CN113504241A - Design method of paper defect detection system - Google Patents
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Abstract
The invention discloses a design method of a paper defect detection system, which comprises the following steps: determining performance parameters of an image acquisition module, a paper defect detection module and a data storage module according to actual requirements; selecting an image acquisition module, a paper defect detection module and a data storage module which meet performance parameters and have the lowest cost; and establishing a paper defect detection system by using the selected image acquisition module, the paper defect detection module and the data storage module. Based on the barrel theory, the invention designs a set of effective construction scheme of a paper defect detection system framework for reference by taking configuration balance as a main research target. Aiming at different production lines, the system architecture is designed by taking the minimum hardware meeting the system requirements as a standard, a minimum adaptation scheme is provided, the effect that the user requirements can be met and the system resources are not wasted is finally achieved, the investment cost is effectively reduced for paper making enterprises, and the detection and the identification of paper defects can be rapidly and accurately finished.
Description
Technical Field
The invention relates to the technical field of papermaking equipment, in particular to a design method of a paper defect detection system.
Background
During the production process of special paper, different appearance defects are easily generated under the influence of internal factors and production environment, and the surface defects of the special paper are called paper defects.
The paper defect detection system based on machine vision is a new paper defect detection technology, and compared with manual detection, the paper defect detection system has the characteristics of non-contact, high precision and high efficiency. However, with the increase of the speed and the width of the paper machine, the rapidity and the accuracy of paper defect detection are greatly reduced.
In the existing paper defect detection system, the detection system caused by unbalanced hardware configuration can only detect a paper machine with low speed and small paper width, and is difficult to meet the detection precision required by enterprises.
Disclosure of Invention
The embodiment of the invention provides a design method of a paper defect detection system, which is used for solving the problems that in the prior art, the detection system only can detect a paper machine with low speed and small paper width due to unbalanced hardware configuration, and the utilization rate of modules in the system is low.
In one aspect, an embodiment of the present invention provides a method for designing a paper defect detection system, where the paper defect detection system includes: the paper defect detection method comprises an image acquisition module, a paper defect detection module and a data storage module, and comprises the following steps:
determining performance parameters of an image acquisition module, a paper defect detection module and a data storage module according to actual requirements;
selecting an image acquisition module, a paper defect detection module and a data storage module which meet performance parameters and have the lowest cost;
and establishing a paper defect detection system by using the selected image acquisition module, the paper defect detection module and the data storage module.
In one possible implementation, the image acquisition module includes: a camera and lens; determining performance parameters of an image acquisition module, comprising: determining the resolution and the acquisition frequency of the camera; the size, focal length, aperture and resolution of the lens are determined.
In one possible implementation, determining the resolution and acquisition frequency of the camera includes: determining the total number of required pixels according to the transverse width of the detection area, the required unit precision and the total number of pixels in the unit precision, and determining the resolution of the camera according to the determined total number of required pixels; and determining the acquisition frequency of the camera according to the running speed of the paper machine, the required unit precision and the total number of pixels in the unit precision.
In one possible implementation, determining the size, focal length, aperture, and resolution of the lens includes: determining the size of a lens according to the imaging size of the camera; determining the focal length of the lens according to the imaging size of the camera, the distance between the lens and the paper and the length of the detection area; determining the aperture of the lens according to the focal length of the lens and the effective aperture of the lens; the resolution of the lens is determined according to the resolution of the camera.
In one possible implementation, the performance parameter of the paper defect detection module is the amount of data that can be processed per unit time, and the performance parameter is determined according to the resolution and the acquisition frequency of the camera.
In one possible implementation, the performance parameter of the data storage module is a data storage speed.
