16384 pix-0.0458 mm/pix.
Preferably, the coating measurement, correction and flaw detection system further comprises an alarm assembly, the alarm assembly is connected with the main control equipment, and the alarm assembly is used for receiving an alarm signal of the main control equipment to perform sound-light alarm.
According to the coating measurement, deviation correction and flaw detection method and system, provided by the invention, size detection, deviation correction detection and flaw detection in the coating production process are realized through a plurality of sets of video detection devices, an ink-jet printer is automatically triggered to perform bad ink-jet printing, and the deviation correction assembly automatically corrects the deviation, so that unmanned automatic production is realized, the production efficiency and the detection efficiency of defective products are greatly improved, and the production quality of coating is improved.
Drawings
FIG. 1 is a schematic flow chart illustrating a method for coating measurement, correction and defect detection according to an embodiment of the present invention;
FIG. 2 is a schematic structural diagram of a system for coating measurement, correction and defect detection according to an embodiment of the present invention;
FIG. 3 is a schematic view of a single camera installation provided by an embodiment of the present invention;
FIG. 4 is a schematic view of a camera arrangement of a video inspection apparatus according to an embodiment of the present invention;
fig. 5 is a schematic diagram of a camera for video detection according to an embodiment of the invention;
FIG. 6 shows a detection standard for dry film defect detection according to an embodiment of the present invention;
FIG. 7 is a diagram illustrating steps of image processing according to an embodiment of the present invention;
FIG. 8 is a diagram illustrating an example of image processing according to an embodiment of the present invention;
FIG. 9 is a schematic flow chart illustrating a method for coating measurement, correction and defect detection according to an embodiment of the present invention;
FIG. 10 is a schematic diagram of an internal structure of a coating measurement, correction and defect detection apparatus according to an embodiment of the present invention;
FIG. 11 is a block diagram of a coating measurement, correction and defect detection process according to an embodiment of the apparatus for coating measurement, correction and defect detection.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention 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 invention and are not intended to limit the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 1, the present invention provides a coating measurement, deviation correction and defect detection method, which is applied to a coating production line, and specifically includes:
step S10: the photographing pulse signal sent by the encoder triggers the first A-side video detection device to acquire a first A-side image and sends the first A-side image to the main control equipment;
step S20: the main control equipment performs image processing on the first A-surface image and performs first detection; the first inspection comprises identifying a coating size inspection and a wet film flaw inspection;
before step S20, the main control device calibrates a detection area according to a preset product model parameter, where the detection area includes an a-side detection area and a B-side detection area, and specifically calibrates a longitudinal position difference between the a-side and the B-side; according to preset product model parameters, the detection area can be automatically determined by calibrating the detection area, edge detection is carried out in the determined area, and the size and dislocation are calculated through all detected edges;
step S30: acquiring a second A-plane image acquired by a second A-plane video detection device and a first B-plane image acquired by a first B-plane video detection device according to the acquisition time point of the first A-plane image and the device speed, and sending the second A-plane image and the first B-plane image to a main control device; the equipment speed is the traveling speed of the coating on the production equipment;
step S40: the master control equipment performs image processing on a second A-plane image and a first B-plane image at the same acquisition time point and performs second detection; the second detection comprises coating size detection, deviation correction detection and dry film defect detection;
step S50: acquiring a third A-plane image acquired by a third A-plane video detection device and a third B-plane image acquired by a second B-plane video detection device according to the acquisition time point and the device speed of the second A-plane image and the first B-plane image, and sending the third A-plane image and the third B-plane image to a main control device;
step S60: the master control equipment performs image processing on a third A-plane image and a third B-plane image at the same acquisition time point and performs third detection; the third inspection includes tail flaw inspection.
