CN113411512B - Industrial camera automatic exposure control method for cigarette field - Google Patents
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Abstract
本发明公开了一种用于卷烟领域的工业相机自动曝光控制方法，本发明的设计构思在于，利用光敏器件特性，实现对光照环境变化的实时检测并转换成电信号，同时提出不能简单利用光敏器件转换的电信号直接进行曝光控制，而是基于既定的策略提供了与光敏器件转换的电信号相关的初始曝光时间转换方法，再结合卷烟应用场景中工业相机的使用特点，设定了与初始曝光时间相关的最终曝光时间及最终增益参数的模型，从而得到用于控制工业相机实施自动曝光的控制参数。本发明提供的自动曝光机制打破了复杂光照条件对普通工业相机的限制，有效提升了工业相机的成像品质，进而提高了工业视觉检测系统的检测准确率。
The invention discloses an automatic exposure control method of an industrial camera used in the field of cigarettes. The design concept of the invention is to use the characteristics of a photosensitive device to realize real-time detection of changes in the lighting environment and convert them into electrical signals. The electrical signal converted by the device directly controls the exposure, but provides an initial exposure time conversion method related to the electrical signal converted by the photosensitive device based on the established strategy. The model of the final exposure time and final gain parameters related to the exposure time is used to obtain the control parameters for controlling the automatic exposure of the industrial camera. The automatic exposure mechanism provided by the invention breaks the limitation of complex lighting conditions on common industrial cameras, effectively improves the imaging quality of the industrial cameras, and further improves the detection accuracy of the industrial vision detection system.
Description
技术领域technical field
本发明涉及烟草工业领域，尤其涉及一种用于卷烟领域的工业相机自动曝光控制方法。The invention relates to the field of tobacco industry, in particular to an automatic exposure control method of an industrial camera used in the field of cigarettes.
背景技术Background technique
目前，机器视觉技术在卷烟工业控制领域已经广泛应用，工业相机作为机器视觉技术实现过程中的图像采集装置，其曝光控制方式一般为：预先手动调节好光圈值并保持不变，然后根据不同的场景使用工业相机控制软件设置曝光值等参数。当场景中的光照强度发生改变时，需要对工业相机控制软件中的参数进行调整后方能实现正常的图像采集功能。具体来说，工业相机的自动曝光功能是为了实现在不同光照环境下拍摄出符合后续检测质量要求的明暗程度合适的图像，为了达到这个目的，可通过在使用过程中调整光圈的大小、工业相机的曝光时间、成像传感器的增益参数等予以实现，但由于工业相机一般不能像数码相机一样自动调整光圈的大小，因此，工业相机的自动曝光功能主要是通过调整曝光时间和成像传感器的增益参数实现。At present, machine vision technology has been widely used in the field of cigarette industrial control. As an image acquisition device in the process of realizing machine vision technology, the exposure control method of industrial cameras is generally: manually adjust the aperture value in advance and keep it unchanged, and then adjust the aperture value according to different The scene uses industrial camera control software to set parameters such as exposure value. When the light intensity in the scene changes, the parameters in the industrial camera control software need to be adjusted before the normal image acquisition function can be realized. Specifically, the automatic exposure function of industrial cameras is to capture images with appropriate brightness and darkness that meet the quality requirements of subsequent inspections in different lighting environments. However, because industrial cameras generally cannot automatically adjust the aperture size like digital cameras, the automatic exposure function of industrial cameras is mainly realized by adjusting the exposure time and the gain parameters of the imaging sensor. .
