WO2020082714A1 - Laser total reflection-type 3c transparent component defect detection apparatus and method - Google Patents

Laser total reflection-type 3c transparent component defect detection apparatus and method Download PDF

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Publication number
WO2020082714A1
WO2020082714A1 PCT/CN2019/085095 CN2019085095W WO2020082714A1 WO 2020082714 A1 WO2020082714 A1 WO 2020082714A1 CN 2019085095 W CN2019085095 W CN 2019085095W WO 2020082714 A1 WO2020082714 A1 WO 2020082714A1
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total reflection
transparent member
laser
light
positioning
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PCT/CN2019/085095
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French (fr)
Chinese (zh)
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张国军
明五一
张红梅
卢亚
尹玲
张臻
耿涛
沈帆
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广东华中科技大学工业技术研究院
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Publication of WO2020082714A1 publication Critical patent/WO2020082714A1/en

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    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84Systems specially adapted for particular applications
    • G01N21/88Investigating the presence of flaws or contamination
    • G01N21/95Investigating the presence of flaws or contamination characterised by the material or shape of the object to be examined
    • G01N21/958Inspecting transparent materials or objects, e.g. windscreens
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/01Arrangements or apparatus for facilitating the optical investigation

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  • the invention belongs to the technical field of product surface defect detection, in particular to a 3C industry transparent component product quality defect detection device and method.
  • the technical problem to be solved by the present invention is to provide a laser total reflection type 3C transparent member defect detection device with stable detection performance, high detection quality and high detection efficiency.
  • the present invention adopts the following technical solutions:
  • a laser total reflection type 3C transparent member defect detection device which includes a positioning drive device, a laser emitter, a light-transmitting workbench, a detection camera, a deep learning arithmetic unit, an ARM embedded controller, and an audible and visual alarm
  • the laser emitter is connected to the positioning drive device.
  • the positioning drive device, the detection camera, the deep learning operation unit and the sound and light alarm device are connected to the ARM embedded controller through the CAN bus, and the detection camera is shot against the light-transmitting working machine to obtain the image.
  • the light-transmitting workbench is also provided with a total reflection upper auxiliary part and a total reflection lower auxiliary part for clamping the transparent member to be tested.
  • the total reflection lower auxiliary part is provided on the light-transmitting workbench, and the transparent member to be tested is provided on the full There is an exposed gap portion between the upper reflective auxiliary member and the total reflective lower auxiliary member, and the total reflective upper auxiliary member and the transparent member to be measured.
  • the positioning drive device includes a microcontroller, an X-direction motor, an X-direction positioning screw, a Y-direction motor, a Y-direction positioning screw, an X-direction load platform, a Y-direction load platform and an angular positioning stepper motor, and an X-direction positioning wire
  • the rod is connected to the X-direction motor and mounted on the X-direction load platform.
  • the Y-direction load platform is screwed onto the X-direction positioning screw.
  • the Y-direction screw is connected to the Y-direction motor and mounted on the Y-direction load platform.
  • the positioning stepping motor is mounted on the Y-positioning screw through a connecting block, the laser emitter is connected to the drive shaft of the angular positioning stepping motor, and the X-direction motor, Y-direction motor and angular positioning stepping motor are respectively connected to the microcontroller.
  • the microcontroller communicates with the ARM embedded controller through the CAN bus, and a grating ruler is connected to the microcontroller.
  • One end of the X-direction load platform and the Y-direction load platform are respectively provided with a zero position sensor in communication connection with a microcontroller.
  • the total reflection upper auxiliary member, the transparent member to be detected, and the total reflection lower auxiliary member meet the requirements of total reflection of laser light, that is, the incident angle C of the laser light incident on the transparent member to be detected satisfies
  • n 2 is the refractive index of the total reflection upper auxiliary member and total reflection lower auxiliary member
  • n 1 is the refractive index of the transparent member to be measured.
  • the laser emitter is provided with at least three laser heads of different specifications side by side for measuring transparent members to be measured with different thicknesses.
  • the detection camera is arranged below the light-transmitting workbench, and a sheet metal shell is arranged on the periphery of the detection camera.
  • a laser total reflection type 3C transparent component defect detection method including the following steps:
  • the refractive index n 2 of the total reflection upper auxiliary member and the total reflection lower auxiliary member is 1/2 or less than the refractive index n 1 of the transparent member to be measured, so that the laser incident angle C of the transparent member to be measured is less than 45 degrees .
  • the transparent member to be tested is a flat 3C transparent member or a curved 3C transparent member.
  • the 3C transparent member to be inspected is detected using a visible laser with strong directivity. Due to defects in the transparent member or on the surface, the laser will be refracted, reflected, and scattered, so that part of the laser does not meet the conditions of total reflection. , Leaking from the surface of the transparent member, captured by the detection camera, and taking pictures to provide basic data for later intelligent analysis.
  • the patent of the present invention can not only detect the flat type 3C transparent member, but also detect the curved type 3C transparent member.
  • Figure 1 is a schematic diagram of the connection principle of the device of the present invention.
  • FIG. 2 is a schematic structural view of the positioning drive device of the present invention
  • Figure 3 is a schematic diagram of the connection principle of the positioning drive device of the present invention.
  • Figure 4 is a schematic structural view of the light-transmitting workbench of the present invention.
  • Figure 5-1 is a schematic diagram of the optical path of the component to be tested without defects
  • Figure 5-2 is a schematic diagram of the optical path with defects on the surface of the component to be tested.
  • Figure 5-3 is a schematic diagram of the optical path with defects inside the component to be tested
  • Figure 6-1 is a schematic diagram of the optical path of the planar type test component
  • Figure 6-2 is a schematic diagram of the optical path refraction of a curved transparent member to be measured
  • Figures 7-1, 7-2 and 7-3 are schematic diagrams of the structure of the deep learning network
  • Figure 8 is a schematic diagram of the principle of detection area division.
  • the present invention discloses a laser total reflection type 3C transparent member defect detection device, which includes a positioning driving device, a laser emitter 1, a light-transmitting workbench 3, a detection camera, a depth Learning operation unit, ARM embedded controller and audible and visual alarm, laser emitter is connected with positioning drive device, positioning drive device, inspection camera, deep learning operation unit and sound and light alarm device communicate with ARM embedded controller via CAN bus Connect and detect the camera to take the image against the light-transmitting work machine.
  • the positioning drive device positions the laser emitter so that the laser emitter emits laser light at an accurate position, ensuring that the laser light accurately enters the transparent member to be measured.
  • the light-transmitting workbench 3 is also provided with a total reflection upper auxiliary part 41 and a total reflection lower auxiliary part 42 for clamping the transparent member to be tested.
  • the total reflection lower auxiliary part 41 is provided on the light-transmitting workbench 3 and is to be tested.
  • the transparent member 5 is provided between the total reflection upper auxiliary member 41 and the total reflection lower auxiliary member 41, and there is a bare gap portion between the total reflection upper auxiliary member 41 and the transparent member 5 to be measured.
  • the materials of the total reflection upper auxiliary part and the total reflection lower auxiliary part are made of flexible wear-resistant light-transmitting materials, and the hardness is lower than that of the 3C transparent member to be tested; different types of supporting total reflection upper auxiliary member and total reflection Lower auxiliary parts, so as to achieve full coverage of the 3C transparent member to be inspected by optical inspection.
  • the total reflection upper auxiliary member, the transparent member to be detected, and the total reflection lower auxiliary member meet the requirements of total reflection of laser light, that is, the incident angle C of the laser light incident on the transparent member to be detected satisfies
  • n 2 is the refractive index of the total reflection upper auxiliary member and total reflection lower auxiliary member
  • n 1 is the refractive index of the transparent member to be measured.
  • the positioning drive device includes a microcontroller, an X-direction motor 6, an X-direction positioning screw 7, a Y-direction motor 11, a Y-direction positioning screw 12, an X-direction load platform 8, a Y-direction load platform 9, and angular positioning Stepper motor 2,
  • X-direction screw 7 is connected to X-direction motor 6 and mounted on X-direction load platform 8
  • Y-direction load platform 9 is screwed on X-direction screw 7 and Y-direction screw 12
  • the angular positioning stepper motor 2 is mounted on the Y-direction screw 12 through a connecting block
  • the laser emitter 1 is connected to the drive shaft of the angular positioning stepper motor 2
  • X-direction motor, Y-direction motor, angle positioning stepper motor are respectively connected to the microcontroller.
  • the microcontroller is connected to the ARM embedded controller via CAN bus.
  • the microcontroller is connected to the grating scale, the X-direction load platform, One end of the Y-direction load platform is also provided with zero sensors in communication connection with the microcontroller.
  • the X-direction motor drives the X-direction positioning screw to rotate, which in turn can adjust the movement stroke of the Y-direction load platform in the X direction, thereby adjusting the position of the laser emitter in the X direction.
  • the grating ruler can accurately control the travel of X-direction motor and Y-direction motor.
  • the X-direction motor, Y-direction motor and grating ruler form a closed-loop control loop.
  • the stepper motor uses an angle zero sensor to automatically return to zero correction after each transparent component to be tested is completed, thereby providing an environment for high-precision positioning.
  • the X-direction motor pauses after a fixed step size at each interval (1/5 to 1/10 of the width of the 3C transparent member to be tested).