Specifically, in one embodiment of the invention, the coating measurement, deviation correction and defect detection method provided by the invention is applied to a coating production line, specifically, the coating material is extremely uniformly coated on a pole piece material, the width of the pole piece material is less than or equal to 1400mm, the pole piece material is divided into an A surface and a B surface, wherein the A surface is an anode, the B surface is a cathode, and the anode coating form comprises continuous coating, gap coating, 2-4 stripe coating and coating with a bottom; the cathode coating forms comprise continuous coating, gap coating, 2-4-width stripe coating, bottom coating and AT9 coating; the coating process includes single-sided coating and double-sided coating. The pole piece material moves on a production line at the equipment speed of 100m/min, and video detection devices are respectively deployed on the surface A and the surface B of the pole piece material production line when coating measurement, deviation correction and flaw detection are carried out; the video detection device comprises a camera and a light source, and particularly when the video detection device is deployed, the imaging of the camera on the A surface and the imaging of the camera on the B surface are parallel to each other and perpendicular to the plane of the pole piece, and the front camera and the back camera are mutually independent for detection.
Referring to fig. 2, in order to implement the coating measurement, deviation correction and defect detection method, the present invention further provides a coating measurement, deviation correction and defect detection system, specifically, the coating measurement, deviation correction and defect detection system includes an encoder 10, a plurality of sets of video detection devices 20, a main control device 30, an inkjet printer 40, a deviation correction component 50 and an alarm component 60; the encoder 10 is pressed on the pole piece before coating to trigger the video detection device 20 to acquire an image; the video detection device 20, the ink-jet printer 40 and the deviation rectifying assembly 50 are connected with the main control equipment 30; the video detection device 20 is configured to collect an image and send the collected image to the main control device 30; the main control device 30 is configured to perform image processing and detection processing, and send a control signal to the inkjet printer 40 and the deviation rectifying assembly 50 according to a detection result; the code spraying machine 40 is used for spraying a poor coating mark for poor detection according to the control signal; the deviation rectifying component 50 is used for rectifying the coating with deviation according to the control signal. The alarm assembly 60 is connected with the main control device 30, and the alarm assembly 60 is used for receiving an alarm signal of the main control device 30 to perform sound and light alarm.
The video detection device 20 includes a first a-side video detection device 21, a second a-side video detection device 22, a first B-side video detection device 23, a third a-side video detection device 24, and a second B-side video detection device 25, where the second a-side video detection device 22 and the first B-side video detection device 23 are disposed opposite to each other, and the third a-side video detection device 24 and the second B-side video detection device 25 are disposed opposite to each other. The video detection device 20 includes a camera and a linear light source cooperating with the camera, the linear light source being a highly focused linear light (1500mm x 5). The video detection device is a high-speed black and white line scanning 16K camera, the field of view of a single camera is 750mm, and the pixel is 750mm/16384 pix-0.0458 mm/pix. Specifically, in an embodiment of the present invention, the width of the pole piece material is less than or equal to 1400mm, the accuracy requirement is 0.05mm/pix, the field of view of a single line scanning camera selected to be used is 750mm, in order to cover the width of the pole piece material, each video detection apparatus 20 selects two line scanning cameras to be arranged side by side, the overlapping area of the middle fields of view of the two cameras is not more than 10mm, the overall field of view of the two cameras reaches about 1490mm, and the resolution accuracy of each camera is: 750mm/16384pix is 0.04578mm/pix, and the precision requirement of 0.05mm/pix is met. Therefore, in the present embodiment, the video detection apparatus 20 needs to be configured with 10 line scanning cameras and 5 sets of linear light sources.
Please refer to fig. 3, which is a schematic view illustrating the installation of a single camera, wherein the working distance D of the camera is 840mm, the installation height H of the camera is 1050mm, and the field of view W of the camera is 750mm, wherein the focal length of the lens of the camera is 60 mm.
Referring to fig. 4, the second a-side video detection device and the first B-side video detection device are disposed opposite to each other, the third a-side video detection device and the second B-side video detection device are disposed opposite to each other, each video detection device includes two cameras, and the view coverage meets the requirements of the pole piece material.
