CN113624458A - Film uniformity detection system based on double-path all-projection light - Google Patents
Film uniformity detection system based on double-path all-projection light Download PDFInfo
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- 238000001514 detection method Methods 0.000 title claims abstract description 57
- 238000003384 imaging method Methods 0.000 claims abstract description 43
- 230000005540 biological transmission Effects 0.000 claims abstract description 15
- 238000012545 processing Methods 0.000 claims abstract description 14
- 238000005286 illumination Methods 0.000 claims abstract description 8
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- 238000001914 filtration Methods 0.000 claims description 11
- 230000004927 fusion Effects 0.000 claims description 8
- 238000000605 extraction Methods 0.000 claims description 7
- 238000010276 construction Methods 0.000 claims description 3
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- 239000010408 film Substances 0.000 description 116
- 238000004519 manufacturing process Methods 0.000 description 6
- 230000003287 optical effect Effects 0.000 description 5
- 238000005070 sampling Methods 0.000 description 5
- 238000007689 inspection Methods 0.000 description 4
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- 239000000284 extract Substances 0.000 description 3
- 238000000034 method Methods 0.000 description 3
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- 238000005259 measurement Methods 0.000 description 2
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- 239000000428 dust Substances 0.000 description 1
- 230000005571 horizontal transmission Effects 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 239000004973 liquid crystal related substance Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
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- 238000012544 monitoring process Methods 0.000 description 1
- 238000003199 nucleic acid amplification method Methods 0.000 description 1
- 229920006267 polyester film Polymers 0.000 description 1
- 238000011158 quantitative evaluation Methods 0.000 description 1
- 239000010409 thin film Substances 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- 238000011179 visual inspection Methods 0.000 description 1
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- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M11/00—Testing of optical apparatus; Testing structures by optical methods not otherwise provided for
- G01M11/02—Testing optical properties
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Abstract
The invention discloses a film uniformity detection system based on double paths of full projection light, which comprises an imaging unit, a collecting unit, a processing unit, a storage unit and a control unit, wherein the imaging unit is used for acquiring the light; the imaging unit is used for generating P polarized light to perform uniform illumination, and comprises an upper surface imaging unit and a lower surface imaging unit which are respectively positioned on the upper surface and the lower surface of the transparent film, and the P polarized light is respectively incident to the upper surface and the lower surface of the transparent film at the same Brewster angle to realize double-path full transmission; the acquisition unit comprises an object stage and a plurality of linear cameras, and is used for acquiring the film images and calibrating the multiple cameras; the processing unit is used for identifying the film image by adopting a preset film uniformity detection model and detecting whether the film image is distorted or not, so that the uniformity and consistency of the film are judged. The invention can detect the uniformity of the upper surface, the lower surface and the interior of the transparent film.
Description
Technical Field
The invention relates to the technical field of film uniformity detection, in particular to a film uniformity detection system based on double paths of all-projected light.
Background
The film is widely applied to the fields of liquid crystal televisions, tablet computers, smart phones, vehicle-mounted display screens and the like, is limited by conditions such as production process or production environment, is easy to generate quality defects in the production process, and mainly shows that the film is uneven in thickness, scratches appear on the surface, bubbles are generated inside the film, or impurities, dust and the like are doped inside the film, so that the film uniformity detection becomes an important part for controlling the production quality of film materials.
The traditional detection is generally realized by visual inspection and simple measurement of experienced detection personnel, the detection result lacks reliability and accuracy, quantitative evaluation cannot be realized, and long-time observation is difficult to carry out. For a transparent film such as a polyester film, the defect that a plurality of isolated noise points exist in an acquired film image, the subsequent processing of the image is seriously influenced, and the judgment accuracy of the uniformity of the film is further influenced.
Therefore, it is desirable to provide a new film uniformity detection system based on two paths of full projection light to solve the above problems.
Disclosure of Invention
The invention aims to provide a film uniformity detection system based on two paths of full projection light, which can realize the uniformity detection of the upper surface, the lower surface and the interior of a transparent film.