  • the laser emitter continuously emits laser light to detect the time of the camera during this detection process
  • the camera is in the exposure state.
  • the camera is detected to take pictures.
  • the angular positioning stepper motor automatically returns to the original position after each piece to be detected is detected by the angle zero sensor, which provides a reference for the angular positioning stepper motor recalibration; the microcontroller communicates with the ARM embedded controller through the CAN bus Connect, sense the information of the detected component, and provide parameters for its servo and positioning motion.
  • the angular positioning stepper motor drives the laser emitter to rotate, and the angle of rotation is adjusted by the ARM embedded controller according to the size information of the member to be inspected and its position to be inspected, so that the inspected laser can meet the total reflection condition for the region to be inspected.
  • the laser emitter is provided with three laser heads of different specifications side by side for measuring transparent members to be measured with different thicknesses.
  • three laser heads with different specifications of 1.5mm ⁇ 1.5mm, 3.5mm ⁇ 3.5mm and 6mm ⁇ 6mm respectively detect 3C transparent members with different thickness specifications less than 1mm, 1-3mm and 3-5mm .
  • the ARM embedded controller Based on the size information of the transparent component to be tested, the ARM embedded controller samples according to the length and width direction of the component, and completes the detection of the entire component by taking multiple photos (length sampling times ⁇ width sampling times).
  • the whole device is sealed by sheet metal parts to reduce the interference of the external light source on the detection results; further, the detection camera is placed under the light-transmitting workbench, and a set of sheet metal shells are set on the periphery to seal, again reducing interference.
  • the deep learning arithmetic unit is implemented with FPGA hardware.
  • the ARM embedded controller Before being passed in, the ARM embedded controller performs graying and segmentation. According to the specifications of the laser head, each image after segmentation is compressed to 64 ⁇ 64 ⁇ 1.
  • each image after segmentation is compressed to 64 ⁇ 64 ⁇ 1.
  • the three-dimensional grayscale image space of 128 ⁇ 128 ⁇ 1 or 256 ⁇ 256 ⁇ 1 after performing three more convolution and pooling operations, perform two fully connected neural networks and output to a 256-dimensional vector.
  • the 256-dimensional vector is output as a vector (normal, defective) through soft regression, and the detection result is transmitted to the ARM embedded controller through the CAN bus communication module, and the detection personnel is informed by an audible and visual alarm.
  • the sample inventory that the deep learning arithmetic unit depends on is in the ARM embedded controller (internal NAND Flash), and the deep convolutional neural network parameters can be updated in the background by the ARM embedded controller and sent to the deep learning arithmetic unit through the CAN bus Store and use in operations.
  • ARM embedded controller internal NAND Flash
  • the offline training sample library of the deep convolutional neural network can increase the number of samples. Therefore, the detection of 3C transparent components can be increased or decreased according to the actual situation of the sample, and the detection accuracy of the components to be tested with specific specifications can be improved.
  • the deep convolutional neural network can be trained and updated by the user during use, or can be periodically updated by the device manufacturer; the device of the present invention supports multiple versions of the deep convolutional neural network, which can be performed by the end user according to the actual application scenario Independent choice.
  • the servo motor in the XY direction drives the positioning screw to move in the X and Y directions, drives the load platform to link in the "XY" direction, the angular positioning stepper motor is installed on the load platform, and then drives the laser transmitter to rotate through the three axes
  • the linkage scheme can position the laser transmitter to the state to be detected to meet the detection requirements.
  • the servo motor in the X direction is paused after a fixed step length (1/5 to 1/10 of the width of the 3C transparent member to be detected).
  • the laser transmitter continuously emits laser light and the detection camera is exposed
  • the detection camera takes a picture; by selecting the material of the auxiliary component on the total reflection, the refractive index n 2 is 1/2 or less of the refractive index n 1 of the transparent member to be detected, so as to achieve
  • the laser incident angle C is less than 45 degrees, and then select the laser head of the corresponding specification according to the thickness of the transparent member to be detected, and then it can be covered by one scan in the Y direction.
  • the specific rules are as follows:
  • the positioning drive device microcontroller selects a 1.5 mm ⁇ 1.5 mm laser head to work;
  • a 3.5 mm ⁇ 3.5 mm laser head is selected for operation by the microcontroller of the positioning drive device;
  • a 6 mm ⁇ 6 mm laser head is selected for operation by the microcontroller of the positioning drive device.
  • the microcontroller of the above positioning drive device is controlled by the ARM embedded controller through the CAN bus, and the user can choose according to the actual situation.
  • the detection is repeated again, and the two detections can completely cover the complete area within a fixed step size.
  • repeat the above process for the remaining area to be tested and continue to scan and test in the X direction to cover the entire area of the transparent member to be tested to complete the detection.
  • the detection principle is shown in Figure 8, the first detection in Figure 8 And the second detection is the two detections along the Y direction in the sampling area. Therefore, the total number of photographs is 2 * (5-10) times.
  • the detection laser beam is controlled by the ARM embedded controller, and the position of the detection laser beam is adjusted through the positioning drive device so that the principle of total reflection is satisfied; the auxiliary part on the total reflection and the 3C transparent member to be detected There is a gap, usually 1.2 to 1.5 times the width of the laser beam, so that the laser beam can enter the inside of the transparent member to be detected; under the total reflection, there is a detection camera under the auxiliary part, which may exist (defective detection sees light leakage Phenomenon) to take photos of light leakage.
  • the detection laser beam satisfies the working principle of total reflection. And the auxiliary component under total reflection, so that the detection camera disposed under the auxiliary component under total reflection cannot acquire the detection laser signal.
  • Figure 5-2 there is a defect on the surface of the transparent member to be tested
  • Figure 5-3 there is a defect inside the transparent member to be detected, then a part of the detection laser beam reflects, refracts, and scatters, which cannot fully satisfy the full Reflection conditions, so that the detection camera placed under the auxiliary part under total reflection can capture the detection laser signal.
  • Figure 6 only shows a schematic diagram of the placement of planar transparent components.
  • two sets of total reflection upper / lower auxiliary parts need to be configured to complete the detection of curved surfaces and flat surfaces respectively according to the detection object. Since the principles are the same, here No longer.
  • FIGS 6-1 and 6-2 are schematic diagrams of the optical paths of the planar transparent member and the curved transparent member.
  • the laser head only needs to emit the detection laser beam into the transparent component to be detected at a fixed angle, and the entire component can be detected by moving the load table in the X direction; however, for The curved 3C transparent member needs to detect the plane part and the curved part separately.
  • the ARM embedded controller calculates the incident angle of the laser beam on the plane and the curved part separately according to the geometric size information to be detected, and then the driving device microcontroller drives the servo
  • the movement of the motor and stepper motor makes the laser head reach the calculated angle, especially the curved surface part, and the laser head with a small size is selected for detection.
  • the ARM embedded controller not only receives the information of the microcontroller, but also sends control instructions to the microcontroller to realize the positioning of the laser head angle, and during the detection process, the load platform drives the laser head to sample at intervals in the X direction, so that The detection camera can take pictures of the detection imaging.
  • a laser total reflection type 3C transparent member defect detection method includes the following steps:
  • the transparent member to be measured is placed between the total reflection upper auxiliary part and the total reflection lower auxiliary part and placed on the light-transmitting workbench.
  • the deep learning arithmetic unit is implemented with FPGA hardware.
  • the ARM embedded controller performs graying and segmentation processing.
  • the specifications of the header each divided image is compressed into a three-dimensional gray image space of 64 ⁇ 64 ⁇ 1, 128 ⁇ 128 ⁇ 1, or 256 ⁇ 256 ⁇ 1, and after three convolution and pooling operations,
  • the neural network that is fully connected twice is output to a 256-dimensional vector, and then the 256-dimensional vector is output as a vector (normal, defective) through soft regression.
  • the network data processing flow is as follows:
  • the three networks are separately trained offline, that is, corresponding to three different specifications of the laser head, the input images of the three networks are 64 ⁇ 64 ⁇ 1, 128 ⁇ 128 ⁇ 1, or 256 ⁇ 256, respectively. ⁇ 1 three-dimensional gray scale size.
  • the deep learning arithmetic unit can process multiple images at a time. Therefore, a batch of divided images can be set to input 32 images into the FPGA-implemented network at the same time, and the identification time can be reduced through concurrent processing.
  • the A1 convolutional layer sent to the convolutional network after using the 3 ⁇ 3 window convolution operation, 12 images of 62 ⁇ 62 pixels are generated, and then the A2 pooling layer in the module Perform compression processing to generate 12 images of 31 ⁇ 31 pixels, and then perform the second convolution operation and send it to the A3 convolution layer in the convolution network.
  • 29 ⁇ is generated.
  • the 36 images of 29 pixels are compressed by the A4 pooling layer in the convolution network to generate 36 images of 14 ⁇ 14 pixels.
  • the third convolution operation is performed and sent to A5 in the convolution network.
  • the convolutional layer uses the 3 ⁇ 3 window convolution operation again to generate 72 images of 12 ⁇ 12 pixels, and then performs compression processing by the A6 pooling layer in the convolution network to generate 72 images of 6 ⁇ 6 pixels. Further, the A7 fully connected layer of the convolutional network is processed to output 1024-dimensional vectors. Further, the A8 fully connected layer of the convolutional network is processed to output 256-dimensional vectors. Finally, the convolutional network A9 The soft regression layer outputs a 2-dimensional vector, indicating that the transparent component to be detected belongs to the category 2 (normal, defective). Density distribution, so that the transparent member identification to be examined for defects 3C.