Referring to fig. 1 again, specifically, in an embodiment of the present invention, when the coating measurement, correction and defect detection method works, a pole piece material moves along a production line at an equipment speed, an encoder is disposed on the pole piece before coating, the encoder sends a pulse signal, a first a-side video detection device first receives a photographing pulse signal sent by the encoder, triggers the first a-side video detection device to acquire a first a-side image, and sends the first a-side image to a main control equipment for image processing and first detection; the first inspection comprises identifying a coating size inspection and a wet film flaw inspection; the coating size detection comprises the measurement of the sizes of the surface A and the surface B of the pole piece, the size of the sizing agent with the base coat and the error.
Referring to fig. 5, in order to calculate the error magnitude when coating with a thickness of 100um, assuming that the object distance of the camera is D, the object to be measured is an opaque object (coating), the thickness thereof is h, the distance from the edge of the object to the center of the camera is W, the error due to the thickness is e, the error e can be roughly estimated by the following method,
from a similar triangular relationship, there is W/(D-h) ═ e/h, or h/D ═ e/(e + W),
give e ═ W × h/(D-h),
when D is 840mm, h is 100um, W is 350mm, then
e＝350*0.1/(840–0.1)＝0.04mm，
That is, the error of the edge of the object having a thickness of 100um is 0.04mm at 350mm from the center of the camera.
Similarly, when W is 100mm, e is 0.012mm, and when W is 200mm, e is 0.024 mm.
The wet film defect detection comprises any one or more of metal leakage detection, slurry dripping detection, slurry black line detection and slurry metal leakage detection. Specifically, the detection criteria are set in advance, for example, the detection criteria are set such that the diameter of the wet film defect is not less than 0.5mm or the area is not less than 0.2mm2。
Acquiring images of a second A-surface video detection device and a first B-surface video detection device according to the acquisition time point of the first A-surface image and the equipment speed, specifically baking a pole piece material after coating slurry, acquiring images of the second A-surface video detection device and the first B-surface video detection device after baking, and sending the second A-surface image and the first B-surface image to a main control equipment; the main control equipment performs image processing on a second A-side image and a first B-side image at the same acquisition time point and performs second detection, wherein the second detection comprises coating size detection, deviation correction detection and dry film defect detection; the correction detection is used for detecting whether the pole piece material and the coating have deviation in the advancing process, and when the correction detection finds that the smear has deviation in the advancing process, the correction component is triggered to control the coating to correct the deviation in the centering process. The dry film defect detection comprises any one or more of metal leakage detection, tape splicing detection, decarburization detection, bubbling detection, scratch detection, streak detection, bubble detection, black spot detection, bright spot detection, size detection and tailing detection. As shown in fig. 6, fig. 6 shows the detection criteria provided in an embodiment of the present invention.
Similarly, a third A-plane image acquired by a third A-plane video detection device and a third B-plane image acquired by a second B-plane video detection device are acquired according to the acquisition time points of the second A-plane image and the first B-plane image and the device speed, and the third A-plane image and the third B-plane image are sent to the main control device; and the main control equipment performs image processing on a third A-plane image and a third B-plane image at the same acquisition time point and performs third detection, wherein the third detection comprises machine tail flaw detection. The machine tail defect detection comprises finished product size detection and finished product defect detection, and the finished product defect detection is the same as dry film defect detection, and is not described herein again.
And after the third detection is finished, triggering the ink-jet printer to automatically spray the bad mark when any detection result is judged to be a bad result according to the detection results of the first detection, the second detection and the third detection.
Referring to fig. 7, in any of the above steps, the image processing performed by the main control device on the acquired image specifically includes:
step S1: discarding the image of the image beyond the calibrated detection area to ensure that the images of the A surface and the B surface are aligned;
step S2: carrying out binarization processing on the image to obtain the position location of the detected object; specifically, in one embodiment of the present invention, the position of the pole piece material and the position of the coating are respectively located, and the pole piece material, the coating and the background area are distinguished;
step S3: filtering out interference elements in the image; for example, carbon powder on the copper foil, stain or damage on the material and the like, so that the interference of the edge part of the material is eliminated, and the accuracy of the measured data is ensured;
step S4: and setting edge detection points at the coating edge, and fitting the edge detection points to form the coating edge by utilizing an interpolation algorithm.
