WO2022021806A1 - 包装袋大小边缺陷自动检测系统及方法 - Google Patents
包装袋大小边缺陷自动检测系统及方法 Download PDFInfo
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- WO2022021806A1 WO2022021806A1 PCT/CN2021/070241 CN2021070241W WO2022021806A1 WO 2022021806 A1 WO2022021806 A1 WO 2022021806A1 CN 2021070241 W CN2021070241 W CN 2021070241W WO 2022021806 A1 WO2022021806 A1 WO 2022021806A1
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- packaging bag
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31B70/00—Making flexible containers, e.g. envelopes or bags
- B31B70/74—Auxiliary operations
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
Definitions
- the invention relates to the field of packaging equipment, in particular to an automatic detection system and method for large and small edge defects of packaging bags.
- Packaging bags can be seen everywhere in our lives.
- the existing packaging bag production process includes printing patterns on the film to obtain the packaging bag printing film, and then placing the rolled packaging bag printing film on the bag making machine, unwinding the roll to process the packaging bag, During the printing process of the packaging bag, it is necessary to seal the packaging bag. However, during the processing process, the width of the sealing edge on the left and right sides of the packaging bag is often different, and the phenomenon of large and small edges appears, resulting in defective packaging bags. .
- the purpose of the present invention is to provide an automatic detection system and method for large and small edge defects of packaging bags, the system has a high degree of automation, is easy to operate, is convenient and efficient, and has reliable functions.
- the present invention provides the following technical solutions:
- a method for automatic detection of the size and edge defects of a packaging bag comprises the following steps:
- the offset of the sealing edge of the packaging bag is obtained by comparing the collected bag inspection image with the standard image.
- the packaging bag is judged whether the packaging bag exceeds the threshold value of qualified products. If not, the packaging bag is qualified; if it is, the packaging bag is unqualified and rejected.
- the offset of the sealing edge of the packaging bag is obtained through the following steps:
- the offset of the edge sealing in the preset direction is calculated by the distance represented by each pixel and the number of offset pixels.
- the offset of the edge sealing of the packaging bag in the preset direction includes the offset of the bottom edge sealing or the offset of the left and right edge sealing.
- the offset is transmitted to an adjustment device for adjusting the position of the packaging bag on the production line, and the position of the packaging bag on the production line is adjusted according to the offset.
- the offset of the bottom edge seal is transmitted to the front and rear adjustment device for adjusting the front and rear position of the packaging bag, and the front and rear positions of the packaging bag on the production line are adjusted according to the offset of the bottom edge seal; or
- the left and right edge sealing offsets are transmitted to the left and right adjusting device for adjusting the left and right positions of the packaging bags, and the left and right positions of the packaging bags on the production line are adjusted according to the left and right edge sealing offsets.
- the present invention also provides an automatic detection system for large and small side defects of packaging bags, comprising a trigger signal generating unit-production line motion sensor, a detection image acquisition unit and a large and small side offset detection device;
- the trigger signal generating unit is used for acquiring the static state signal of the packaging bag that triggers the acquisition of the detection image of the packaging bag;
- the detection image acquisition unit is used to acquire the detection image of the packaging bag under the triggering control of the static state signal of the packaging bag;
- the large and small edge offset detection device is used to obtain the offset of the edge sealing of the packaging bag by comparing the collected detection image of the packaging bag with the standard image.
- the rejecting device also includes a rejecting device; the rejecting device is connected in communication with the large and small side offset detection device, and the large and small side offset detection device obtains the rejection of unqualified products according to the comparison between the offset of the packaging bag and the threshold value of qualified products signal, the rejection signal drives the rejection device to reject the corresponding unqualified products.
- the large and small edge offset detection device is provided with a packaging bag edge sealing offset generation unit, and the packaging bag edge sealing offset generation unit obtains the position of the packaging bag in a preset direction by comparing the current detection image and the standard image. offset.
- the offset of the edge sealing of the packaging bag in the preset direction includes the offset of the bottom edge sealing or the offset of the left and right edge sealing.
- the packaging bag position adjustment device is arranged on the production line, the packaging bag position adjustment device is in communication connection with the large and small side offset detection device, and receives the large and small side offset detection device. Send the offset, and adjust the position of the bag on the production line according to the offset.