The design method of the paper defect detection system has the following advantages:
based on the wooden barrel theory, the configuration balance is taken as a main research target, and an effective construction scheme for a reference paper defect detection system framework is designed. Aiming at different production lines, the system architecture is designed by taking the minimum hardware meeting the system requirements as a standard, a minimum adaptation scheme is provided, the effect that the user requirements can be met and the system resources are not wasted is finally achieved, the investment cost is effectively reduced for paper making enterprises, and the detection and the identification of paper defects can be rapidly and accurately finished.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
Fig. 1 is a flowchart of a method for designing a paper defect detection system according to an embodiment of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. 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.
Fig. 1 is a flowchart of a method for designing a paper defect detection system according to an embodiment of the present invention. The invention provides a design method of a paper defect detection system, and the paper defect detection system to be designed comprises the following steps: the paper machine comprises an image acquisition module, a paper defect detection module and a data storage module, wherein the image acquisition module is used for acquiring paper images in the running process of the paper machine, the paper defect detection module is used for processing the paper images and judging whether paper defects exist in the paper images, and the data storage module is used for storing the paper images. The design method comprises the following steps:
s100, determining performance parameters of an image acquisition module, a paper defect detection module and a data storage module according to actual requirements;
s101, selecting an image acquisition module, a paper defect detection module and a data storage module which meet performance parameters and have the lowest cost;
s102, establishing a paper defect detection system by using the selected image acquisition module, the paper defect detection module and the data storage module.
Illustratively, when the paper defect detection module determines that paper defects exist in the paper image, the paper image with the paper defects is transmitted to a data storage module connected with a PC (personal computer), and the PC further processes the paper image to determine the position and the type of the paper defects. And transmitting the paper image without paper defects to the data storage module for storage by the paper defect detection module. Therefore, in the paper defect detection system, the data storage module with two purposes has fewer paper images stored in the data storage module connected with the PC, and the requirement on the data storage speed, namely the performance parameter is not high, so that a general storage device, such as a mechanical hard disk or a common solid state hard disk, can be selected, and the data storage module for storing the paper image without paper defects has a high requirement on the storage speed, and is specifically determined according to the data volume of the generated paper image.
In an embodiment of the present invention, the paper defect detecting system further includes a light source module and a mechanical control module, wherein the light source module is used for generating an illumination light source to improve the brightness of the paper image acquired by the image acquisition module. The mechanical control module can use a marking machine, and after the PC determines the position of the paper defect on the paper, the mechanical control module can mark the position with the paper defect on the paper.
The invention designs a paper defect detection system by adopting a barrel theory. The core content of the wood barrel theory, which is also called as the short plate theory, is as follows: the amount of water contained in a wooden barrel does not depend on the longest wooden plate on the barrel wall, but depends on the shortest wooden plate on the barrel wall. From this, there can be two inferences: first, only if all the wooden boards on the barrel wall are high enough, the barrel can be filled with water. Secondly, as long as a wood board in the wooden barrel is not high enough, water in the wooden barrel cannot be full, and materials used by the wood board higher than the shortest wood board are wasted. To the extent that the paper defect detection system of the present invention is used: if a complete paper defect detection process is to be realized, all modules of the system are required to meet the requirement of processing data in real time, and as long as one module does not meet the requirement, the real-time online detection function of paper defects cannot be finished, while the modules higher than the minimum standard waste resources. In order to save cost, the design of the paper defect detection system architecture is carried out by taking the minimum hardware meeting the system requirements as a standard when the system architecture is designed.
In one possible embodiment, the image acquisition module comprises: a camera and lens; determining performance parameters of an image acquisition module, comprising: determining the resolution and the acquisition frequency of the camera; the size, focal length, aperture and resolution of the lens are determined.
In the paper defect detection system based on machine vision, the selection of the camera determines the image quality and indirectly determines the detection accuracy, so that the selection of a proper camera plays a decisive role in the detection accuracy, and the real-time calculation of the data processing capacity of the camera mainly takes the data generated by the camera in unit time as a reference. The quality of the lens affects the image acquisition range and the imaging effect.