Referring to FIG. 8, several practical examples of image processing are shown, in particular, in one embodiment of the present invention.
The main control equipment displays the current point data in real time in the production process according to the detected data and generates a real-time curve graph; analyzing and processing the data before/after drying the surface A to obtain the shrinkage rate of the coating film and using the shrinkage rate of the coating film for judging a corrected value of the alignment; meanwhile, a data report can be checked through an interface of the main control equipment or bad (Not Good, NG) defect classification can be carried out through algorithms such as depth analysis and neural network based on detection data, the defect types such as metal leakage, bright spots, streaks and bubbles are distinguished according to the characteristics of an image formed by composition data such as gray level energy, gray level correlation, homogeneity, contrast, edge gray level distribution, entropy and anisotropy of the image, and then alarm is carried out according to a bad grade standard. The analysis is also used for guiding each link optimization of the production line so as to solve the problem of influencing the production quality.
Referring to fig. 9, in an embodiment of the present invention, a main control device performs a coating measurement, deviation correction, and defect detection method, before performing detection, a detection area is calibrated in the main control device in advance according to preset product model parameters, the detection area is calibrated, the detection area can be automatically determined, edge detection is performed in the determined area, and size and misalignment calculation is performed through all detected edges.
Specifically, the method for the main control equipment to perform coating measurement, deviation correction and flaw detection comprises the following steps:
step S101: receiving a first A-plane image sent by a first A-plane video detection device;
step S102: performing image processing on the first A-plane image and performing first detection; the first inspection comprises identifying a coating size inspection and a wet film flaw inspection;
step S103: judging a first detection result, and executing the step S111 when the first detection result is bad;
step S104: receiving a second A-surface image acquired by a second A-surface video detection device and a first B-surface image acquired by a first B-surface video detection device;
step S105: performing image processing on the second A-plane image and the first B-plane image and performing second detection; the second detection comprises coating size detection, deviation correction detection and dry film defect detection;
step S106: judging a second detection result, and executing the step S111 when the second detection result is bad; when the deviation rectifying detection result in the second detection result is that deviation occurs, executing step S107;
step S107: sending a control command to a deviation rectifying assembly to realize the deviation rectifying of the deviation rectifying assembly;
step S108: receiving a third A-surface image acquired by a third A-surface video detection device and a third B-surface image acquired by a second B-surface video detection device;
step S109: performing image processing on the third A-surface image and the third B-surface image and performing third detection; the third detection comprises tail defect detection;
step S110: judging a third detection result, and executing the step S111 when the third detection result is bad;
step S111: sending a control instruction to an ink-jet printer to trigger the ink-jet printer to automatically spray a bad mark;
step S112: and carrying out data processing and analysis on the stored image data and the detection data, and outputting a data report and an analysis report.
In addition, the invention also provides a coating measurement, deviation correction and flaw detection device.
Referring to fig. 10, an internal structure diagram of a coating measurement, correction and defect detection apparatus according to an embodiment of the present invention is provided, where the coating measurement, correction and defect detection apparatus at least includes a memory 11, a processor 12, a communication bus 13, and a network interface 14.
The memory 11 includes at least one type of readable storage medium, which includes a flash memory, a hard disk, a multimedia card, a card type memory (e.g., SD or DX memory, etc.), a magnetic memory, a magnetic disk, an optical disk, and the like. The memory 11 may be an internal storage unit of the coating measuring, correcting and defect detecting apparatus in some embodiments, such as a hard disk of the coating measuring, correcting and defect detecting apparatus. The memory 11 may also be an external storage device of the coating measuring, correcting and defect detecting apparatus in other embodiments, such as a plug-in hard disk, a Smart Media Card (SMC), a Secure Digital (SD) Card, a Flash memory Card (Flash Card), and the like, which are equipped on the coating measuring, correcting and defect detecting apparatus. Further, the memory 11 may also include both an internal memory unit of the coating measuring, correcting and defect detecting apparatus and an external memory device. The memory 11 may be used not only to store application software installed in the coating measuring, deviation correcting and defect detecting apparatus and various data, such as codes of coating measuring, deviation correcting and defect detecting programs, etc., but also to temporarily store data that has been output or will be output.