- the packaging bag position adjustment device is a left-right adjustment device, the left-right adjustment device is arranged on the production line, and the left-right adjustment device is connected in communication with the large and small side offset detection device, and receives the large and small side offset detection device. Sent offset, and adjust the left and right position of the bag on the production line according to the offset; or
- the packaging bag position adjustment device is a front-rear adjustment device, the front-rear adjustment device is arranged on the production line, the front-rear adjustment device is in communication connection with the large and small side offset detection device, and receives the data sent by the large and small side offset detection device. Offset, and adjust the front and rear position of the packaging bag on the production line according to the offset.
- a detection result display device is also included, and the detection result display device is communicatively connected with the large and small side offset detection device, and is used for outputting and displaying the offset of the sealing edge of the packaging bag.
- the automatic detection system for the size and edge defects of the packaging bag detects the front and rear and left and right deviation values of the front and back sides (or single side) of the packaging bag on the packaging bag production line through a visual camera, and adjusts the front and rear adjustment device or the left and right adjustment according to the detection result.
- the device is used to adjust the front and rear or left and right positions of the packaging bags on the production line to achieve the effect of correcting the position deviation of the packaging bags on the production line.
- the adjustment goal is to minimize the front and rear and left and right deviations of each packaging bag. According to the test results, it is judged whether the packaging bag has an abnormal size edge and becomes a defective product.
- the specific method is to compare the preset threshold value in this direction.
- the deviation exceeds the preset threshold value in this direction, it is considered that the size edge abnormality occurs and becomes a secondary product.
- the information of unqualified products will be sent to the rejection device of the production line, which will send an alarm signal and automatically reject the unqualified packaging bags.
- the detection of big and small sides includes front and rear and left and right directions. No matter which direction the deviation is too large, it will lead to abnormal big and small sides. If the deviation in a certain direction exceeds the maximum allowable deviation in this direction, the packaging bag is considered to be a defective product.
- Figure 1 is the flow chart of the automatic detection method for the size and edge defects of the packaging bag
- Figure 2 is the structure diagram of the automatic detection system for large and small edge defects of packaging bags.
- Figure 3 is a standard unbiased image acquired.
- Figure 4 is a detection image of the backward displacement of the packaging bag.
- Figure 5 is an inspection image of the bag being shifted backwards and forwards at the same time.
- Figure 6 is a detection image of the forward displacement of the packaging bag.
- Fig. 7 is a detection image with a shift to the front and the right at the same time.
- Fig. 8 is a detected image shifted to the right.
- FIG. 9 is a detected image shifted to the left.
- FIG. 10 is a comparison effect diagram of detecting image shift by moving forward.
- trigger signal generation unit 1 detection image acquisition unit, installation device 3 , large and small side offset detection device 4 , detection result display device 5 , left and right adjustment device 6 , and rejection device 7 .
- the automatic detection method for the size and edge defects of packaging bags includes the following steps:
- the static state signal of the packaging bag is sent to the packaging bag detection image acquisition device as a trigger signal; the packaging bag detection image acquisition device is started to operate, thereby obtaining the packaging bag Detect images.
- the static state signal (ie trigger signal) of the packaging bag described in this embodiment is the running state signal of the production line obtained by a photoelectric proximity switch sensor, a laser beam sensor or a laser range finder. Since each packaging bag needs to be divided by a cutter at the end of the production line, when the cutter falls, the packaging bags on the production line near the cutter are in a relatively static state, and the production line running sensor detects the falling of the cutter directly or indirectly. The signal obtains the trigger signal of the camera.
- the packaging bag detection image acquisition device provided in this embodiment adopts an industrial camera disposed on the production line, and the detection image is obtained by taking pictures of the industrial camera.
- Detecting image requirements When there is a shift in front and rear or left and right, the image photographing area can clearly reflect this change.
- Qualified images are: the text pattern or irregular pattern in the middle of the photographing area, the pattern background color is single or other regular colors that are easy to distinguish from the pattern.
- Unqualified examples are: there is no obvious pattern in the image area, the pattern is a straight line or rectangular area in the front and rear or left and right directions, the background color of the image is disordered, and the pattern is located at the edge of the image, etc.