In one possible embodiment, determining the resolution and acquisition frequency of the camera comprises: determining the total number of required pixels according to the transverse width of the detection area, the required unit precision and the total number of pixels in the unit precision, and determining the resolution of the camera according to the determined total number of required pixels; and determining the acquisition frequency of the camera according to the running speed of the paper machine, the required unit precision and the total number of pixels in the unit precision.
Illustratively, the camera resolution refers to the total number of pixels of an image that can be captured by the camera in a single capture of the image, and is generally determined by multiplying the total number of pixels in the lateral direction by the total number of pixels in the longitudinal direction. In a paper defect detection system, the resolution of a camera generally needs to be determined according to the width of a detected surface and the precision required by a user, as shown in formula 1.
In the formula PnThe total number of required pixels is represented, w represents the transverse width of the detection area and is expressed in millimeters, epsilon represents unit precision required by a user and is expressed in square millimeters, n represents the total number of pixels in the unit precision, the larger the value of n is, the more pixels are required in the unit precision, the lower the detectable speed of the system is under the same acquisition frequency, and the value of n is generally concentrated in {1,4,9,16,25 }. When the width of the paper machine is large, PnThe value of (a) is far beyond the resolution of a single camera, the resolution of the single camera cannot meet the requirement of full-width detection, a plurality of cameras need to be transversely arranged in parallel to meet the detection requirement, and the number of the cameras is obtained by dividing the total number of pixels required by the transverse detection width by the transverse resolution of the single camera.
The acquisition frequency of the camera is mainly determined by the required unit accuracy and detection speed. Generally, when the required detection accuracy of cameras with the same frequency is high, the detection speed of the system is slow, and when the required detection accuracy is low, the detection speed of the system is fast. The relational expression between the acquisition frequency of the camera and the detection precision and the detection speed is shown in formula 2.
Wherein f represents the acquisition frequency of the camera in hertz (Hz); s represents the running speed of the paper machine in meters per minute; epsilon represents the unit precision required by the user, and the unit is square millimeter; n represents the total number of pixels in unit precision. When the detection accuracy and speed are high, the camera frequency also becomes high, and the hardware cost also increases.
In one possible embodiment, determining the size, focal length, aperture and resolution of the lens comprises: determining the size of a lens according to the imaging size of the camera; determining the focal length of the lens according to the imaging size of the camera, the distance between the lens and the paper and the length of the detection area; determining the aperture of the lens according to the focal length of the lens and the effective aperture of the lens; the resolution of the lens is determined according to the resolution of the camera.
Illustratively, the imaging capability of the camera can be fully utilized only when the size of the lens is equal to or larger than the imaging size of the camera, otherwise the effective size of the camera is wasted. In order to better utilize the performance of the camera, a lens larger than the imaging size of the camera is generally selected.
According to the imaging principle of the camera, the length of the focal length is in direct proportion to the distance from the camera to the collected object, when the distance between the camera and the collected object is determined, the area which can be collected by the lens with the large focal length is smaller, and the area which can be collected by the lens with the small focal length is larger. To select a proper lens, a lens with a proper focal length can be selected by the calculation of equation 3.
f＝A×H/L (3)
In the paper defect detection system, f in formula 3 represents a focal length, a represents an imaging size of a camera, H represents a distance between a lens and a captured object, that is, paper, and L represents a length of a region that needs to be detected. The imaging size a of the camera is generally determined in advance, and may be determined according to the detection accuracy and the resolution of the camera. The short-focus lens can realize wide-angle acquisition, but in an area far away from the center, distortion may be generated, so that image distortion is caused; when the distance between the telephoto lens and the collected object is determined, the collected area becomes smaller, when the width of the collected object is fixed, more cameras are needed to realize the full-width collection of the collected object, and the system cost is higher.