  • the B1 convolutional layer sent to the convolutional network using a 5 ⁇ 5 window convolution operation, generates 12 images of 124 ⁇ 124 pixels, and then the B2 pooling layer in the module Perform compression processing to generate 12 images of 62 ⁇ 62 pixels, and then perform the second convolution operation and send it to the B3 convolution layer in the convolution network. After using the 3 ⁇ 3 window convolution operation again, 60 ⁇ is generated.
  • the convolution layer uses the 3 ⁇ 3 window convolution operation again to generate 72 images of 28 ⁇ 28 pixels, which are then compressed by the B6 pooling layer in the convolutional network to generate 72 images of 14 ⁇ 14 pixels.
  • the B7 fully connected layer of the convolutional network is processed to output a 2048-dimensional vector.
  • the B8 fully connected layer of the convolutional network is processed to output a 256-dimensional vector.
  • the soft regression layer outputs a 2-dimensional vector, indicating that the transparent component to be detected belongs to category 2 (normal, defective) Probability density distribution, so that the transparent member identification to be examined for defects 3C.
  • the C1 convolutional layer sent to the convolutional network after using the 5 ⁇ 5 window convolution operation, 12 images of 252 ⁇ 252 pixels are generated, and then the C2 pooling layer in the module Perform compression processing to generate 12 images of 126 ⁇ 126 pixels, and then perform the second convolution operation and send them to the C3 convolution layer in the convolution network.
  • 124 ⁇ is generated.
  • the 36 images of 124 pixels are compressed by the C4 pooling layer in the convolution network to generate 36 images of 62 ⁇ 62 pixels.
  • the third convolution operation is performed and sent to C5 in the convolution network.
  • the convolution layer uses the 3 ⁇ 3 window convolution operation again to generate 72 images of 60 ⁇ 60 pixels, which are then compressed by the C6 pooling layer in the convolution network to generate 72 images of 30 ⁇ 30 pixels. Further, the C7 fully connected layer of the convolutional network is processed to output a 4096-dimensional vector. Further, the C8 fully connected layer of the convolutional network is processed to output a 256-dimensional vector. Finally, the C9 in the convolutional network The soft regression layer outputs a 2-dimensional vector, indicating that the transparent component to be detected belongs to category 2 (normal, missing) ) Is the probability density distribution, so that the transparent member identification to be examined for defects 3C.
  • the offline training sample library of the convolutional network can increase the number of samples. Therefore, the accuracy of detection can be further improved with the increase of the number of samples; the convolutional network can also be trained and updated by the user during use, or can be periodically updated by the device manufacturer.

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Abstract

A laser total reflection-type 3C transparent component defect detection apparatus and method, the apparatus comprising a positioning drive apparatus, a laser emitter (1), a light-transmissive work platform (3), a detection camera, a deep learning operation unit, an ARM embedded controller, and an acousto-optic warning device, the laser emitter (1) being connected to the positioning drive apparatus, the positioning drive apparatus, the detection camera, the deep learning operation unit, and the acousto-optic warning device having a communication connection with the ARM embedded controller by means of a CAN boss, and the detection camera photographing images of the light-transmissive work platform (3).

Description

一种激光全反射式的3C透明构件缺陷检测装置及方法Laser total reflection type 3C transparent member defect detection device and method 技术领域Technical field
本发明属于产品表面缺陷检测技术领域,具体地说是一种3C行业透明构件产品质量缺陷检测装置与方法。The invention belongs to the technical field of product surface defect detection, in particular to a 3C industry transparent component product quality defect detection device and method.
背景技术Background technique
我国是3C产品制造大国,透明构件在行业中的应用也越来越多,而且产品的质量要求也越来越高。但是对于3C透明构件缺陷的检测,大部分还停留在依靠人工肉眼识别的阶段,存在劳动强度较大、光学污染严重,对检测人员的视力有伤害,并且由于检测人员的经验不一致,存在漏检的风险。另外,我国劳动力资源溃乏,成本不断攀升,迫切需要3C行业检测设备智能化升级,减少零件缺陷的概率,提高良品率,从而提升企业的利润。China is a big country of 3C product manufacturing, and the application of transparent components in the industry is also increasing, and the quality requirements of products are becoming higher and higher. However, for the detection of 3C transparent component defects, most of them still remain in the stage of relying on artificial naked eye recognition. There is a large labor intensity and serious optical pollution, which hurts the eyesight of the inspectors, and due to the inconsistency of the inspectors' experience, there is a missed inspection risks of. In addition, China's labor resources are depleted and costs continue to rise. There is an urgent need for the intelligent upgrade of 3C industry testing equipment to reduce the probability of part defects and improve the yield rate, thereby increasing corporate profits.
目前,市面上的透明购件缺陷检测大部分以人工为主,少量的有自动化的检测设备,以光学检测为主,通过一次性整件产品光照(可见光为主),再以摄像头采集图像,进行分析并判断是否存在缺陷,但是由于3C透明构件尺寸小、缺陷不明显,从而通过常规光学原理进行检测,其识别准确率有待进一步提升。因而,迫切需要一种的新的检测方法,提升信噪比,更容易辨识细微的产品缺陷,为相关的行业企业提升良品率,降低成本,从而为3C行业的发展贡献力量。At present, most of the defect detection of transparent purchased parts on the market is mainly manual, a small number of automated detection equipment, mainly optical detection, through a one-time whole product illumination (visible light mainly), and then use the camera to collect images, Analyze and judge whether there is a defect, but because the 3C transparent member has a small size and the defect is not obvious, it is detected by conventional optical principles, and its recognition accuracy rate needs to be further improved. Therefore, there is an urgent need for a new detection method to improve the signal-to-noise ratio, make it easier to identify subtle product defects, improve the yield of related industries and reduce the cost, and thus contribute to the development of the 3C industry.
发明内容Summary of the invention
本发明要解决的技术问题是提供一种激光全反射式的3C透明构件缺陷检测装置,检测性能稳定,检测质量和检测效率较高。The technical problem to be solved by the present invention is to provide a laser total reflection type 3C transparent member defect detection device with stable detection performance, high detection quality and high detection efficiency.
为了解决上述技术问题,本发明采取以下技术方案:In order to solve the above technical problems, the present invention adopts the following technical solutions:
一种激光全反射式的3C透明构件缺陷检测装置,所述装置包括定位驱动装置、激光发射器、透光工作台、检测摄像机、深度学习运算单元、ARM嵌入式控制器和声光报警器,激光发射器与定位驱动装置连接,定位驱动装置、检测摄像机、深度学习运算单元和声光报警装置通过CAN总线 与ARM嵌入式控制器通讯连接,检测摄像机对着透光工作机拍摄获取图像。A laser total reflection type 3C transparent member defect detection device, which includes a positioning drive device, a laser emitter, a light-transmitting workbench, a detection camera, a deep learning arithmetic unit, an ARM embedded controller, and an audible and visual alarm, The laser emitter is connected to the positioning drive device. The positioning drive device, the detection camera, the deep learning operation unit and the sound and light alarm device are connected to the ARM embedded controller through the CAN bus, and the detection camera is shot against the light-transmitting working machine to obtain the image.
所述透光工作台上还设有用于夹装待测透明构件的全反射上辅助件和全反射下辅助件,全反射下辅助件设在透光工作台上,待测透明构件设在全反射上辅助件和全反射下辅助件之间,全反射上辅助件与待测透明构件之间具有裸露间隙部分。The light-transmitting workbench is also provided with a total reflection upper auxiliary part and a total reflection lower auxiliary part for clamping the transparent member to be tested. The total reflection lower auxiliary part is provided on the light-transmitting workbench, and the transparent member to be tested is provided on the full There is an exposed gap portion between the upper reflective auxiliary member and the total reflective lower auxiliary member, and the total reflective upper auxiliary member and the transparent member to be measured.
所述定位驱动装置包括微控制器、X向电机、X向定位丝杆、Y向电机、Y向定位丝杆、X向负载平台、Y向负载平台和角度定位步进电机,X向定位丝杆与X向电机连接且装在X向负载平台上,Y向负载平台通过螺套装在X向定位丝杆上,Y向定位丝杆与Y向电机连接且装在Y向负载平台上,角度定位步进电机通过连接块装在Y向定位丝杆上,激光发射器与角度定位步进电机的驱动轴连接,X向电机、Y向电机、角度定位步进电机分别与微控制器连接,微控制器通过CAN总线与ARM嵌入式控制器通讯连接,微控制器上连接有光栅尺。The positioning drive device includes a microcontroller, an X-direction motor, an X-direction positioning screw, a Y-direction motor, a Y-direction positioning screw, an X-direction load platform, a Y-direction load platform and an angular positioning stepper motor, and an X-direction positioning wire The rod is connected to the X-direction motor and mounted on the X-direction load platform. The Y-direction load platform is screwed onto the X-direction positioning screw. The Y-direction screw is connected to the Y-direction motor and mounted on the Y-direction load platform. The positioning stepping motor is mounted on the Y-positioning screw through a connecting block, the laser emitter is connected to the drive shaft of the angular positioning stepping motor, and the X-direction motor, Y-direction motor and angular positioning stepping motor are respectively connected to the microcontroller. The microcontroller communicates with the ARM embedded controller through the CAN bus, and a grating ruler is connected to the microcontroller.