- Figure 3 is a standard non-offset image collected. This image can be stored as a template image, and then the inspection images collected during the production process of the packaging bag are compared and processed, as shown in Figure 4 , Figure 4 is the detection image of the packaging bag shifting backward; Figure 6 is the detection image that the packaging bag is shifting forward; Figure 5 is the detection image that the packaging bag is offset backward and forward at the same time; from Figure 4 From -6, it can be seen that after comparing with the template image, it is obvious that the offset amount of the forward and backward offset of the packaging bag can be obtained, so as to obtain the adjustment amount that needs to adjust the front and rear offset position of the packaging bag.
- Figure 7 is the detection image that shifts forward and to the right at the same time
- Figure 8 is the detection image that shifts to the right
- Figure 9 is the detection image that shifts to the left.
- the collected packaging bag detection image is transmitted to the size edge offset detection device; the position offset of the packaging bag on the production line is obtained through the size edge offset detection device, and the position offset includes the bottom edge sealing Offset and left and right edge sealing offset; in this embodiment, the bottom edge sealing offset and the left and right edge sealing offset are obtained by comparing the detection image of the packaging bag with the standard image.
- the specific process is as follows:
- the comparison method provided in this embodiment is to obtain the pixel value of the deviation after moving the standard picture and compare it with the deviation picture, and then convert it into an offset distance. This method has a fast processing speed and a better effect.
- Figure 10 is a comparison effect diagram of detecting image offset by moving forward.
- moving forward the difference between the number of rows and the gray value matrix of the standard image, in the figure, it means that the standard image is moved forward by 10 rows.
- the stored image template is obtained in the following way: after the production line is debugged, the operator manually judges that the offset of the bottom edge sealing and the left and right edge sealing of the current packaging bag are within the preset threshold range. When it is less than the preset threshold, it can be stored in the template library as a standard image.
- the packaging bag exceeds the threshold value of qualified products. If not, the packaging bag is a qualified product;
- the non-conforming product detection signal is sent to the rejection device, and the non-conforming product is rejected.
- the automatic detection of the size and edge defects of the packaging bag provided by this embodiment can not only detect the single side of the packaging bag, but also detect both sides of the packaging bag at the same time, and each detection surface of the packaging bag can set a threshold value for qualified products respectively. , that is, four threshold values of front and rear and left and right. At the same time, the specific setting of the threshold value can be determined according to the requirements of different packaging bag products.
- the offset of the bottom edge sealing is transmitted to the front and rear adjustment device, and the position of the packaging bag on the production line is adjusted according to the front and rear offset through the front and rear adjustment device;
- the left and right adjustment device adjusts the position of the packaging bag on the production line according to the left and right offset;
- the detected offset of the edge sealing of the packaging bag is output through the display device.
- the automatic detection system for large and small side defects of packaging bags includes a trigger signal generation unit, a detection image acquisition unit, an installation device, a large and small side offset detection device, a detection result display device, and a front and rear adjustment device. , Left and right adjustment device, rejection device;
- the cover defect detection device is arranged on one side of the rack, and is connected to the cover image acquisition unit in a wired or wireless manner.
- the cover image acquisition unit is arranged on the rack through the installation device, and the trigger signal generation unit is arranged on the machine.
- the position on the rack is suitable for judging the movement state of the packaging bag on the rack, the trigger signal generating unit sends the generated signal to the cover image acquisition unit;
- the cover defect detection device sends the detection result to the detection result display device, the
- the detection result display device is arranged on one side of the rack or other positions that are easy to observe;
- the rejecting device is arranged on the rack and is located at the rear end of the cover image acquisition unit, so as to be suitable for the packaging of defective products after the cover image acquisition unit has been acquired
- the bag is removed; the front and rear adjustment devices or the left and right adjustment devices are respectively arranged on the frame, and realize the adjustment of the position of the packaging bag in the left and right directions and the front and rear directions.
- the trigger signal generation unit is used to obtain a trigger signal that triggers the collection of the detection image of the packaging bag, and the trigger signal can be preset as a specific state during the operation of the production line; this state is conducive to collecting the best detection image of the packaging bag,
- the specific state set in this embodiment is a short-term state in which the cutter set on the production line for cutting the packaging bag just cuts the packaging bag, and the packaging bag is in a stationary state during the period from the drop of the cutter to the completion of the cutting , the detection image of the packaging bag collected during this static time has the best effect. Of course, it can also be judged according to the actual situation. Make the detection image captured just when the packaging bag is in a stationary state.