现有具备自动曝光功能的普通工业相机，一般是采用统计成像传感器在拍摄前输出的经过量化的图像灰度值来判断光线的强弱，并根据预设的阈值来判断曝光过度或者不足，从而通过调整成像传感器的曝光时间、增益等参数来完成自动曝光功能，具体过程如下：The existing ordinary industrial cameras with automatic exposure function generally use the quantified image gray value output by the statistical imaging sensor before shooting to judge the intensity of light, and judge the overexposure or underexposure according to the preset threshold, thereby The automatic exposure function is completed by adjusting the exposure time, gain and other parameters of the imaging sensor. The specific process is as follows:
第一步：对当前图像进行亮度统计；Step 1: Perform brightness statistics on the current image;
第二步：根据当前图像亮度确定曝光值；Step 2: Determine the exposure value according to the current image brightness;
第三步：计算新的曝光参数，如曝光时间、增益；Step 3: Calculate new exposure parameters, such as exposure time, gain;
第四步：将新的曝光参数应用到相机；Step 4: Apply the new exposure parameters to the camera;
第五步：重复步骤一到四，直到亮度满足要求。Step 5: Repeat steps 1 to 4 until the brightness meets the requirements.
而上述自动曝光调整方式在实际使用过程中，会因为需要涉及大量的计算，导致收敛速度较低，难以满足光照强度变化剧烈的卷烟工业应用场景的使用需求。However, in the actual use process of the above automatic exposure adjustment method, a large number of calculations are required, resulting in a low convergence speed, which is difficult to meet the use requirements of cigarette industrial application scenarios where the light intensity changes drastically.
发明内容SUMMARY OF THE INVENTION
鉴于上述，本发明旨在提供一种用于卷烟领域的工业相机自动曝光控制方法，以实现普通工业相机在复杂光照环境下的自动曝光控制，为机器视觉技术在复杂光照的卷烟工业场景的应用提供了可靠的解决方案。In view of the above, the present invention aims to provide an automatic exposure control method for an industrial camera used in the field of cigarettes, so as to realize the automatic exposure control of a common industrial camera in a complex lighting environment, and for the application of machine vision technology in a complex lighting cigarette industrial scene Provides a reliable solution.
本发明采用的技术方案如下：The technical scheme adopted in the present invention is as follows:
一种用于卷烟领域的工业相机自动曝光控制方法，其中包括：An automatic exposure control method for an industrial camera used in the field of cigarettes, comprising:
获取安装在工业相机处的光敏器件实时检测并转换的电压信号，其中，所述电压信号与光敏器件感应到的当前光照强度具有既定的对应关系；acquiring a voltage signal detected and converted in real time by a photosensitive device installed at the industrial camera, wherein the voltage signal has a predetermined corresponding relationship with the current light intensity sensed by the photosensitive device;
根据预设的曝光时间基数、所述电压信号以及预设的加权系数值，计算初始曝光时间；Calculate the initial exposure time according to the preset exposure time base, the voltage signal and the preset weighting coefficient value;
利用预先基于工业相机使用场景的特性构建的第一模型、第二模型以及所述初始曝光时间，得到最终曝光时间以及最终增益参数；其中，所述第一模型表征阳光直射环境时的第一曝光时间、工业相机所允许的最大曝光时间以及所述初始曝光时间的关系；所述第二模型表征预设的增益中值数、预设的增益调整系数、所述第一曝光时间、所述最大曝光时间以及初始曝光时间的关系；The final exposure time and the final gain parameter are obtained by using the first model, the second model and the initial exposure time constructed in advance based on the characteristics of the industrial camera usage scene; wherein, the first model represents the first exposure in a direct sunlight environment time, the maximum exposure time allowed by the industrial camera, and the relationship between the initial exposure time; the second model represents a preset median gain value, a preset gain adjustment coefficient, the first exposure time, the maximum The relationship between exposure time and initial exposure time;
利用所述最终曝光时间以及所述最终增益参数控制工业相机在当前光照强度下进行自动曝光控制。The industrial camera is controlled to perform automatic exposure control under the current light intensity by using the final exposure time and the final gain parameter.
在其中至少一种可能的实现方式中，所述初始曝光时间的计算公式包括：In at least one possible implementation, the calculation formula of the initial exposure time includes:
t＝z-x*yt=z-x*y
其中，t为初始曝光时间，z为曝光时间基数，x为光敏器件转换的电压信号数值，y为加权系数值。Among them, t is the initial exposure time, z is the exposure time base, x is the voltage signal value converted by the photosensitive device, and y is the weighting coefficient value.