所述X向负载平台、Y向负载平台的一端还分别设有与微控制器通讯连接的零位传感器。One end of the X-direction load platform and the Y-direction load platform are respectively provided with a zero position sensor in communication connection with a microcontroller.
所述全反射上辅助件、待检测透明构件、全反射下辅助件三者之间满足激光全反射的要求,也即是入射到待检测透明构件的激光入射角C满足The total reflection upper auxiliary member, the transparent member to be detected, and the total reflection lower auxiliary member meet the requirements of total reflection of laser light, that is, the incident angle C of the laser light incident on the transparent member to be detected satisfies
C≥sin -1(n 2/n 1), C≥sin -1 (n 2 / n 1 ),
其中n 2为全反射上辅助件和全反射下辅助件的折射率,n 1为待测透明构件的折射率。 Where n 2 is the refractive index of the total reflection upper auxiliary member and total reflection lower auxiliary member, and n 1 is the refractive index of the transparent member to be measured.
所述激光发射器并排设有至少三个不同规格的激光头,用于测量不同厚度的待测透明构件。The laser emitter is provided with at least three laser heads of different specifications side by side for measuring transparent members to be measured with different thicknesses.
所述检测摄像机设在透光工作台的下方,并且检测摄像机外围设有钣金外壳。The detection camera is arranged below the light-transmitting workbench, and a sheet metal shell is arranged on the periphery of the detection camera.
一种激光全反射式的3C透明构件缺陷检测方法,包括以下步骤:A laser total reflection type 3C transparent component defect detection method, including the following steps:
将待测透明构件放置在全反射上辅助件和全反射下辅助之间并置于透光工作台上;Place the transparent member to be tested between the total reflection upper auxiliary part and the total reflection lower auxiliary part and place it on the light-transmitting workbench;
将激光发射器移动到预定位置,旋转调整好激光发射器的角度,将激 光发射器定位至待检测状态,然后激光发射器朝向待测透明构件持续发射激光,激光入射到待测透明构件内,Move the laser emitter to a predetermined position, rotate and adjust the angle of the laser emitter, position the laser emitter to the state to be detected, then the laser emitter continuously emits laser light toward the transparent member to be tested, and the laser light is incident into the transparent member to be tested.
检测摄像机拍照获取图像,将图像传输到ARM嵌入式控制器进行图像预处理,再将图像传送到深度学习运算单元,自动识别出漏光的强弱和位置,从而自动检测出待检测构件的缺陷类型及其位置。Detect the camera to take a picture to obtain an image, transfer the image to the ARM embedded controller for image preprocessing, and then transfer the image to the deep learning arithmetic unit to automatically identify the strength and position of the light leakage, thus automatically detecting the type of defect of the component to be detected And its location.
所述全反射上辅助件和全反射下辅助件的折射率n 2为待测透明构件折射率n 1的1/2或1/2以下,使得待测透明构件的激光入射角C小于45度。 The refractive index n 2 of the total reflection upper auxiliary member and the total reflection lower auxiliary member is 1/2 or less than the refractive index n 1 of the transparent member to be measured, so that the laser incident angle C of the transparent member to be measured is less than 45 degrees .
所述待测透明构件为平面3C透明构件或曲面3C透明构件。The transparent member to be tested is a flat 3C transparent member or a curved 3C transparent member.
本发明具有以下有益效果:The invention has the following beneficial effects:
1)基于光学全反射原理,使用方向性强的可见激光对待检测3C透明构件进行检测,由于透明构件内部或者表面的缺陷都会导致激光发生折射、反射、撒射,从而部分激光不满足全反射条件,从透明构件表面漏出,被检测摄像机捕获到,并拍照为后面智能分析提供基础数据。1) Based on the principle of optical total reflection, the 3C transparent member to be inspected is detected using a visible laser with strong directivity. Due to defects in the transparent member or on the surface, the laser will be refracted, reflected, and scattered, so that part of the laser does not meet the conditions of total reflection. , Leaking from the surface of the transparent member, captured by the detection camera, and taking pictures to provide basic data for later intelligent analysis.
2)为了检测不同厚度的3C透明购机,采用不同规格尺寸的激光头,从而自动检测既能考虑到检测质量,也能兼顾检测效率。2) In order to detect 3C transparent purchases of different thicknesses, laser heads of different specifications and sizes are used, so that automatic detection can take into account both the detection quality and the detection efficiency.
3)利用全反射原理及其激光定位辅助装置,本发明专利不仅能检测平面类型的3C透明构件,还能对曲面类型的3C透明构件进行检测。3) Using the principle of total reflection and its laser positioning auxiliary device, the patent of the present invention can not only detect the flat type 3C transparent member, but also detect the curved type 3C transparent member.
4)采用深度学习的3C透明构件智能检测技术,完成透明构件精密、在线自动检测,克服了人工检测的不一致性,使得检测过程中质量稳定。4) Using deep learning 3C transparent component intelligent detection technology to complete the precise and online automatic detection of transparent components, which overcomes the inconsistency of manual detection and makes the quality stable during the detection process.
附图说明BRIEF DESCRIPTION
附图1为本发明装置的连接原理示意图;Figure 1 is a schematic diagram of the connection principle of the device of the present invention;
附图2为本发明定位驱动装置的结构示意图;2 is a schematic structural view of the positioning drive device of the present invention;
附图3为本发明定位驱动装置的连接原理示意图;Figure 3 is a schematic diagram of the connection principle of the positioning drive device of the present invention;
附图4为本发明透光工作台的结构示意图;Figure 4 is a schematic structural view of the light-transmitting workbench of the present invention;
附图5-1为待测构件不存在缺陷的光路示意图;Figure 5-1 is a schematic diagram of the optical path of the component to be tested without defects;
附图5-2为待测构件表面存在缺陷的光路示意图;Figure 5-2 is a schematic diagram of the optical path with defects on the surface of the component to be tested;
附图5-3为待测构件内部存在缺陷的光路示意图;Figure 5-3 is a schematic diagram of the optical path with defects inside the component to be tested;
附图6-1为平面型待测构件的光路示意图;Figure 6-1 is a schematic diagram of the optical path of the planar type test component;
附图6-2为曲面型的待测透明构件的光路折射示意图;Figure 6-2 is a schematic diagram of the optical path refraction of a curved transparent member to be measured;
附图7-1、图7-2、图7-3为深度学习网络结构示意图;Figures 7-1, 7-2 and 7-3 are schematic diagrams of the structure of the deep learning network;
附图8为检测区域划分原理示意图。Figure 8 is a schematic diagram of the principle of detection area division.
具体实施方式detailed description
为能进一步了解本发明的特征、技术手段以及所达到的具体目的、功能,下面结合附图与具体实施方式对本发明作进一步详细描述。To further understand the features, technical means, and specific objectives and functions of the present invention, the present invention will be described in further detail below with reference to the accompanying drawings and specific embodiments.
如附图1-4所示,本发明揭示了一种激光全反射式的3C透明构件缺陷检测装置,所述装置包括定位驱动装置、激光发射器1、透光工作台3、检测摄像机、深度学习运算单元、ARM嵌入式控制器和声光报警器,激光发射器与定位驱动装置连接,定位驱动装置、检测摄像机、深度学习运算单元和声光报警装置通过CAN总线与ARM嵌入式控制器通讯连接,检测摄像机对着透光工作机拍摄获取图像。定位驱动装置对激光发射器进行定位,使激光发射器在准确的位置发射激光,确保激光准确的进入到待测透明构件中。As shown in FIGS. 1-4, the present invention discloses a laser total reflection type 3C transparent member defect detection device, which includes a positioning driving device, a laser emitter 1, a light-transmitting workbench 3, a detection camera, a depth Learning operation unit, ARM embedded controller and audible and visual alarm, laser emitter is connected with positioning drive device, positioning drive device, inspection camera, deep learning operation unit and sound and light alarm device communicate with ARM embedded controller via CAN bus Connect and detect the camera to take the image against the light-transmitting work machine. The positioning drive device positions the laser emitter so that the laser emitter emits laser light at an accurate position, ensuring that the laser light accurately enters the transparent member to be measured.