The processor 12, which in some embodiments may be a Central Processing Unit (CPU), controller, microcontroller, microprocessor or other data Processing chip, is used for executing program codes or Processing data stored in the memory 11, such as performing coating measurement, error correction and defect detection.
The communication bus 13 is used to realize connection communication between these components.
The network interface 14 may optionally include a standard wired interface, a wireless interface (e.g., WI-FI interface) typically used to establish communication links between the coating measurement, deviation correction and fault detection apparatus and other electronic devices.
Optionally, the coating measuring, deviation correcting and flaw detecting device may further include a user interface, the user interface may include a Display (Display), an input unit such as a Keyboard (Keyboard), and the optional user interface may further include a standard wired interface, a wireless interface. Alternatively, in some embodiments, the display may be an LED display, a liquid crystal display, a touch-sensitive liquid crystal display, an OLED (Organic Light-Emitting Diode) touch device, or the like. The display, which may also be referred to as a display screen or display unit, is used to display information processed in the coating measuring, deviation correcting and defect detecting device and to display a visual user interface.
While FIG. 10 shows only the coating measurement, deviation correction and fault detection apparatus with components 11-14 and coating measurement, deviation correction and fault detection routines, those skilled in the art will appreciate that the configuration shown in FIG. 10 does not constitute a limitation of the coating measurement, deviation correction and fault detection apparatus and may include fewer or more components than shown, or some components in combination, or a different arrangement of components.
In the embodiment of the coating measuring, correcting and defect detecting apparatus shown in fig. 10, the memory 11 stores a coating measuring, correcting and defect detecting program; the processor 12 implements the following steps when executing the coating measurement, correction and defect detection programs stored in the memory 11:
step S101: receiving a first A-plane image sent by a first A-plane video detection device;
step S102: performing image processing on the first A-plane image and performing first detection; the first inspection comprises identifying a coating size inspection and a wet film flaw inspection;
step S103: judging a first detection result, and executing the step S111 when the first detection result is bad;
step S104: receiving a second A-surface image acquired by a second A-surface video detection device and a first B-surface image acquired by a first B-surface video detection device;
step S105: performing image processing on the second A-plane image and the first B-plane image and performing second detection; the second detection comprises coating size detection, deviation correction detection and dry film defect detection;
step S106: judging a second detection result, and executing the step S111 when the second detection result is bad; when the deviation rectifying detection result in the second detection result is that deviation occurs, executing step S107;
step S107: sending a control command to a deviation rectifying assembly to realize the deviation rectifying of the deviation rectifying assembly;
step S108: receiving a third A-surface image acquired by a third A-surface video detection device and a third B-surface image acquired by a second B-surface video detection device;
step S109: performing image processing on the third A-surface image and the third B-surface image and performing third detection; the third detection comprises tail defect detection;
step S110: judging a third detection result, and executing the step S111 when the third detection result is bad;
step S111: sending a control instruction to an ink-jet printer to trigger the ink-jet printer to automatically spray a bad mark;
step S112: and carrying out data processing and analysis on the stored image data and the detection data, and outputting a data report and an analysis report.
Referring to fig. 11, a schematic block diagram of a coating measurement, deviation correction and defect detection procedure in an embodiment of the coating measurement, deviation correction and defect detection apparatus of the present invention is shown, in this embodiment, the coating measurement, deviation correction and defect detection procedure can be divided into a receiving module 10, a processing module 20, a detection module 30 and a control module 40, for example:
a receiving module 10, configured to receive an acquired image;
a processing module 20 for performing image processing;
a detection module 30, configured to perform a first detection, a second detection, and a third detection;
and the control module 40 is used for sending a control instruction.
The functions or operation steps implemented by the program modules such as the receiving module 10, the processing module 20, the detecting module 30, and the control module 40 when executed are substantially the same as those of the above embodiments, and are not described herein again.