- This embodiment avoids collecting inspection images during the movement of the packaging bag, because the quality of the images collected during the fast moving speed of the packaging bag is poor, or the collected inspection images cannot be accurately positioned, resulting in deformation of the collected packaging bag.
- the detection trigger signal in this embodiment is an operation state signal of the production line obtained by a photoelectric proximity switch sensor, a laser beam sensor, or a laser range finder or the like. Set the photoelectric proximity switch sensor at the position close to the cutter, and set the photoelectric proximity switch sensor at the position suitable for installation on the production line through the fixing device.
- the detection image acquisition unit is used to collect a preset image area on the packaging bag, the preset image area is photographed by a camera, which can easily identify the position of the packaging bag, so as to analyze whether the position of the packaging bag has changed;
- the camera of the example can be an industrial camera.
- the industrial camera is installed on the production line through the installation device, and the installation device can adjust the installation position of the camera, so that the camera can be conveniently fixed on the production line where the inspection image needs to be collected.
- Detecting image requirements When there is a shift in front and rear or left and right, the image photographing area can clearly reflect this change.
- Qualified images are: the text pattern or irregular pattern in the middle of the photographing area, the pattern background color is single or other regular colors that are easy to distinguish from the pattern.
- Unqualified examples are: there is no obvious pattern in the image area, the pattern is a straight line or rectangular area in the front and rear or left and right directions, the background color of the image is disordered, and the pattern is located at the edge of the image, etc.
- the large and small edge offset detection device is used to obtain the position offset of the packaging bag on the production line; the position offset includes the offset of the bottom edge sealing and the offset of the left and right edge sealing;
- the large and small edge offset detection device receives the detection image of the packaging bag, and obtains the offset of the bottom edge sealing and the offset of the left and right edge sealing respectively by comparing the detection image of the packaging bag with the standard image;
- the stored image template is obtained in the following way: after the production line is debugged, the operator manually judges that the offset of the bottom edge sealing and the left and right edge sealing of the current packaging bag are within the preset threshold range. When it is less than the preset threshold, it can be stored in the template library as a standard image. According to the offset of bottom edge sealing and the offset of left and right edge sealing, it is judged whether the packaging bag exceeds the threshold value of qualified products. If not, the packaging bag is qualified; The product detection signal is sent to the rejecting device, and the defective product is rejected.
- the large and small side offset detection device is a processor that stores the detection image analysis of the packaging bag, and can use a general computer system, a notebook computer or other intelligent devices and devices capable of digital image processing.
- the automatic detection of the size and edge defects of the packaging bag provided by this embodiment can not only detect the single side of the packaging bag, but also detect both sides of the packaging bag at the same time, and each detection surface of the packaging bag can set a threshold value for qualified products respectively. , that is, four threshold values of front and rear and left and right. At the same time, the specific setting of the threshold value can be determined according to the requirements of different packaging bag products.
- the detection result display device is used to output and display the offset of the edge sealing of the packaging bag;
- the sealing edge of the packaging bag in this embodiment includes left and right edge sealing and bottom edge sealing;
- the front and rear adjustment device adjusts the front and rear positions of the packaging bag on the production line by the received offset of the bottom edge sealing
- the left and right adjustment device adjusts the left and right positions of the packaging bag on the production line by receiving the offset of the left and right edge sealing;
- This embodiment provides a front-rear adjustment device and a left-right adjustment device, which can use a deviation correction system for adjusting the position in the mechanical device, and adjust the deflection angle through the deviation correction guide roller and the reference guide roller in the deviation correction system.
- the front and rear adjustment devices are not marked in the figure.
- the rejecting device is used to receive the detection signal of unqualified products that exceeds the threshold value of qualified products sent by the large and small side offset detection device;
- the rejection device provided in this embodiment includes a transmission mechanism, a rejection channel, and a rejection mechanism.
- the rejection passage includes a gap on the transmission mechanism.
- the rejection mechanism is located above the rejection passage. After the rejection mechanism receives the rejection signal, the packaging bag is rejected from the rejection passage downward.
- the rejecting mechanism includes a pressing module and/or a guiding module. When the rejecting mechanism receives the rejecting signal, the rejecting mechanism extends downward, the guiding module guides the packaging bag to the rejecting channel, and the pressing module presses down the packaging bag toward the rejecting channel. .
- a suitable rejecting device can also be selected according to the actual situation, for example, the application number is CN201920918097.2, and the name is the rejecting device described in a mechanical defective rejecting device for sheet materials.