The aperture of the lens determines the amount of light entering the camera in unit time, and the larger the aperture is, the more light enters the camera in unit time, and the brighter the acquired image is. The size of the aperture is generally expressed by adding a number to F, and the size of the aperture is inversely proportional to the number following F, and the larger the number, the smaller the aperture. The calculation formula is shown in formula 4.
F＝f/d (4)
Wherein F represents the aperture value, F represents the focal length of the lens, and d represents the effective aperture of the lens.
The resolution of the lens refers to the number of lines between black and white which can be resolved within 1mm of the image plane, and the unit is line pair/mm, which is a way to quantify the contrast definition of the image. Under the condition that the resolution of the camera is constant, the higher the resolution of the lens is, the higher the definition of the acquired image is. Typically a lens is selected with a resolution slightly higher than the resolution of the camera.
In a possible embodiment, the performance parameter of the paper defect detection module is the amount of data that can be processed per unit time, which is determined according to the resolution and acquisition frequency of the camera.
Illustratively, the calculation formula of the data amount generated per unit time by the camera, that is, the data amount that can be processed per unit time by the paper defect detection module is shown in formula 5.
Data＝P*f (5)
Wherein Data represents the amount of Data generated per unit time in bytes per second (B/s); p is the camera resolution and f is the acquisition frequency of the camera.
When the speed and width of the paper machine are increased, the serial CPU can not complete the data processing in real time. The FPGA (field programmable gate array) can realize resource scheduling among multiple cores, lays a good foundation for pipeline and data parallel, and is suitable for a detection module with high real-time requirement in a paper defect detection system due to the advantage of rapid customization, so that the FPGA is selected as the paper defect detection module.
In one possible embodiment, the performance parameter of the data storage module is a data storage speed.
Illustratively, the data storage module is connected with the FPGA, and the FPGA is responsible for storing the acquired paper images on the data storage module by using a data bus, so that the data volume generated by the data storage module is large, the real-time requirement is high, and the storage speed of the data storage module is required to be higher than the data generation speed of a camera. To achieve an optimal configuration of the system, the storage speeds of the different storage devices need to be compared, as shown in table 1.
TABLE 1 comparison of storage speeds of different storage devices
As can be seen from the table, the storage speed of the solid state disk is much higher than that of the mechanical hard disk and the flash disk, the speed of 300MBps can be realized by the ordinary solid state disk, and similarly, the storage speed of the high-end solid state disk of the PCI-E interface is higher than that of the solid state disk of the SATA3.0 interface by approximately 10 times, which is mainly caused by different storage modes of two different interfaces. In the solid state disk of the traditional SATA interface, data needs to be read from the hard disk to the memory first, then the data is extracted to the inside of the CPU for calculation, and after calculation, the data needs to be written into the memory of the computer through the CPU, and then the data is stored in the solid state disk through the memory. The PCI-E interface has no memory link, the data to be stored can be directly communicated with the CPU through a system bus, and the transmission efficiency and the transmission speed are improved in multiples.
Description of the experiment:
in the experiment based on the invention, the paper width detected by the medium-high speed paper machine paper defect detection system is 0.8m, the unit precision requirement is 0.1mm multiplied by 0.1mm, and if 1 pixel is used in the unit precision, the number of pixels required in the transverse direction can be determined to be 8000 according to the formula 1, and the requirements of the transverse pixels can be met by three modes, namely 4 2K cameras, 2 4K cameras and 1 8K camera. The paper can reach 1130.1m/min line speed at the fastest speed, the acquisition frequency required by the system is 188.35KHZ by substituting formula 2, according to the frequency extension condition of the camera, the acquisition frequency required by the camera is more than 200KHZ, the types of CCD cameras which can reach more than 200KHZ in the industrial linear array camera at present can be selected are not many, and many CMOS cameras can reach more than 300KHZ, so that only CMOS cameras can be selected. The total data volume that can be generated per second is 1436.996MB, and only two of Camera link HS and optical fiber can satisfy the condition in the selection of the transmission interface. In the aspect of paper defect detection, the hardware device capable of processing 1436.996MB of data per second is only satisfied by the DSP and the FPGA. In the aspect of data storage, the data to be written into the hard disk exceeds 1GB every second, and the common hard disk does not meet the requirement, and only the high-end solid state hard disk can be selected.