In addition, an embodiment of the present invention further provides a storage medium, where the storage medium is a computer-readable storage medium, and the storage medium stores a coating measurement, deviation correction, and defect detection program, where the coating measurement, deviation correction, and defect detection program may be executed by one or more processors to implement the following operations:
step S101: receiving a first A-plane image sent by a first A-plane video detection device;
step S102: performing image processing on the first A-plane image and performing first detection; the first inspection comprises identifying a coating size inspection and a wet film flaw inspection;
step S103: judging a first detection result, and executing the step S111 when the first detection result is bad; when the first detection result is bad, executing step S104;
step S104: receiving a second A-surface image acquired by a second A-surface video detection device and a first B-surface image acquired by a first B-surface video detection device;
step S105: performing image processing on the second A-plane image and the first B-plane image and performing second detection; the second detection comprises coating size detection, deviation correction detection and dry film defect detection;
step S106: judging a second detection result, and executing the step S111 when the second detection result is bad; when the deviation rectifying detection result in the second detection result is that deviation occurs, executing step S107; when the second detection result is normal, executing step S108;
step S107: sending a control command to a deviation rectifying assembly to realize the deviation rectifying of the deviation rectifying assembly;
step S108: receiving a third A-surface image acquired by a third A-surface video detection device and a third B-surface image acquired by a second B-surface video detection device;
step S109: performing image processing on the third A-surface image and the third B-surface image and performing third detection; the third detection comprises tail defect detection;
step S110: judging a third detection result, and executing the step S111 when the third detection result is bad; when the third detection result is normal, executing step S112;
step S111: sending a control instruction to an ink-jet printer to trigger the ink-jet printer to automatically spray a bad mark;
step S112: and carrying out data processing and analysis on the stored image data and the detection data, and outputting a data report and an analysis report.
The storage medium of the present invention is substantially the same as the above-mentioned coating measurement, correction and defect detection method and apparatus, and will not be described herein.
Compared with the prior art, the coating measurement, deviation correction and flaw detection method, device and storage medium provided by the invention realize size detection, deviation correction detection and flaw detection in the coating production process through a plurality of sets of video detection devices, automatically trigger an ink-jet printer to perform bad ink-jet printing, automatically correct the deviation of the deviation correction assembly, realize unmanned automatic production, greatly improve the production efficiency and the detection efficiency of defective products, and improve the production quality of coating.
It should be noted that the above-mentioned numbers of the embodiments of the present invention are merely for description, and do not represent the merits of the embodiments. And the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, apparatus, article, or method that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, apparatus, article, or method. Without further limitation, an element defined by the phrase "comprising an … …" does not exclude the presence of other like elements in a process, apparatus, article, or method that comprises the element.
Through the above description of the embodiments, those skilled in the art will clearly understand that the method of the above embodiments can be implemented by software plus a necessary general hardware platform, and certainly can also be implemented by hardware, but in many cases, the former is a better implementation manner. Based on such understanding, the technical solution of the present invention may be embodied in the form of a software product, which is stored in a storage medium (e.g., ROM/RAM, magnetic disk, optical disk) as described above, and includes instructions for enabling a terminal device (e.g., a drone, a mobile phone, a computer, a server, or a network device) to execute the method according to the embodiments of the present invention.
It is to be noted that the foregoing is only illustrative of the preferred embodiments of the present invention and the technical principles employed. It will be understood by those skilled in the art that the present invention is not limited to the particular embodiments described herein, but is capable of various obvious changes, rearrangements and substitutions as will now become apparent to those skilled in the art without departing from the scope of the invention. Therefore, although the present invention has been described in greater detail by the above embodiments, the present invention is not limited to the above embodiments, and may include other equivalent embodiments without departing from the spirit of the present invention, and the scope of the present invention is determined by the scope of the appended claims.