在其中至少一种可能的实现方式中，设定所述加权系数值的方式包括：对不同的图片的亮度与相应光照强度关系进行统计分析，确定用于曝光控制的加权系数值。In at least one possible implementation manner, the manner of setting the weighting coefficient value includes: performing statistical analysis on the relationship between the brightness of different pictures and the corresponding light intensity to determine the weighting coefficient value for exposure control.
在其中至少一种可能的实现方式中，所述第一模型包括：In at least one possible implementation manner, the first model includes:
其中，T为所述最终曝光时间，T0为所述第一曝光时间，Tmax为所述最大曝光时间。Wherein, T is the final exposure time, T 0 is the first exposure time, and T max is the maximum exposure time.
在其中至少一种可能的实现方式中，所述第二模型包括：In at least one possible implementation manner, the second model includes:
其中，E为所述最终增益参数，A为所述增益中值数，k为所述增益调整系数。Wherein, E is the final gain parameter, A is the median value of the gain, and k is the gain adjustment coefficient.
本发明的设计构思在于，利用光敏器件特性，实现对光照环境变化的实时检测并转换成电信号，同时提出不能简单利用光敏器件转换的电信号直接进行曝光控制，而是基于既定的策略提供了与光敏器件转换的电信号相关的初始曝光时间转换方法，再结合卷烟应用场景中工业相机的使用特点，设定了与初始曝光时间相关的最终曝光时间及最终增益参数的模型，从而得到用于控制工业相机实施自动曝光的控制参数。本发明提供的自动曝光机制打破了复杂光照条件对普通工业相机的限制，有效提升了工业相机的成像品质，进而提高了工业视觉检测系统的检测准确率。The design concept of the present invention is to use the characteristics of the photosensitive device to realize real-time detection of changes in the lighting environment and convert it into an electrical signal, and at the same time, it is proposed that the exposure control cannot be directly performed by simply using the electrical signal converted by the photosensitive device, but based on the established strategy. The initial exposure time conversion method related to the electrical signal converted by the photosensitive device, combined with the use characteristics of industrial cameras in cigarette application scenarios, set the final exposure time and final gain parameters related to the initial exposure time model, so as to obtain a model for the final exposure time and final gain parameters. Control parameters that control industrial cameras to implement automatic exposure. The automatic exposure mechanism provided by the invention breaks the limitation of complex lighting conditions on common industrial cameras, effectively improves the imaging quality of the industrial cameras, and further improves the detection accuracy of the industrial vision detection system.
附图说明Description of drawings
为使本发明的目的、技术方案和优点更加清楚，下面将结合附图对本发明作进一步描述，其中：In order to make the objects, technical solutions and advantages of the present invention clearer, the present invention will be further described below in conjunction with the accompanying drawings, wherein:
图1为本发明实施例提供的用于卷烟领域的工业相机自动曝光控制方法的流程图。FIG. 1 is a flowchart of an automatic exposure control method for an industrial camera in the field of cigarettes provided by an embodiment of the present invention.
具体实施方式Detailed ways
下面详细描述本发明的实施例，实施例的示例在附图中示出，其中自始至终相同或类似的标号表示相同或类似的器件或具有相同或类似功能的器件。下面通过参考附图描述的实施例是示例性的，仅用于解释本发明，而不能解释为对本发明的限制。The following describes in detail the embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals refer to the same or similar devices or devices having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, but not to be construed as a limitation of the present invention.