In order to solve the technical problems, the invention adopts a technical scheme that: the film uniformity detection system based on two paths of full projection light comprises an imaging unit, a collecting unit, a processing unit, a storage unit and a control unit;
the imaging unit is used for generating P polarized light to perform uniform illumination, and comprises an upper surface imaging unit and a lower surface imaging unit which are respectively positioned on the upper surface and the lower surface of the transparent film, and the P polarized light is respectively incident to the upper surface and the lower surface of the transparent film at the same Brewster angle to realize double-path full transmission;
the acquisition unit comprises an object stage and two groups of linear array cameras, is used for acquiring film images and carrying out multi-camera calibration, and the two groups of linear array cameras are respectively positioned on the upper surface and the lower surface of the transparent film;
the processing unit is used for identifying the film image by adopting a preset film uniformity detection model and detecting whether the film image is distorted or not, so that the uniformity and consistency of the film are judged;
the storage unit is used for prestoring various filtering algorithms, film uniformity detection models and a typical film image library which is uniform and consistent and non-uniform in film and is obtained by the linear array camera;
the control unit is used for setting various control parameters of the imaging unit, the acquisition unit and the processing unit.
In a preferred embodiment of the present invention, the imaging unit includes a light source, a P-polarizer, a filter, a collimator lens, a dodging lens, and a condenser lens, which are sequentially disposed, centers of which are all located on the same axis, the dodging lens is located at a focal point of the condenser lens, light emitted from the light source passes through the P-polarizer to obtain P-polarized light, the light intensity and wavelength of the light source are adjusted by the filter, and finally the P-polarized light for uniform illumination is generated after passing through the collimator lens, the dodging lens, and the condenser lens in sequence.
In a preferred embodiment of the invention, two line cameras are respectively arranged on the positions of the bright area and the dark area of the upper surface and the lower surface of the transparent film of each group of line cameras to acquire high-quality images of all defects.
In a preferred embodiment of the present invention, the stage is configured to carry a film to be detected, and is matched with an external film transmission system to implement high-precision imaging of the film to be detected, and a start position sensor and an end position sensor are respectively installed at the start position and the end position.
In a preferred embodiment of the present invention, the storage unit is further configured to pre-store a dictionary of relationship among film defect types, film transfer speeds, light sources, and line cameras.
In a preferred embodiment of the present invention, the film uniformity inspection model provides two inspection modes, including a precision mode and a simple mode.
Furthermore, the precise mode respectively extracts the image characteristics of the film measured area obtained by each linear array camera by using a parallel characteristic extraction network, then performs fusion construction by using a multi-mode fusion network, and trains the film image sets with uniform and consistent films and non-uniform films after marking to obtain the film image.
Furthermore, in the simple mode, similarity comparison is carried out between the images of the detected area of the film obtained by each linear array camera and the images obtained by the corresponding linear array camera in the typical film image library, and quick and simple detection of whether the film is uniform or not or the specified defect type is given according to set detection conditions.
In a preferred embodiment of the present invention, the inspection system further comprises a display unit for displaying the uniformity of each thin film on a large screen.
In a preferred embodiment of the present invention, the inspection system further comprises an execution unit for performing an operation after the defective film is detected.
The invention has the beneficial effects that:
(1) according to the invention, a light source sequentially passes through the P polarizing film, the optical filter, the collimating lens, the light homogenizing lens and the condensing lens to generate P polarized light for uniform illumination, and the P polarized light is respectively incident to the upper surface and the lower surface of the transparent film at the same Brewster angle, so that double-path full transmission is realized, and the influence of reflected light on the imaging quality of the linear array camera is reduced;
(2) the invention images by projecting the transmitted light on the upper and lower surfaces of the film to the linear array camera at the positions of the bright area and the dark area, extracts the image characteristics by adopting the characteristic extraction network, and detects after fusing by using the multi-mode fusion network, thereby realizing the uniformity detection of the upper and lower surfaces and the interior of the transparent film;
(3) the film uniformity detection model provided by the invention provides two detection modes, namely an accurate mode and a simple mode, and the film uniformity detection has more flexibility.
Drawings
FIG. 1 is a block diagram of a preferred embodiment of a dual path, full projection light based film uniformity detection system according to the present invention;
fig. 2 is a block diagram of an optical path of the imaging unit;
fig. 3 is a schematic diagram of the optical path of the detection system.
Detailed Description
The following detailed description of the preferred embodiments of the present invention, taken in conjunction with the accompanying drawings, will make the advantages and features of the invention easier to understand by those skilled in the art, and thus will clearly and clearly define the scope of the invention.
Referring to fig. 1, an embodiment of the present invention includes:
a film uniformity detection system based on double paths of full projection light comprises an imaging unit, a collecting unit, a processing unit, a storage unit, a control unit, a display unit and an execution unit.