Claims (10)
1. A coating measurement, deviation correction and flaw detection method is characterized by comprising the following steps:
the photographing pulse signal sent by the encoder triggers the first A-side video detection device to acquire a first A-side image and sends the first A-side image to the main control equipment;
the main control equipment performs image processing on the first A-surface image and performs first detection; the first inspection comprises identifying a coating size inspection and a wet film flaw inspection;
acquiring a second A-plane image acquired by a second A-plane video detection device and a first B-plane image acquired by a first B-plane video detection device according to the acquisition time point of the first A-plane image and the device speed, and sending the second A-plane image and the first B-plane image to a main control device; the equipment speed is the traveling speed of the coating on the production equipment;
the master control equipment performs image processing on a second A-plane image and a first B-plane image at the same acquisition time point and performs second detection; the second detection comprises coating size detection, deviation correction detection and dry film defect detection;
acquiring a third A-plane image acquired by a third A-plane video detection device and a third B-plane image acquired by a second B-plane video detection device according to the acquisition time point and the device speed of the second A-plane image and the first B-plane image, and sending the third A-plane image and the third B-plane image to a main control device;
the master control equipment performs image processing on a third A-plane image and a third B-plane image at the same acquisition time point and performs third detection; the third inspection includes tail flaw inspection.
2. The coating measurement, correction and defect detection method according to claim 1, wherein the wet film defect detection comprises any one or more of metal leakage detection, slurry dripping detection, slurry black line detection and slurry metal leakage detection.
3. The coating measurement, correction and defect detection method according to claim 1, wherein the dry film defect detection includes any one or more of metal leakage detection, tape splicing detection, decarburization detection, bubbling detection, scratch detection, streak detection, bubble detection, black spot detection, bright spot detection, size detection and tailing detection.
4. The coating measurement, correction and defect detection method according to claim 1, wherein the coating measurement, correction and defect detection method further comprises, before the first detection step:
and the main control equipment calibrates the detection area according to preset product model parameters.
5. The coating measurement, correction and flaw detection method according to claim 4, wherein the image processing comprises:
discarding the image of the image beyond the calibrated detection area to ensure that the images of the A surface and the B surface are aligned;
carrying out binarization processing on the image to obtain the position location of the detected object;
filtering out interference elements in the image;
and setting edge detection points at the coating edge, and fitting the edge detection points to form the coating edge by utilizing an interpolation algorithm.
6. The coating measurement, deviation correction and defect detection method according to claim 1, further comprising after the third detection:
and triggering the ink-jet printer to automatically spray the bad marks when any detection result is judged to be a bad result according to the detection results of the first detection, the second detection and the third detection.
7. A coating measurement, correction and flaw detection system is characterized by comprising an encoder, a plurality of sets of video detection devices, a main control device, an ink-jet printer and a correction assembly; the encoder is pressed on the pole piece before coating to trigger the video detection device to acquire an image; the video detection device, the ink-jet printer and the deviation rectifying assembly are connected with the main control equipment; the video detection device is used for acquiring images and sending the acquired images to the main control equipment; the main control equipment is used for carrying out image processing and detection processing and sending a control signal to the ink-jet printer and the deviation rectifying assembly according to a detection result; the code spraying machine is used for spraying a poor coating mark for poor detection according to the control signal; the deviation rectifying assembly is used for rectifying the coating with deviation according to the control signal.
8. The coating measurement, deviation correction and defect detection system according to claim 7, wherein the video detection devices comprise a first A-side video detection device, a second A-side video detection device, a first B-side video detection device, a third A-side video detection device and a second B-side video detection device, wherein the second A-side video detection device and the first B-side video detection device are oppositely arranged, and the third A-side video detection device and the second B-side video detection device are oppositely arranged.
9. The coating measurement, correction and defect detection system of claim 8, wherein the video detection device is a high speed black and white line scan 16K camera, the single camera view size is 750mm, and the pixels are 750mm/16384 pix-0.0458 mm/pix.
10. The coating measurement, deviation correction and defect detection system according to claim 8, further comprising an alarm component, wherein the alarm component is connected to the main control device, and the alarm component is used for receiving an alarm signal from the main control device to perform an audible and visual alarm.
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