所述透光工作台3上还设有用于夹装待测透明构件的全反射上辅助件41和全反射下辅助件42,全反射下辅助件41设在透光工作台3上,待测透明构件5设在全反射上辅助件41和全反射下辅助件41之间,全反射上辅助件41与待测透明构件5之间具有裸露间隙部分。全反射上辅助件和全反射下辅助件的材质选用柔性耐磨透光材料,硬度比待检测3C透明构件低;根据检测透明构件的要求可配置不同类型的配套全反射上辅助件和全反射下辅助件,从而实现光学检测对待检测3C透明构件的全覆盖。所述全反射上辅助件、待检测透明构件、全反射下辅助件三者之间满足激光全反射的要求,也即是入射到待检测透明构件的激光入射角C满足The light-transmitting workbench 3 is also provided with a total reflection upper auxiliary part 41 and a total reflection lower auxiliary part 42 for clamping the transparent member to be tested. The total reflection lower auxiliary part 41 is provided on the light-transmitting workbench 3 and is to be tested The transparent member 5 is provided between the total reflection upper auxiliary member 41 and the total reflection lower auxiliary member 41, and there is a bare gap portion between the total reflection upper auxiliary member 41 and the transparent member 5 to be measured. The materials of the total reflection upper auxiliary part and the total reflection lower auxiliary part are made of flexible wear-resistant light-transmitting materials, and the hardness is lower than that of the 3C transparent member to be tested; different types of supporting total reflection upper auxiliary member and total reflection Lower auxiliary parts, so as to achieve full coverage of the 3C transparent member to be inspected by optical inspection. The total reflection upper auxiliary member, the transparent member to be detected, and the total reflection lower auxiliary member meet the requirements of total reflection of laser light, that is, the incident angle C of the laser light incident on the transparent member to be detected satisfies
C≥sin -1(n 2/n 1), C≥sin -1 (n 2 / n 1 ),
其中n 2为全反射上辅助件和全反射下辅助件的折射率,n 1为待测透明构件的折射率。 Where n 2 is the refractive index of the total reflection upper auxiliary member and total reflection lower auxiliary member, and n 1 is the refractive index of the transparent member to be measured.
此外,所述定位驱动装置包括微控制器、X向电机6、X向定位丝杆7、 Y向电机11、Y向定位丝杆12、X向负载平台8、Y向负载平台9和角度定位步进电机2,X向定位丝杆7与X向电机6连接且装在X向负载平台8上,Y向负载平台9通过螺套装在X向定位丝杆7上,Y向定位丝杆12与Y向电机11连接且装在Y向负载平台9上,角度定位步进电机2通过连接块装在Y向定位丝杆12上,激光发射器1与角度定位步进电机2的驱动轴连接,X向电机、Y向电机、角度定位步进电机分别与微控制器连接,微控制器通过CAN总线与ARM嵌入式控制器通讯连接,微控制器上连接有光栅尺,X向负载平台、Y向负载平台的一端还分别设有与微控制器通讯连接的零位传感器。X向电机带动X向定位丝杆转动,进而可调整Y向负载平台在X方向上的移动行程,从而调整激光发射器在X方向的位置。再通过Y向电机调整激光发射器在Y方向上的位置,从而调整好X-Y方向的位置,再通过角度定位步进电机带动激光发射器旋转,调整好角度,使得激光发射器被调整好预定的位置。光栅尺能够准确的控制X向电机、Y向电机的运行行程。X向电机、Y向电机与光栅尺构成一个闭环控制回路,步进电机通过角度零位传感器,在每件待测透明构件完成后自动重新回零校正,从而实现高精定位提供环境。In addition, the positioning drive device includes a microcontroller, an X-direction motor 6, an X-direction positioning screw 7, a Y-direction motor 11, a Y-direction positioning screw 12, an X-direction load platform 8, a Y-direction load platform 9, and angular positioning Stepper motor 2, X-direction screw 7 is connected to X-direction motor 6 and mounted on X-direction load platform 8, Y-direction load platform 9 is screwed on X-direction screw 7 and Y-direction screw 12 Connected to the Y-direction motor 11 and mounted on the Y-direction load platform 9, the angular positioning stepper motor 2 is mounted on the Y-direction screw 12 through a connecting block, and the laser emitter 1 is connected to the drive shaft of the angular positioning stepper motor 2 , X-direction motor, Y-direction motor, angle positioning stepper motor are respectively connected to the microcontroller. The microcontroller is connected to the ARM embedded controller via CAN bus. The microcontroller is connected to the grating scale, the X-direction load platform, One end of the Y-direction load platform is also provided with zero sensors in communication connection with the microcontroller. The X-direction motor drives the X-direction positioning screw to rotate, which in turn can adjust the movement stroke of the Y-direction load platform in the X direction, thereby adjusting the position of the laser emitter in the X direction. Then adjust the position of the laser emitter in the Y direction by the Y-direction motor, so as to adjust the position of the XY direction, and then rotate the laser emitter through the angular positioning stepper motor to adjust the angle, so that the laser emitter is adjusted to the predetermined position. The grating ruler can accurately control the travel of X-direction motor and Y-direction motor. The X-direction motor, Y-direction motor and grating ruler form a closed-loop control loop. The stepper motor uses an angle zero sensor to automatically return to zero correction after each transparent component to be tested is completed, thereby providing an environment for high-precision positioning.
X向电机每次间隔(1/5~1/10的待检测3C透明构件宽度)固定步长后暂停,X向电机运动过程中,激光发射器持续发射激光,检测摄像机在此检测过程的时间内处于曝光状态,X方向固定步长移动到位后,检测摄像机进行拍照。角度定位步进电机在每件待检测构件完成后自动回原始位置,由角度零位传感器进行检测,为角度定位步进电机重新校正提供基准;微控制器通过CAN总线与ARM嵌入式控制器通讯连接,感知被检测构件的信息,为其伺服及定位运动提供参数。The X-direction motor pauses after a fixed step size at each interval (1/5 to 1/10 of the width of the 3C transparent member to be tested). During the movement of the X-direction motor, the laser emitter continuously emits laser light to detect the time of the camera during this detection process The camera is in the exposure state. After the fixed step in the X direction moves into place, the camera is detected to take pictures. The angular positioning stepper motor automatically returns to the original position after each piece to be detected is detected by the angle zero sensor, which provides a reference for the angular positioning stepper motor recalibration; the microcontroller communicates with the ARM embedded controller through the CAN bus Connect, sense the information of the detected component, and provide parameters for its servo and positioning motion.
角度定位步进电机带动激光发射器进行旋转,其旋转的角度由ARM嵌入式控制器根据待检测构件的尺寸信息及其待检测位置进行调整,使得检测激光能针对待检测区域满足全反射条件。The angular positioning stepper motor drives the laser emitter to rotate, and the angle of rotation is adjusted by the ARM embedded controller according to the size information of the member to be inspected and its position to be inspected, so that the inspected laser can meet the total reflection condition for the region to be inspected.
所述激光发射器并排设有三个不同规格的激光头,用于测量不同厚度的待测透明构件。在本实施例中,三个不同规格的激光头1.5mm×1.5mm、 3.5mm×3.5mm和6mm×6mm,分别对不同厚度规格小于1mm、1~3mm和3~5mm的3C透明构件进行检测。The laser emitter is provided with three laser heads of different specifications side by side for measuring transparent members to be measured with different thicknesses. In this embodiment, three laser heads with different specifications of 1.5mm × 1.5mm, 3.5mm × 3.5mm and 6mm × 6mm respectively detect 3C transparent members with different thickness specifications less than 1mm, 1-3mm and 3-5mm .
ARM嵌入式控制器根据待检测透明构件的尺寸信息,按构件长度和宽度方向进行采样,通过多次(长度采样次数×宽度采样次数)拍照完成整件构件的检测。Based on the size information of the transparent component to be tested, the ARM embedded controller samples according to the length and width direction of the component, and completes the detection of the entire component by taking multiple photos (length sampling times × width sampling times).
另外,整个装置外部由钣金件进行密封,减少外部光源对检测结果的干扰;进一步,检测摄像机安置在透光工作台下方,并在外围再设置一套钣金外壳进行密封,再次减少干扰。In addition, the whole device is sealed by sheet metal parts to reduce the interference of the external light source on the detection results; further, the detection camera is placed under the light-transmitting workbench, and a set of sheet metal shells are set on the periphery to seal, again reducing interference.
所述深度学习运算单元采用FPGA硬件进行实现,在传入之前,由ARM嵌入式控制器进行灰度化和分割处理,按激光头的规格,分割后的每幅图像分别压缩到64×64×1、128×128×1或者256×256×1的三维灰度图像空间里,再进行三次卷积和池化操作后,再进行两次全连接的神经网络,输出到256维向量里,再通过软回归将256维向量输出为矢量(正常、有缺陷),并将检测结果通过CAN总线通信模块传输到ARM嵌入式控制器,并通过声光报警器告知检测人员。The deep learning arithmetic unit is implemented with FPGA hardware. Before being passed in, the ARM embedded controller performs graying and segmentation. According to the specifications of the laser head, each image after segmentation is compressed to 64 × 64 × 1. In the three-dimensional grayscale image space of 128 × 128 × 1 or 256 × 256 × 1, after performing three more convolution and pooling operations, perform two fully connected neural networks and output to a 256-dimensional vector. The 256-dimensional vector is output as a vector (normal, defective) through soft regression, and the detection result is transmitted to the ARM embedded controller through the CAN bus communication module, and the detection personnel is informed by an audible and visual alarm.
所述的深度学习运算单元所依赖的样本库存在于ARM嵌入式控制器中(内部NAND Flash),可由ARM嵌入式控制器后台更新深度卷积神经网络参数,并通过CAN总线发送深度学习运算单元中存储并在运算中使用。The sample inventory that the deep learning arithmetic unit depends on is in the ARM embedded controller (internal NAND Flash), and the deep convolutional neural network parameters can be updated in the background by the ARM embedded controller and sent to the deep learning arithmetic unit through the CAN bus Store and use in operations.
所述深度卷积神经网络的离线训练样本库可以增加样本数量。因而,3C透明构件检测可根据样本的实际情况进行增减,提升特定规格待检测构件的检测准确度。The offline training sample library of the deep convolutional neural network can increase the number of samples. Therefore, the detection of 3C transparent components can be increased or decreased according to the actual situation of the sample, and the detection accuracy of the components to be tested with specific specifications can be improved.