With reference to fig. 2, the imaging unit is configured to generate P-polarized light for uniform illumination, and includes a light source, a P-polarizer, a filter, a collimating lens, a light uniformizing mirror, and a condensing lens, which are sequentially disposed, and centers of the light uniformizing mirror and the condensing lens are located on the same axis. The light emitted by the light source passes through the P polaroid to obtain P polarized light, then passes through the optical filter to adjust the light intensity and wavelength of the light source, and then passes through the collimating lens, the dodging lens and the condensing lens in sequence to generate the P polarized light for uniform illumination. The imaging units are two groups, each imaging unit comprises an upper surface imaging unit and a lower surface imaging unit, the upper surface imaging unit and the lower surface imaging unit are respectively positioned on the upper surface and the lower surface of the transparent film, and the P polarized light is respectively incident to the upper surface and the lower surface of the transparent film at the same Brewster angle to realize double-path full transmission.
Further, the light source is a visible light source, a laser light source or an infrared light source.
Referring to fig. 3, the collecting unit includes an object stage, a sliding guide rail, and two sets of line cameras, and is configured to collect the film image and perform multi-camera calibration.
Further, the line camera can adopt a line CCD camera or/and a CMOS camera to improve the imaging efficiency.
The stage is located on the sliding guide rail and may be a region of the sliding guide rail. And the external film conveying system conveys the film to be detected to the sliding guide rail. The object stage is used for bearing the film to be detected, high-precision imaging of the film to be detected can be achieved by matching with an external film conveying system, and like a production line production link, the film to be detected continuously passes through the object stage, and image acquisition and detection can be achieved without stopping.
Specifically, the object stage is provided with a starting position sensor and an end position sensor at a starting position and an end position respectively, and image acquisition and detection are automatically started and stopped under the signal identification of the sensors.
The two groups of linear array cameras are respectively positioned on the upper surface and the lower surface of the transparent film, the upper surface linear array camera is used for receiving light transmitted by the upper surface after the lower surface imaging unit is incident on the lower surface for imaging, and the lower surface linear array camera is used for receiving light transmitted by the lower surface after the upper surface imaging unit is incident on the upper surface for imaging. Because the incident light of the upper and lower surfaces adopts Brewster angle incidence, full transmission can be realized, and the influence of reflected light on the imaging quality of the linear array camera is reduced.
Specifically, because a proper imaging mode influences the film uniformity detection, for example, different defects have different imaging characteristics, and some defects are sensitive to angles, for the mainly existing dark field imaging and bright field imaging modes, two linear array cameras are respectively arranged at the positions of the bright area and the dark area of the upper surface and the lower surface of the transparent film by each group of linear array cameras, so as to acquire high-quality images of all the defects.
The multi-camera calibration method comprises the following steps: firstly, aligning a film to be detected to a position close to an end point by a position sensor arranged on an objective table, giving a coordinate origin O, establishing a world coordinate system by taking a horizontal transmission direction as an X axis and a vertical direction as a Y axis on the objective table in the whole area of the film to be detected, and dividing grid points of the whole area of the film to be detected; secondly, a plurality of calibration plates with known position relations are arranged on the objective table, each linear array camera can shoot at least one calibration plate, and the coordinate value of each calibration plate is given out under a world coordinate system; and finally, each linear array camera collects the image of the object stage containing the calibration plate and calibrates the image by adopting a Zhang-Yongyou calibration method, a camera coordinate system is respectively established, the respective pixel coordinate of the calibration plate in the camera coordinate system is obtained, a pixel coordinate system in each camera visual unit is established, the mapping relation between the coordinate value of each pixel unit of the whole pixel coordinate system and the corresponding coordinate value of the world coordinate system is determined, the coordinate value of the grid point is given according to the mapping relation, and the calibration of the multiple cameras is realized.
The processing unit is used for identifying the film image by adopting a preset film uniformity detection model and detecting whether the film image is distorted or not, so that the uniformity and consistency of the film are judged.
In order to improve the detection accuracy, the processing unit can also perform preprocessing on the film image information, wherein the preprocessing comprises performing median filtering, gaussian filtering or wavelet threshold filtering denoising on the acquired monitoring area image.
Furthermore, the processing unit can also judge the distortion type of the film image and give the film defect type.
The storage unit is used for prestoring various filtering algorithms, including median filtering, Gaussian filtering, wavelet threshold filtering and innovation self-adaptive Kalman filtering algorithms, a film uniformity detection model and a typical film image library with uniform and inconsistent films obtained by the linear array camera, and is also used for prestoring parameter relation dictionaries of film defect types, film transmission speeds and light sources and the linear array camera.