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Abstract
一种包装袋大小边缺陷自动检测方法及系统，首先获取用于触发采集包装袋检测图像的包装袋静止状态信号；然后通过得到的包装袋静止状态信号触发包装袋检测图像采集装置；通过包装袋检测图像采集装置获取包装袋检测图像；最后通过对比采集到的包装袋检测图像与标准图像来获取包装袋封边的偏移量。该方法通过视觉相机检测包装袋生产线上包装袋正反双面(或单面)的前后和左右偏差值，根据检测结果通过前后调节装置或者左右调节装置来调整生产线上包装袋的前后或左右位置，达到纠正包装袋在生产线上位置偏差的效果，调整目标是使得每一个包装袋的前后和左右偏差达到最小。
Description
本发明涉及包装设备领域，特别涉及一种包装袋大小边缺陷自动检测系统及方法。
包装袋在我们的生活中随处可见，现有的包装袋生产流程包括在薄膜上印刷图案，得到包装袋印刷膜，然后将成卷的包装袋印刷膜置于制袋机上，放卷加工包装袋，在包装袋的印刷过程中，需要对包装袋进行封边处理，但是，在加工过程中，往往会出现包装袋左右两边的封边宽度不一样，出现大小边的现象，从而造成次品包装袋。
目前，包装袋封边大小是否符合生产要求通常是通过人工来检测，这样检测效率低，且容易出现漏检、误检等现象，因此需要一种能自动且高速检测包装袋分别大小是否符合生产要求的设备。
发明内容
有鉴于此，本发明的目的在于提供一种包装袋大小边缺陷自动检测系统及方法，该系统自动化程度高、操作容易、方便高效且功能可靠。
为达到上述目的，本发明提供如下技术方案：
本发明提供的一种包装袋大小边缺陷自动检测方法，包括以下步骤：
获取用于触发采集包装袋检测图像的包装袋静止状态信号；
通过得到的包装袋静止状态信号触发包装袋检测图像采集装置；
通过包装袋检测图像采集装置获取包装袋检测图像；
通过对比采集到的包装袋检测图像与标准图像来获取包装袋封边的偏移量。
进一步，还包括以下步骤：
根据封边偏移量判断包装袋是否超过合格品门限值，如果否，则包装袋为合格品；如果是，则包装袋为不合格品并剔除。
进一步，所述包装袋封边的偏移量是通过以下步骤获取：
获取标准图像，并标定标准图像中每个像素所代表的距离；
通过对比当前检测图像与标准图像得到在预设方向上的偏移像素数；
通过每个像素所代表的距离和偏移像素数计算得到封边在预设方向上的偏移量。
进一步，所述包装袋封边在预设方向上的偏移量包括底部封边偏移量或左右封边偏移量。
进一步，还包括以下步骤：
将所述偏移量传送到用于调节包装袋在生产线上位置的调节装置中，并根据偏移量调节包装袋在生产线上的位置。
进一步，还包括以下步骤：
将所述底部封边偏移量传送到用于调节包装袋前后位置的前后调节装置中，并根据底部封边偏移量调节包装袋在生产线上的前后位置；或
将所述左右封边偏移量传送到用于调节包装袋左右位置的左右调节装置中，并根据左右封边偏移量调节包装袋在生产线上的左右位置。
本发明还提供了一种包装袋大小边缺陷自动检测系统，包括触发信号生成单元-生产线运动传感器、检测图像采集单元和大小边偏移量检测装置；
所述触发信号生成单元，用于获取触发采集包装袋检测图像的包装袋静止状态信号；
所述检测图像采集单元，用于在包装袋静止状态信号触发控制作用下采集包装袋检测图像；
所述大小边偏移量检测装置，用于通过对比采集到的包装袋检测图像与标准图像来获取包装袋封边的偏移量。
进一步，还包括剔除装置；所述剔除装置与大小边偏移量检测装置通信连接，所述大小边偏移量检测装置根据包装袋偏移量与合格品门限值比较得到不合格品的剔除信号，所述剔除信号驱动剔除装置剔除对应的不合格品。
进一步，所述大小边偏移量检测装置设置有包装袋封边偏移量生成单元，所述包装袋封边偏移量生成单元通过对比当前检测图像与标准图像得到包装袋在预设方向上的偏移量。