The performance of a single slave is analyzed, and the hardware configuration of the paper defect detection system can be met, for example, in the selection of the Camera, a CMOS Camera with the acquisition frequency of 200KHz, the resolution of 8192 and the adoption of Camera link HS is selected; selecting an FPGA plate on paper defect detection; selecting a high-end solid-state disk adopting an M.2 interface on data storage; the high-end upper computer can be selected for paper defect type identification. There are also various options for hardware devices that meet the above conditions. However, for paper making enterprises, in the process of hardware matching, not only the requirements of the system are met, but also the economic cost and the stability of the system are higher, the higher the product is, the higher the design difficulty and the implementation difficulty of the product are, the price is also correspondingly higher, for example, the total price of the current 4 2K cameras is less than one 8K camera, and the stability of the camera with low resolution is relatively higher; the data volume generated by a single 2K camera is relatively small, and an adaptive FPGA board is easier to find.
According to the previous analysis, a mode of a CMOS camera, an FPGA and an upper computer is adopted in the experiment, in order to effectively store data and test the storage effect of the FPGA, a Samsung 970EVO Plus 250GB M.2 interface (NVMe protocol) solid state disk is selected, the actual storage speed can reach 2300MB/s, and the system requirement is met.
While preferred embodiments of the present invention have been described, additional variations and modifications in those embodiments may occur to those skilled in the art once they learn of the basic inventive concepts. Therefore, it is intended that the appended claims be interpreted as including preferred embodiments and all such alterations and modifications as fall within the scope of the invention.
It will be apparent to those skilled in the art that various changes and modifications may be made in the present invention without departing from the spirit and scope of the invention. Thus, if such modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include such modifications and variations.
Claims (6)
1. A paper defect detection system design method is characterized in that the paper defect detection system comprises: the paper defect detection method comprises an image acquisition module, a paper defect detection module and a data storage module, and comprises the following steps:
determining performance parameters of the image acquisition module, the paper defect detection module and the data storage module according to actual requirements;
selecting the image acquisition module, the paper defect detection module and the data storage module which meet the performance parameters and have the lowest cost;
and establishing the paper defect detection system by using the selected image acquisition module, the selected paper defect detection module and the selected data storage module.
2. The method of claim 1, wherein the image capturing module comprises: a camera and lens;
determining performance parameters of the image acquisition module, comprising:
determining a resolution and an acquisition frequency of the camera;
determining the size, focal length, aperture and resolution of the lens.
3. A method as claimed in claim 2, wherein said determining a resolution and a capture frequency of said camera comprises:
determining the total number of required pixels according to the transverse width of the detection area, the required unit precision and the total number of pixels in the unit precision, wherein the resolution of the camera is determined according to the determined total number of required pixels;
and determining the acquisition frequency of the camera according to the running speed of the paper machine, the required unit precision and the total number of pixels in the unit precision.
4. The method for designing a paper defect detecting system according to claim 2, wherein the determining the size, the focal length, the aperture and the resolution of the lens comprises:
determining the size of the lens according to the imaging size of the camera;
determining the focal length of the lens according to the imaging size of the camera, the distance between the lens and the paper and the length of the detection area;
determining the aperture of the lens according to the focal length of the lens and the effective aperture of the lens;
determining a resolution of the lens according to a resolution of the camera.
5. The method for designing a paper defect detection system according to claim 2, wherein the performance parameter of the paper defect detection module is a data amount which can be processed in a unit time, and the performance parameter is determined according to the resolution and the acquisition frequency of the camera.
6. A method as claimed in claim 1, wherein the performance parameter of the data storage module is data storage speed.
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