所述深度卷积神经网络即可以由用户在使用过程中进行训练更新,也可以选择由装置生产厂家定期更新;本发明装置支持多版本的深度卷积神经网络,可由最终用户根据实际应用场景进行自主选择。The deep convolutional neural network can be trained and updated by the user during use, or can be periodically updated by the device manufacturer; the device of the present invention supports multiple versions of the deep convolutional neural network, which can be performed by the end user according to the actual application scenario Independent choice.
X-Y方向的伺服电机带动定位丝杆进行X方向和Y方向的运动,带动负载平台进行“X-Y”方向联动,角度定位步进电机安装在负载平台上,再带动激光发射器进行旋转,通过三轴联动方案,可将激光发射器定位到待检测状态,满足检测要求。检测过程中,X方向的伺服电机每次间隔 (1/5~1/10的待检测3C透明构件宽度)固定步长后暂停,在此过程中,激光发射器持续发射激光,检测摄像机处于曝光状态,X方向固定步长移动到位后,检测摄像机进行拍照;通过选择全反射上辅助件的材料,使得折射率n 2为待检测透明构件折射率n 1的1/2及其以下,从而达到激光入射角C小于45度,再针对待检测透明构件的厚度,选择对应规格的激光头,即可实现Y方向一次扫描即可覆盖,具体规则如下: The servo motor in the XY direction drives the positioning screw to move in the X and Y directions, drives the load platform to link in the "XY" direction, the angular positioning stepper motor is installed on the load platform, and then drives the laser transmitter to rotate through the three axes The linkage scheme can position the laser transmitter to the state to be detected to meet the detection requirements. During the detection process, the servo motor in the X direction is paused after a fixed step length (1/5 to 1/10 of the width of the 3C transparent member to be detected). During this process, the laser transmitter continuously emits laser light and the detection camera is exposed In the state, after the fixed step in the X direction moves into place, the detection camera takes a picture; by selecting the material of the auxiliary component on the total reflection, the refractive index n 2 is 1/2 or less of the refractive index n 1 of the transparent member to be detected, so as to achieve The laser incident angle C is less than 45 degrees, and then select the laser head of the corresponding specification according to the thickness of the transparent member to be detected, and then it can be covered by one scan in the Y direction. The specific rules are as follows:
a)对于待检测透明构件厚度小于1mm的情况,由定位驱动装置微控制器选择1.5mm×1.5mm激光头进行工作;a) For the case where the thickness of the transparent member to be tested is less than 1 mm, the positioning drive device microcontroller selects a 1.5 mm × 1.5 mm laser head to work;
b)对于待检测透明构件厚度处于1~3mm情况,由定位驱动装置微控制器选择3.5mm×3.5mm激光头进行工作;b) For the case where the thickness of the transparent member to be tested is between 1 and 3 mm, a 3.5 mm × 3.5 mm laser head is selected for operation by the microcontroller of the positioning drive device;
c)对于待检测透明构件厚度处于3~5mm的情况,由定位驱动装置微控制器选择6mm×6mm激光头进行工作。c) For the case where the thickness of the transparent member to be detected is 3 to 5 mm, a 6 mm × 6 mm laser head is selected for operation by the microcontroller of the positioning drive device.
d)上述定位驱动装置微控制器通过CAN总线,受ARM嵌入式控制器控制,由用户根据实际情况进行选择。d) The microcontroller of the above positioning drive device is controlled by the ARM embedded controller through the CAN bus, and the user can choose according to the actual situation.
上述区域采样Y方向移动一个单位的激光头宽度后,再重复检测一次,两次检测能完整覆盖固定步长内的完整区域。同理,对剩下的待检测区域重复上述过程,沿X方向继续扫描检测,即可覆盖整个待测透明构件区域,完成检测,其检测原理如图8所示,图8中第一次检测和第二次检测为本采样区域内沿Y方向的两次检测。因而,总的拍照次数为2*(5~10)次。After the above-mentioned area is sampled and moved by one unit of laser head width in the Y direction, the detection is repeated again, and the two detections can completely cover the complete area within a fixed step size. In the same way, repeat the above process for the remaining area to be tested, and continue to scan and test in the X direction to cover the entire area of the transparent member to be tested to complete the detection. The detection principle is shown in Figure 8, the first detection in Figure 8 And the second detection is the two detections along the Y direction in the sampling area. Therefore, the total number of photographs is 2 * (5-10) times.
如附图4所示,检测激光束在ARM嵌入式控制器控制下,通过定位驱动装置实现对检测激光束的位置调整,使得满足全反射性原理;全反射上辅助件与待检测3C透明构件留有间隙,通常为1.2~1.5倍的激光束宽度,使得激光束能射入道待检测透明构件内部;全反射下辅助件下方设置有检测摄像机,对可能存在(有缺陷的检测见有漏光现象)的漏光进行拍照。As shown in Figure 4, the detection laser beam is controlled by the ARM embedded controller, and the position of the detection laser beam is adjusted through the positioning drive device so that the principle of total reflection is satisfied; the auxiliary part on the total reflection and the 3C transparent member to be detected There is a gap, usually 1.2 to 1.5 times the width of the laser beam, so that the laser beam can enter the inside of the transparent member to be detected; under the total reflection, there is a detection camera under the auxiliary part, which may exist (defective detection sees light leakage Phenomenon) to take photos of light leakage.
如附图5-1所示,对于待检测的3C透明构件,如果内部或者表面没有缺陷,检测激光束满足全反射工作原理,激光在透明构件内部上下全反射,没有激光射向全反射上辅助件或者和全反射下辅助件,从而设置在全反射下辅助件下方的检测摄像机就不能获取检测激光信号。相反,如附图 5-2待测透明构件表面存在缺陷,图5-3所示,待检测透明构件内部存在缺陷,那么有一部分检测激光束发生反射、折射、散射现象,从而不能完全满足全反射条件,这样设置在全反射下辅助件下方的检测摄像机就能捕捉到检测激光信号。As shown in Figure 5-1, for the 3C transparent member to be inspected, if there are no defects inside or on the surface, the detection laser beam satisfies the working principle of total reflection. And the auxiliary component under total reflection, so that the detection camera disposed under the auxiliary component under total reflection cannot acquire the detection laser signal. On the contrary, as shown in Figure 5-2, there is a defect on the surface of the transparent member to be tested, as shown in Figure 5-3, there is a defect inside the transparent member to be detected, then a part of the detection laser beam reflects, refracts, and scatters, which cannot fully satisfy the full Reflection conditions, so that the detection camera placed under the auxiliary part under total reflection can capture the detection laser signal.
图6只给出了平面透明构件的放置示意图,对于曲面透明构件,根据检测对象的不同,需要配置两套全反射上/下辅助件,分别完成曲面和平面的检测,由于原理相同,在此不再赘述。Figure 6 only shows a schematic diagram of the placement of planar transparent components. For curved transparent components, two sets of total reflection upper / lower auxiliary parts need to be configured to complete the detection of curved surfaces and flat surfaces respectively according to the detection object. Since the principles are the same, here No longer.
如附图6-1、图6-2所示,分别是平面型透明构件和曲面型透明构件的光路示意图。对于平面3C透明构件,激光头只需要以一个固定的角度将检测激光束射入待检测的透明构件内部即可,通过沿X方向移动负载工作台即可完成整件构件的检测;但是,对于曲面3C透明构件,需要分别检测平面部分和曲面部分,通过ARM嵌入式控制器根据待检测构建的几何尺寸信息,分别计算平面和曲面部分的激光束入射角,再由驱动装置微控制器带动伺服电机和步进电机运动,使得激光头达到计算的角度,特别是曲面部分,选择尺寸规格小的激光头进行检测。As shown in Figures 6-1 and 6-2, they are schematic diagrams of the optical paths of the planar transparent member and the curved transparent member. For a flat 3C transparent component, the laser head only needs to emit the detection laser beam into the transparent component to be detected at a fixed angle, and the entire component can be detected by moving the load table in the X direction; however, for The curved 3C transparent member needs to detect the plane part and the curved part separately. The ARM embedded controller calculates the incident angle of the laser beam on the plane and the curved part separately according to the geometric size information to be detected, and then the driving device microcontroller drives the servo The movement of the motor and stepper motor makes the laser head reach the calculated angle, especially the curved surface part, and the laser head with a small size is selected for detection.
ARM嵌入式控制器既接收微控制器的信息,同时也对微控制器发送控制指令,实现激光头角度的定位,并在检测过程中使得负载平台带动激光头沿着X方向间隔采样,从而使得检测摄像机能对检测成像进行拍照。The ARM embedded controller not only receives the information of the microcontroller, but also sends control instructions to the microcontroller to realize the positioning of the laser head angle, and during the detection process, the load platform drives the laser head to sample at intervals in the X direction, so that The detection camera can take pictures of the detection imaging.
另外,一种激光全反射式的3C透明构件缺陷检测方法,包括以下步骤:In addition, a laser total reflection type 3C transparent member defect detection method includes the following steps:
将待测透明构件放置在全反射上辅助件和全反射下辅助之间并置于透光工作台上。The transparent member to be measured is placed between the total reflection upper auxiliary part and the total reflection lower auxiliary part and placed on the light-transmitting workbench.