本发明提出了一种用于卷烟领域的工业相机自动曝光控制方法的实施例，具体来说，如图1所示，可以包括：The present invention proposes an embodiment of an industrial camera automatic exposure control method used in the field of cigarettes. Specifically, as shown in FIG. 1 , it may include:
步骤S1、获取安装在工业相机处的光敏器件实时检测并转换的电压信号，其中，所述电压信号与光敏器件感应到的当前光照强度具有既定的对应关系；Step S1, acquiring a voltage signal detected and converted in real time by a photosensitive device installed at the industrial camera, wherein the voltage signal has a predetermined corresponding relationship with the current light intensity sensed by the photosensitive device;
步骤S2、根据预设的曝光时间基数、所述电压信号以及预设的加权系数值，计算初始曝光时间；Step S2, calculating the initial exposure time according to the preset exposure time base, the voltage signal and the preset weighting coefficient value;
步骤S3、利用预先基于工业相机使用场景的特性构建的第一模型、第二模型以及所述初始曝光时间，得到最终曝光时间以及最终增益参数；其中，所述第一模型表征阳光直射环境时的第一曝光时间、工业相机所允许的最大曝光时间以及所述初始曝光时间的关系；所述第二模型表征预设的增益中值数、预设的增益调整系数、所述第一曝光时间、所述最大曝光时间以及初始曝光时间的关系；Step S3, using the first model, the second model and the initial exposure time constructed in advance based on the characteristics of the industrial camera usage scene, to obtain the final exposure time and the final gain parameter; wherein, the first model represents the direct sunlight environment. The relationship between the first exposure time, the maximum exposure time allowed by the industrial camera, and the initial exposure time; the second model represents a preset median gain value, a preset gain adjustment coefficient, the first exposure time, the relationship between the maximum exposure time and the initial exposure time;
步骤S4、利用所述最终曝光时间以及所述最终增益参数控制工业相机在当前光照强度下进行自动曝光控制。Step S4, using the final exposure time and the final gain parameter to control the industrial camera to perform automatic exposure control under the current light intensity.
进一步地，所述初始曝光时间的计算公式包括：Further, the calculation formula of the initial exposure time includes:
t＝z-x*yt=z-x*y
其中，t为初始曝光时间，z为曝光时间基数，x为光敏器件转换的电压信号数值，y为加权系数值。Among them, t is the initial exposure time, z is the exposure time base, x is the voltage signal value converted by the photosensitive device, and y is the weighting coefficient value.
进一步地，设定所述加权系数值的方式包括：对不同的图片的亮度与相应光照强度关系进行统计分析，确定用于曝光控制的加权系数值。Further, the method of setting the weighting coefficient value includes: performing statistical analysis on the relationship between the brightness of different pictures and the corresponding light intensity, and determining the weighting coefficient value for exposure control.
进一步地，所述第一模型包括：Further, the first model includes:
其中，T为所述最终曝光时间，T0为所述第一曝光时间，Tmax为所述最大曝光时间。Wherein, T is the final exposure time, T 0 is the first exposure time, and T max is the maximum exposure time.
进一步地，所述第二模型包括：Further, the second model includes:
其中，E为所述最终增益参数，A为所述增益中值数，k为所述增益调整系数。Wherein, E is the final gain parameter, A is the median value of the gain, and k is the gain adjustment coefficient.
为便于理解上述实施例及其优选方案，此处提供如下具体的说明示意：In order to facilitate the understanding of the above-mentioned embodiments and their preferred solutions, the following specific descriptions are provided here:
使用光敏器件实时将当前拍摄环境光照强度转换成电信号，并传输至控制器进行处理，控制器利用转换后的电信号与曝光时间、成像传感器增益建立模型，通过模型处理输出所需的曝光控制参数，并通过工业通信方式传送至工业相机，工业相机根据接收到的曝光控制参数实现自动曝光功能。The photosensitive device is used to convert the current shooting ambient light intensity into an electrical signal in real time, and transmit it to the controller for processing. The controller uses the converted electrical signal, exposure time, and imaging sensor gain to build a model, and outputs the required exposure control through the model. The parameters are transmitted to the industrial camera through industrial communication, and the industrial camera realizes the automatic exposure function according to the received exposure control parameters.