Furthermore, the film uniformity detection model provides two detection modes, including an accurate mode and a simple mode, for respectively providing a more accurate but relatively time-consuming detection result and a more accurate but relatively quick detection result, and the film uniformity detection has more flexibility.
Specifically, the precise mode uses a parallel feature extraction network to respectively extract the image features of the measured area of the film obtained by each linear array camera, then uses a multi-mode fusion network to perform fusion construction, and trains the film through the marked uniform and consistent film image set and the non-consistent film image set.
Wherein, the feature extraction network includes, but is not limited to, CNN, RNN, LSTM, and other network models, and combinations or variants thereof.
The multi-mode fusion network adopts a fully-connected network, and generally 2-4 layers are selected. The output of the previous layer of fully-connected network is used as the input of the next layer of fully-connected network, the input of the first layer of fully-connected network is a characteristic vector obtained by a characteristic extraction network, the output of the last layer of fully-connected network is a characteristic vector representing the uniformity condition of the film, the length of the characteristic vector is equal to the number of types of labels of the uniformity condition of the film (whether the uniformity of the film is consistent or not is detected, and whether the defect type is detected is a defect type number) contained in a group of input detection data, each element of the characteristic vector respectively represents the probability of the uniformity condition of each type of film, the type with the maximum probability and the probability exceeding a set threshold value is the determined uniformity classification of the film, and simultaneously, the coordinate range of grid points of the defect in a detected area of the film is given.
Preferably, the feature extraction network can adopt a U-Net network improved by ResNeXt, and a residual error module is introduced and mainly comprises two parts of down sampling and up sampling. The down-sampling adopts a typical convolution network structure, each characteristic scale adopts two 3 x 3 convolutions, then the down-sampling is carried out by using 2 x 2 maximum pooling, and the number of channels of the down-sampling characteristics is doubled each time. The upsampling uses maximal pooling up-convolution (the number of characteristic channels is reduced by half), and is directly spliced with the characteristic image of the downsampling part with the same scale, then two convolutions of 3 multiplied by 3 are used, and finally the characteristic image is mapped to the number of channels of the actually required classification number by using 1 multiplied by 3 convolution for classification detection.
Specifically, in the simple mode, similarity comparison is performed between the image of the detected area of the film obtained by each line camera and the image obtained by the corresponding line camera in the typical film image library, and quick and simple detection of whether the film is uniform or not or the specified defect type is given according to set detection conditions. For example, the following table 1 shows the detection of whether the uniformity is consistent or not, and the result determined to be undetermined can be manually detected again by a code mark, an interface pop-up window and a voice prompt for the relevant personnel.
The set detection conditions can construct a judgment matrix of expert scoring by quantitatively analyzing factors such as similarity, number of cameras and the like, quantitatively analyze the influence weight of the factors on the detection result, give the expert scoring value based on the factors, and evaluate and grade-judge the detection result on the basis, for example, whether the film is uniform or not is detected to be uniform, undetermined or inconsistent.
TABLE 1
Preferably, when the films are uniform and consistent, the film images acquired by the two groups of linear cameras are almost the same, that is, the film images have very high similarity, and the simple mode can also compare the similarity of the film measured area image obtained by each group of linear cameras with the film image obtained by the corresponding linear camera of the other group, so that the film uniformity and consistency can be quickly and simply detected without depending on a typical film image library, and the application range is wider.
The control unit is used for setting various control parameters of the imaging unit, the acquisition unit and the processing unit, including optical filter bandwidth, light source irradiation angle, linear array camera light and dark area position, acquisition line frequency and detection mode. Particularly, the acquisition line frequency of the linear array camera is controlled to be matched with the film transmission speed, the maximum transmission speed of the film is limited according to the acquisition line frequency, and the relationship between the acquisition line frequency and the maximum transmission speed satisfies f ═ v × b/s, wherein f represents the acquisition line frequency, v represents the film transmission speed, b represents the amplification rate of an imaging unit, and s represents the pixel size of the linear array camera. The working parameters of the two groups of imaging units and the working parameters of the two groups of linear array cameras need to be kept consistent respectively.
Further, the control unit receives film transmission speed information sensed by an encoder in an external film transmission system, performs high-precision speed measurement by adopting a new information adaptive Kalman filtering algorithm, and performs searching according to the film defect type, the film transmission speed and a parameter relation dictionary of the light source and the linear array camera to obtain and set the current parameter values of the light source and the linear array camera.