将激光发射器移动到预定位置,旋转调整好激光发射器的角度,将激光发射器定位至待检测状态,然后激光发射器朝向待测透明构件持续发射激光,激光入射到待测透明构件内。Move the laser emitter to a predetermined position, rotate and adjust the angle of the laser emitter, position the laser emitter to the state to be detected, and then the laser emitter continuously emits laser light toward the transparent member to be tested, and the laser light is incident into the transparent member to be tested.
检测摄像机拍照获取图像,将图像传输到ARM嵌入式控制器进行图像预处理,再将图像传送到深度学习运算单元,自动识别出漏光的强弱和位置,从而自动检测出待检测构件的缺陷类型及其位置。Detect the camera to take a picture to obtain an image, transfer the image to the ARM embedded controller for image preprocessing, and then transfer the image to the deep learning arithmetic unit to automatically identify the strength and position of the light leakage, thus automatically detecting the type of defect of the component to be detected And its location.
如附图7-1、图7-2、图7-3所示,深度学习运算单元采用FPGA硬件进行实现,在传入之前,由ARM嵌入式控制器进行灰度化和分割处理,按激光头的规格,分割后的每幅图像分别压缩到64×64×1、128×128×1或者256×256×1的三维灰度图像空间里,再进行三次卷积和池化操作后,再进行两次全连接的神经网络,输出到256维向量里,再通过软回归将256维向量输出为矢量(正常、有缺陷),网络的数据处理流程如下:As shown in Figure 7-1, Figure 7-2, and Figure 7-3, the deep learning arithmetic unit is implemented with FPGA hardware. Prior to the introduction, the ARM embedded controller performs graying and segmentation processing. The specifications of the header, each divided image is compressed into a three-dimensional gray image space of 64 × 64 × 1, 128 × 128 × 1, or 256 × 256 × 1, and after three convolution and pooling operations, The neural network that is fully connected twice is output to a 256-dimensional vector, and then the 256-dimensional vector is output as a vector (normal, defective) through soft regression. The network data processing flow is as follows:
a)为了提高辨识精度,分别离线训练三个网络,也即是分别对应三种不同规格的激光头,三个网络的输入图像分别是64×64×1、128×128×1或者256×256×1的三维灰度规格尺寸。a) In order to improve the recognition accuracy, the three networks are separately trained offline, that is, corresponding to three different specifications of the laser head, the input images of the three networks are 64 × 64 × 1, 128 × 128 × 1, or 256 × 256, respectively. × 1 three-dimensional gray scale size.
b)深度学习运算单元可一次处理多张图像。因而,分割好的图像可设置一批同时将32张输入到FPGA实现的网络里,通过并发处理减少辨识时间。b) The deep learning arithmetic unit can process multiple images at a time. Therefore, a batch of divided images can be set to input 32 images into the FPGA-implemented network at the same time, and the identification time can be reduced through concurrent processing.
c)对于64×64×1,送入卷积网络中的A1卷积层,采用3×3窗口卷积操作后,生成62×62像素的12幅图像,再由模块中的A2池化层进行压缩处理,生成31×31像素的12幅图像,之后,进行第二次卷积操作,送入卷积网络中的A3卷积层,再次采用3×3窗口卷积操作后,生成29×29像素的36幅图像,再由卷积网络中的A4池化层进行压缩处理,生成14×14像素的36幅图像,之后,进行第三次卷积操作,送入卷积网络中的A5卷积层,再次采用3×3窗口卷积操作后,生成12×12像素的72幅图像,再由卷积网络中的A6池化层进行压缩处理,生成6×6像素的72幅图像,进一步,经过卷积网络的A7全连接层处理,输出1024维度的向量,再进一步,经过卷积网络中的A8全连接层处理,输出256维度的向量,最后,再由卷积网络中的A9软回归层输出2维向量,表示待检测透明构件属于2类(正常、有缺陷)的概率密度分布,从而辨识待检3C透明构件是否存在缺陷。c) For 64 × 64 × 1, the A1 convolutional layer sent to the convolutional network, after using the 3 × 3 window convolution operation, 12 images of 62 × 62 pixels are generated, and then the A2 pooling layer in the module Perform compression processing to generate 12 images of 31 × 31 pixels, and then perform the second convolution operation and send it to the A3 convolution layer in the convolution network. After using the 3 × 3 window convolution operation again, 29 × is generated. The 36 images of 29 pixels are compressed by the A4 pooling layer in the convolution network to generate 36 images of 14 × 14 pixels. After that, the third convolution operation is performed and sent to A5 in the convolution network. The convolutional layer uses the 3 × 3 window convolution operation again to generate 72 images of 12 × 12 pixels, and then performs compression processing by the A6 pooling layer in the convolution network to generate 72 images of 6 × 6 pixels. Further, the A7 fully connected layer of the convolutional network is processed to output 1024-dimensional vectors. Further, the A8 fully connected layer of the convolutional network is processed to output 256-dimensional vectors. Finally, the convolutional network A9 The soft regression layer outputs a 2-dimensional vector, indicating that the transparent component to be detected belongs to the category 2 (normal, defective). Density distribution, so that the transparent member identification to be examined for defects 3C.
d)对于128×128×1,送入卷积网络中的B1卷积层,采用5×5窗口卷积操作后,生成124×124像素的12幅图像,再由模块中的B2 池化层进行压缩处理,生成62×62像素的12幅图像,之后,进行第二次卷积操作,送入卷积网络中的B3卷积层,再次采用3×3窗口卷积操作后,生成60×60像素的36幅图像,再由卷积网络中的B4池化层进行压缩处理,生成30×30像素的36幅图像,之后,进行第三次卷积操作,送入卷积网络中的B5卷积层,再次采用3×3窗口卷积操作后,生成28×28像素的72幅图像,再由卷积网络中的B6池化层进行压缩处理,生成14×14像素的72幅图像,进一步,经过卷积网络的B7全连接层处理,输出2048维度的向量,再进一步,经过卷积网络中的B8全连接层处理,输出256维度的向量,最后,再由卷积网络中的B9软回归层输出2维向量,表示待检测透明构件属于2类(正常、有缺陷)的概率密度分布,从而辨识待检3C透明构件是否存在缺陷。d) For 128 × 128 × 1, the B1 convolutional layer sent to the convolutional network, using a 5 × 5 window convolution operation, generates 12 images of 124 × 124 pixels, and then the B2 pooling layer in the module Perform compression processing to generate 12 images of 62 × 62 pixels, and then perform the second convolution operation and send it to the B3 convolution layer in the convolution network. After using the 3 × 3 window convolution operation again, 60 × is generated. 36 images of 60 pixels, then compressed by the B4 pooling layer in the convolution network to generate 36 images of 30 × 30 pixels, after which, the third convolution operation is performed and sent to B5 in the convolution network The convolution layer uses the 3 × 3 window convolution operation again to generate 72 images of 28 × 28 pixels, which are then compressed by the B6 pooling layer in the convolutional network to generate 72 images of 14 × 14 pixels. Further, the B7 fully connected layer of the convolutional network is processed to output a 2048-dimensional vector. Further, the B8 fully connected layer of the convolutional network is processed to output a 256-dimensional vector. Finally, the B9 in the convolutional network The soft regression layer outputs a 2-dimensional vector, indicating that the transparent component to be detected belongs to category 2 (normal, defective) Probability density distribution, so that the transparent member identification to be examined for defects 3C.
e)对于256×256×1,送入卷积网络中的C1卷积层,采用5×5窗口卷积操作后,生成252×252像素的12幅图像,再由模块中的C2池化层进行压缩处理,生成126×126像素的12幅图像,之后,进行第二次卷积操作,送入卷积网络中的C3卷积层,再次采用3×3窗口卷积操作后,生成124×124像素的36幅图像,再由卷积网络中的C4池化层进行压缩处理,生成62×62像素的36幅图像,之后,进行第三次卷积操作,送入卷积网络中的C5卷积层,再次采用3×3窗口卷积操作后,生成60×60像素的72幅图像,再由卷积网络中的C6池化层进行压缩处理,生成30×30像素的72幅图像,进一步,经过卷积网络的C7全连接层处理,输出4096维度的向量,再进一步,经过卷积网络中的C8全连接层处理,输出256维度的向量,最后,再由卷积网络中的C9软回归层输出2维向量,表示待检测透明构件属于2类(正常、有缺陷)的概率密度分布,从而辨识待检3C透明构件是否存在缺陷。e) For 256 × 256 × 1, the C1 convolutional layer sent to the convolutional network, after using the 5 × 5 window convolution operation, 12 images of 252 × 252 pixels are generated, and then the C2 pooling layer in the module Perform compression processing to generate 12 images of 126 × 126 pixels, and then perform the second convolution operation and send them to the C3 convolution layer in the convolution network. After using the 3 × 3 window convolution operation again, 124 × is generated. The 36 images of 124 pixels are compressed by the C4 pooling layer in the convolution network to generate 36 images of 62 × 62 pixels. After that, the third convolution operation is performed and sent to C5 in the convolution network. The convolution layer uses the 3 × 3 window convolution operation again to generate 72 images of 60 × 60 pixels, which are then compressed by the C6 pooling layer in the convolution network to generate 72 images of 30 × 30 pixels. Further, the C7 fully connected layer of the convolutional network is processed to output a 4096-dimensional vector. Further, the C8 fully connected layer of the convolutional network is processed to output a 256-dimensional vector. Finally, the C9 in the convolutional network The soft regression layer outputs a 2-dimensional vector, indicating that the transparent component to be detected belongs to category 2 (normal, missing) ) Is the probability density distribution, so that the transparent member identification to be examined for defects 3C.