具体来说，可以使用线性光敏传感器(如光敏元件、光伏电池板等)将环境光照强度转化成电压信号，并将该电压信号经由PLC的模拟量模块送入PLC。Specifically, a linear photosensitive sensor (such as a photosensitive element, a photovoltaic cell panel, etc.) can be used to convert the ambient light intensity into a voltage signal, and the voltage signal is sent to the PLC through the analog module of the PLC.
因为光照强度与线性光敏传感器的输出电压呈正相关线性关系，而曝光时间又与光照强度呈负相关线性关系，所以，为保证不同光照条件下工业相机均能正常曝光，本发明认为不能直接使用线性光敏传感器输出的电压数据，而需要构建模型予以实现。在经过多次试验测试，对海量的不同图片的亮度与光照强度关系进行统计分析，得出了曝光值的加权系数值，并由此构建了曝光时间转换关系，如下：Because the light intensity has a positive linear relationship with the output voltage of the linear photosensitive sensor, and the exposure time has a negative linear relationship with the light intensity. Therefore, in order to ensure normal exposure of industrial cameras under different lighting conditions, the present invention believes that the linear relationship cannot be directly used. The voltage data output by the photosensitive sensor needs to be realized by building a model. After many experiments and tests, the relationship between the brightness and light intensity of a large number of different pictures was statistically analyzed, and the weighted coefficient value of the exposure value was obtained, and the exposure time conversion relationship was constructed, as follows:
t＝z-x*yt=z-x*y
其中t为初始曝光时间，x光敏器件输出电压，y为加权系数值，z为预设的曝光时间基数值(可结合所使用的工业相机确定)。Among them, t is the initial exposure time, x is the output voltage of the photosensitive device, y is the weighting coefficient value, and z is the preset exposure time base value (which can be determined in combination with the industrial camera used).
为保证工业相机的最短曝光时间大于等于0，且最长曝光时间不大于工业相机在应用场景中的预设最大曝光时间(例如，在一些的工业场景中，被拍摄物是移动的，曝光时间过长会工业相机拍摄的图片将会不清晰)，预先建立如下第一模型、第二模型以控制工业相机的曝光参数：In order to ensure that the shortest exposure time of the industrial camera is greater than or equal to 0, and the longest exposure time is not greater than the preset maximum exposure time of the industrial camera in the application scene (for example, in some industrial scenes, the subject is moving, the exposure time The picture taken by the industrial camera will be unclear if it is too long), and the following first and second models are established in advance to control the exposure parameters of the industrial camera:
第一模型中，T为工业相机的最终曝光时间，T0为工业相机在有阳光直射时(如正午)的光照强度环境下的曝光时间，Tmax为工业相机结合实际生产场景预设的最大曝光时间，t为初始曝光时间；以及第二模型中，E为工业相机的最终增益参数，A为增益参数的中值数，k为增益参数的调整系数。In the first model, T is the final exposure time of the industrial camera, T 0 is the exposure time of the industrial camera under the light intensity environment when there is direct sunlight (such as noon), and T max is the maximum preset by the industrial camera combined with the actual production scene. Exposure time, t is the initial exposure time; and in the second model, E is the final gain parameter of the industrial camera, A is the median number of the gain parameter, and k is the adjustment coefficient of the gain parameter.
由此，在每次启动工业相机拍照时，PLC可以根据当前获取到光电转换信号(优选地，还可以结合当前相机采集到的图像信号，例如但不限于实施拍摄前有镜头捕获的图像信息)，按前述方式计算出工业相机的最终曝光时间T和最终增益参数E，然后通过诸如profinet网络等方式传输至工业相机的控制模块中，用以控制工业相机实现自动曝光。Therefore, every time the industrial camera is started to take a picture, the PLC can obtain the photoelectric conversion signal according to the current acquisition (preferably, it can also be combined with the image signal collected by the current camera, such as but not limited to the image information captured by the lens before the shooting) , calculate the final exposure time T and final gain parameter E of the industrial camera in the aforementioned manner, and then transmit them to the control module of the industrial camera through means such as the profinet network to control the industrial camera to realize automatic exposure.