The display unit is used for carrying out large-screen visual display on the uniformity detection condition of each film, and comprises the batch number, the system number, the detection time, the operator information and the like of the current detection film, the number of the detected films, the number of the films to be detected, the number of the qualified films and the like.
Furthermore, the display unit supports terminal display of a mobile phone, a tablet, a computer and the like, can give batch numbers of unqualified films by one key, and supports data export.
The execution unit is used for detecting the operation after the unqualified film is detected.
Furthermore, the execution unit can be customized according to the requirement of the customer, such as providing an alarm message, or performing voice playing on unqualified film batch numbers, and the like.
The above description is only an embodiment of the present invention, and not intended to limit the scope of the present invention, and all modifications of equivalent structures and equivalent processes performed by the present specification and drawings, or directly or indirectly applied to other related technical fields, are included in the scope of the present invention.
Claims (10)
1. A film uniformity detection system based on double paths of full projection light is characterized by comprising an imaging unit, a collecting unit, a processing unit, a storage unit and a control unit;
the imaging unit is used for generating P polarized light to perform uniform illumination, and comprises an upper surface imaging unit and a lower surface imaging unit which are respectively positioned on the upper surface and the lower surface of the transparent film, and the P polarized light is respectively incident to the upper surface and the lower surface of the transparent film at the same Brewster angle to realize double-path full transmission;
the acquisition unit comprises an object stage and two groups of linear array cameras, is used for acquiring film images and carrying out multi-camera calibration, and the two groups of linear array cameras are respectively positioned on the upper surface and the lower surface of the transparent film;
the processing unit is used for identifying the film image by adopting a preset film uniformity detection model and detecting whether the film image is distorted or not, so that the uniformity and consistency of the film are judged;
the storage unit is used for prestoring various filtering algorithms, film uniformity detection models and a typical film image library which is uniform and consistent and non-uniform in film and is obtained by the linear array camera;
the control unit is used for setting various control parameters of the imaging unit, the acquisition unit and the processing unit.
2. The film uniformity detection system based on two paths of full projection light as claimed in claim 1, wherein the imaging unit comprises a light source, a P-polarizer, a filter, a collimator lens, a dodging lens and a condenser lens, which are arranged in sequence, the centers of the two paths of full projection light are all located on the same axis, the dodging lens is located at the focus of the condenser lens, the light emitted by the light source passes through the P-polarizer to obtain P-polarized light, the light intensity and the wavelength of the light source are adjusted through the filter, and finally the P-polarized light for uniform illumination is generated after passing through the collimator lens, the dodging lens and the condenser lens in sequence.
3. The system of claim 1, wherein each set of line cameras has two line cameras respectively positioned at the bright and dark areas of the upper and lower surfaces of the transparent film to acquire high quality images of all defects.
4. The film uniformity detection system based on two-way full projection light as claimed in claim 1, wherein the stage is used for carrying a film to be detected, high-precision imaging of the film to be detected is realized by matching with an external film conveying system, and a start position sensor and an end position sensor are respectively installed at the start disposal position and the end position.
5. The system of claim 1, wherein the storage unit is further configured to pre-store a dictionary of film defect types, film transport speeds and parameter relationships of the light source and the line camera.
6. The system of claim 1, wherein the film uniformity model provides two detection modes, including a precision mode and a simple mode.
7. The system as claimed in claim 6, wherein the precise model uses a parallel feature extraction network to extract the image features of the measured area of the film obtained by each line camera, then uses a multi-modal fusion network to perform fusion construction, and is obtained by training the labeled uniform and non-uniform film image sets.
8. The system as claimed in claim 6, wherein the simple mode provides fast and simple detection of film uniformity or specified defect type according to the set detection condition by comparing the similarity between the image of the measured area of the film obtained by each line camera and the image obtained by the corresponding line camera in the typical film image library.
9. The system of claim 1, further comprising a display unit for displaying the uniformity detection condition of each film on a large screen.
10. The system of claim 1, further comprising an execution unit for detecting an operation after a defective film.
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| CN115629079A (en) * | 2022-10-19 | 2023-01-20 | 湖南迪普视智能科技有限公司 | Film surface defect detection system and method |
| WO2024120333A1 (en) * | 2022-12-07 | 2024-06-13 | 中国联合网络通信集团有限公司 | Steel plate inspection system, steel plate inspection method, electronic device, and storage medium |
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