进一步,卷积网络的离线训练样本库可以增加样本数量。因而,检测的精度可随着样本数量的增加而进一步提升;卷积网络也可由用户在使用 过程中进行训练更新,也可以选择由装置生产厂家定期更新。Further, the offline training sample library of the convolutional network can increase the number of samples. Therefore, the accuracy of detection can be further improved with the increase of the number of samples; the convolutional network can also be trained and updated by the user during use, or can be periodically updated by the device manufacturer.
需要说明的是,以上仅为本发明的优选实施例而已,并不用于限制本发明,尽管参照实施例对本发明进行了详细的说明,对于本领域的技术人员来说,其依然可以对前述实施例所记载的技术方案进行修改,或者对其中部分技术特征进行等同替换,但是凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。It should be noted that the above are only preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the embodiments, those skilled in the art can still implement the foregoing The technical solutions described in the examples are modified, or some of the technical features are equivalently replaced, but any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present invention should be included in the protection of the present invention Within range.

Claims (10)

  1. 一种激光全反射式的3C透明构件缺陷检测装置,其特征在于,所述装置包括定位驱动装置、激光发射器、透光工作台、检测摄像机、深度学习运算单元、ARM嵌入式控制器和声光报警器,激光发射器与定位驱动装置连接,定位驱动装置、检测摄像机、深度学习运算单元和声光报警装置通过CAN总线与ARM嵌入式控制器通讯连接,检测摄像机对着透光工作机拍摄获取图像。A laser total reflection type 3C transparent member defect detection device, characterized in that the device includes a positioning drive device, a laser emitter, a light-transmitting workbench, a detection camera, a deep learning arithmetic unit, an ARM embedded controller and a sound The optical alarm and laser transmitter are connected to the positioning drive device. The positioning drive device, the detection camera, the deep learning arithmetic unit, and the sound and light alarm device are connected to the ARM embedded controller through the CAN bus, and the detection camera is shot against the light-transmitting work machine Get the image.
  2. 根据权利要求1所述的激光全反射式的3C透明构件缺陷检测装置,其特征在于,所述透光工作台上还设有用于夹装待测透明构件的全反射上辅助件和全反射下辅助件,全反射下辅助件设在透光工作台上,待测透明构件设在全反射上辅助件和全反射下辅助件之间,全反射上辅助件与待测透明构件之间具有裸露间隙部分。The laser total reflection type 3C transparent member defect detection device according to claim 1, characterized in that a total reflection upper auxiliary part and a total reflection lower part for clamping the transparent member to be tested are further provided on the light-transmitting worktable Auxiliary parts, the total reflection lower auxiliary part is set on the light-transmitting workbench, the transparent member to be measured is arranged between the total reflection upper auxiliary part and the total reflection lower auxiliary part, and there is bareness between the total reflection upper auxiliary part and the transparent member to be tested Gap section.
  3. 根据权利要求2所述的激光全反射式的3C透明构件缺陷检测装置,其特征在于,所述定位驱动装置包括微控制器、X向电机、X向定位丝杆、Y向电机、Y向定位丝杆、X向负载平台、Y向负载平台和角度定位步进电机,X向定位丝杆与X向电机连接且装在X向负载平台上,Y向负载平台通过螺套装在X向定位丝杆上,Y向定位丝杆与Y向电机连接且装在Y向负载平台上,角度定位步进电机通过连接块装在Y向定位丝杆上,激光发射器与角度定位步进电机的驱动轴连接,X向电机、Y向电机、角度定位步进电机分别与微控制器连接,微控制器通过CAN总线与ARM嵌入式控制器通讯连接,微控制器上连接有光栅尺。The laser total reflection type 3C transparent member defect detection device according to claim 2, wherein the positioning driving device comprises a microcontroller, an X-direction motor, an X-direction positioning screw, a Y-direction motor, and a Y-direction positioning Screw rod, X-direction load platform, Y-direction load platform and angle positioning stepper motor. The X-direction screw is connected to the X-direction motor and mounted on the X-direction load platform. The Y-direction load platform is screwed on the X-direction positioning wire On the rod, the Y-positioning screw is connected to the Y-direction motor and mounted on the Y-direction load platform. The angle positioning stepper motor is mounted on the Y-positioning screw through the connection block. The laser emitter and the angle positioning stepper motor are driven Axis connection, X-direction motor, Y-direction motor, and angular positioning stepper motor are connected to the microcontroller respectively. The microcontroller communicates with the ARM embedded controller via CAN bus, and the microcontroller is connected with a grating ruler.
  4. 根据权利要求3所述的激光全反射式的3C透明构件缺陷检测装置,其特征在于,所述X向负载平台、Y向负载平台的一端还分别设有与微控制器通讯连接的零位传感器。The laser total reflection type 3C transparent member defect detection device according to claim 3, characterized in that one end of the X-direction load platform and the Y-direction load platform are respectively provided with a zero sensor in communication connection with a microcontroller .
  5. 根据权利要求4所述的激光全反射式的3C透明构件缺陷检测装置,其特征在于,所述全反射上辅助件、待检测透明构件、全反射下辅助件三者之间满足激光全反射的要求,也即是入射到待检测透明构件的激光 入射角C满足The laser total reflection type 3C transparent member defect detection device according to claim 4, characterized in that the total reflection upper auxiliary member, the transparent member to be detected, and the total reflection lower auxiliary member satisfy laser total reflection between the three The requirement, that is, the incident angle C of the laser light incident on the transparent member to be detected satisfies
    C≥sin -1(n 2/n 1), C≥sin -1 (n 2 / n 1 ),
    其中n 2为全反射上辅助件和全反射下辅助件的折射率,n 1为待测透明构件的折射率。 Where n 2 is the refractive index of the total reflection upper auxiliary member and total reflection lower auxiliary member, and n 1 is the refractive index of the transparent member to be measured.
  6. 根据权利要求5所述的激光全反射式的3C透明构件缺陷检测装置,其特征在于,所述激光发射器并排设有至少三个不同规格的激光头,用于测量不同厚度的待测透明构件。The laser total reflection type 3C transparent member defect detection device according to claim 5, wherein the laser emitter is provided with at least three laser heads of different specifications side by side for measuring transparent members to be measured with different thicknesses .
  7. 根据权利要求6所述的激光全反射式的3C透明构件缺陷检测装置,其特征在于,所述检测摄像机设在透光工作台的下方,并且检测摄像机外围设有钣金外壳。The laser total reflection type 3C transparent member defect detection device according to claim 6, characterized in that the detection camera is provided below the light-transmitting worktable, and a sheet metal shell is provided on the periphery of the detection camera.
  8. 一种激光全反射式的3C透明构件缺陷检测方法,包括以下步骤:A laser total reflection type 3C transparent component defect detection method, including the following steps:
    将待测透明构件放置在全反射上辅助件和全反射下辅助之间并置于透光工作台上;Place the transparent member to be tested between the total reflection upper auxiliary part and the total reflection lower auxiliary part and place it on the light-transmitting workbench;
    将激光发射器移动到预定位置,旋转调整好激光发射器的角度,将激光发射器定位至待检测状态,然后激光发射器朝向待测透明构件持续发射激光,激光入射到待测透明构件内,Move the laser emitter to a predetermined position, rotate and adjust the angle of the laser emitter, position the laser emitter to the state to be detected, then the laser emitter continuously emits laser light toward the transparent member to be tested, and the laser light is incident into the transparent member to be tested.
    检测摄像机拍照获取图像,将图像传输到ARM嵌入式控制器进行图像预处理,再将图像传送到深度学习运算单元,自动识别出漏光的强弱和位置,从而自动检测出待检测构件的缺陷类型及其位置。Detect the camera to take a picture to obtain an image, transfer the image to the ARM embedded controller for image preprocessing, and then transfer the image to the deep learning arithmetic unit to automatically identify the strength and position of the light leakage, thus automatically detecting the type of defect of the component to be detected And its location.
  9. 根据权利要求8所述的激光全反射式的3C透明构件缺陷检测方法,其特征在于,所述全反射上辅助件和全反射下辅助件的折射率n 2为待测透明构件折射率n 1的1/2或1/2以下,使得待测透明构件的激光入射角C小于45度。 The laser total reflection type 3C transparent member defect detection method according to claim 8, wherein the refractive index n 2 of the total reflection upper auxiliary member and the total reflection lower auxiliary member is the refractive index n 1 of the transparent member to be measured 1/2 or less than 1/2, so that the laser incident angle C of the transparent member to be measured is less than 45 degrees.
  10. 根据权利要求9所述的激光全反射式的3C透明构件缺陷检测方法,其特征在于,所述待测透明构件为平面3C透明构件或曲面3C透明构件。The laser total reflection type 3C transparent member defect detection method according to claim 9, wherein the transparent member to be tested is a flat 3C transparent member or a curved 3C transparent member.
PCT/CN2019/085095 2018-10-25 2019-04-30 Laser total reflection-type 3c transparent component defect detection apparatus and method WO2020082714A1 (en)

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