综上所述，本发明的设计构思在于，利用光敏器件特性，实现对光照环境变化的实时检测并转换成电信号，同时提出不能简单利用光敏器件转换的电信号直接进行曝光控制，而是基于既定的策略提供了与光敏器件转换的电信号相关的初始曝光时间转换方法，再结合卷烟应用场景中工业相机的使用特点，设定了与初始曝光时间相关的最终曝光时间及最终增益参数的模型，从而得到用于控制工业相机实施自动曝光的控制参数。本发明提供的自动曝光机制打破了复杂光照条件对普通工业相机的限制，有效提升了工业相机的成像品质，进而提高了工业视觉检测系统的检测准确率。To sum up, the design concept of the present invention is to use the characteristics of the photosensitive device to realize the real-time detection of changes in the lighting environment and convert it into an electrical signal. The established strategy provides an initial exposure time conversion method related to the electrical signal converted by the photosensitive device, and combined with the use characteristics of industrial cameras in cigarette application scenarios, the final exposure time and final gain parameter models related to the initial exposure time are set , so as to obtain the control parameters used to control the industrial camera to implement automatic exposure. The automatic exposure mechanism provided by the invention breaks the limitation of complex lighting conditions on ordinary industrial cameras, effectively improves the imaging quality of the industrial cameras, and further improves the detection accuracy of the industrial vision detection system.
本发明实施例中，“至少一个”是指一个或者多个，“多个”是指两个或两个以上。“和/或”，描述关联对象的关联关系，表示可以存在三种关系，例如，A和/或B，可以表示单独存在A、同时存在A和B、单独存在B的情况。其中A，B可以是单数或者复数。字符“/”一般表示前后关联对象是一种“或”的关系。“以下至少一项”及其类似表达，是指的这些项中的任意组合，包括单项或复数项的任意组合。例如，a，b和c中的至少一项可以表示：a，b，c，a和b，a和c，b和c或a和b和c，其中a，b，c可以是单个，也可以是多个。In the embodiments of the present invention, "at least one" refers to one or more, and "multiple" refers to two or more. "And/or", which describes the association relationship of the associated objects, means that there can be three kinds of relationships, for example, A and/or B, which can indicate the existence of A alone, the existence of A and B at the same time, and the existence of B alone. where A and B can be singular or plural. The character "/" generally indicates that the associated objects are an "or" relationship. "At least one of the following" and similar expressions refer to any combination of these items, including any combination of single or plural items. For example, at least one of a, b, and c may represent: a, b, c, a and b, a and c, b and c or a and b and c, where a, b, c may be single, or Can be multiple.
以上依据图式所示的实施例详细说明了本发明的构造、特征及作用效果，但以上仅为本发明的较佳实施例，需要言明的是，上述实施例及其优选方式所涉及的技术特征，本领域技术人员可以在不脱离、不改变本发明的设计思路以及技术效果的前提下，合理地组合搭配成多种等效方案；因此，本发明不以图面所示限定实施范围，凡是依照本发明的构想所作的改变，或修改为等同变化的等效实施例，仍未超出说明书与图示所涵盖的精神时，均应在本发明的保护范围内。The structure, features and effects of the present invention have been described in detail above according to the embodiments shown in the drawings, but the above are only preferred embodiments of the present invention. It should be noted that the above-mentioned embodiments and their preferred modes involve technologies Features, those skilled in the art can reasonably combine and match into a variety of equivalent solutions without departing from or changing the design ideas and technical effects of the present invention; therefore, the present invention does not limit the scope of implementation as shown in the drawings, Any changes made in accordance with the concept of the present invention, or modifications to equivalent embodiments with equivalent changes, shall fall within the protection scope of the present invention if they do not exceed the spirit covered by the description and drawings.
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