进一步，所述包装袋封边在预设方向上的偏移量包括底部封边偏移量或左右封边偏移量。
进一步，还包括包装袋位置调节装置，所述包装袋位置调节装置设置于生产线上，所述包装袋位置调节装置与大小边偏移量检测装置通信连接，接收所述大小边偏移量检测装置发送的偏移量，并根据偏移量调节包装袋在生产线上的位置。
进一步，所述包装袋位置调节装置为左右调节装置，所述左右调节装置设置于生产线上， 所述左右调节装置与大小边偏移量检测装置通信连接，接收所述大小边偏移量检测装置发送的偏移量，并根据偏移量调节包装袋在生产线上的左右位置；或
所述包装袋位置调节装置为前后调节装置，所述前后调节装置设置于生产线上，所述前后调节装置与大小边偏移量检测装置通信连接，接收所述大小边偏移量检测装置发送的偏移量，并根据偏移量调节包装袋在生产线上的前后位置。
进一步，还包括检测结果显示装置，所述检测结果显示装置与大小边偏移量检测装置通信连接，用于输出和显示包装袋封边的偏移量。
本发明的有益效果在于：
本发明提供的包装袋大小边缺陷自动检测系统，通过视觉相机检测包装袋生产线上的包装袋正反双面(或单面)的前后和左右偏差值，根据检测结果通过前后调节装置或者左右调节装置来调整生产线上包装袋的前后或左右位置，达到纠正包装袋在生产线上位置偏差的效果，调整目标是使的每一个包装袋的前后和左右偏差达到最小。根据检测结果判断包装袋是否出现大小边异常并成为次品，具体办法为该方向预设的门限值进行比较，一般偏差超过该方向的预设门限值则认为出现大小边异常并成为次品，此时会把不合格品信息发送给生产线的剔除装置，该装置会发出报警信号并自动剔除不合格包装袋。
大小边检测包括前后和左右两个方向，无论哪一个方向的偏差过大都会导致出现大小边异常，前后左右的最大允许偏差可以分别设置，反正面的最大允许偏差也可以分别设置。如果某一个方向的偏差超过该方向的最大允许偏差，则认为包装袋成为次品。
本发明的其他优点、目标和特征在某种程度上将在随后的说明书中进行阐述，并且在某种程度上，基于对下文的考察研究对本领域技术人员而言将是显而易见的，或者可以从本发明的实践中得到教导。本发明的目标和其他优点可以通过下面的说明书来实现和获得。
为了使本发明的目的、技术方案和有益效果更加清楚，本发明提供如下附图进行说明：
图1为包装袋大小边缺陷自动检测方法流程图
图2为包装袋大小边缺陷自动检测系统结构图。
图3为采集到的标准无偏移的图像。
图4为包装袋向后发生偏移的检测图像。
图5为包装袋同时向后和向前发生偏移的检测图像。
图6为包装袋向前发生偏移的检测图像。
图7为向前和向右同时发生偏移的检测图像。
图8为向右发生偏移的检测图像。
图9为向左发生偏移的检测图像。
图10为向前移动方式检测图像偏移的对比效果图。
标记说明：触发信号生成单元1，检测图像采集单元、安装装置3、大小边偏移量检测装置4、检测结果显示装置5、左右调节装置6、剔除装置7。
下面结合附图和具体实施例对本发明作进一步说明，以使本领域的技术人员可以更好的理解本发明并能予以实施，但所举实施例不作为对本发明的限定。
如图1所示，本实施例提供的包装袋大小边缺陷自动检测方法，包括以下步骤：
首先获取生产线上用于触发采集包装袋检测图像的包装袋静止状态信号；
当设置于生产线上的传感器检测到包装袋静止状态信号时，将该包装袋静止状态信号作为触发信号发送到包装袋检测图像采集装置中；启动该包装袋检测图像采集装置运行，从而获取包装袋检测图像。
本实施例所述的包装袋静止状态信号(即触发信号)是通过光电接近开关传感器、激光对射传感器或者激光测距仪等获取的生产线的运行状态信号。由于每一个包装袋在生产线终点都需要使用切刀进行分割，在切刀下落时，切刀附近生产线上的包装袋处于相对静止状态，生产线运行传感器通过直接或间接的方式检测这个切刀下落的信号获得相机的触发信号。
本实施例提供的包装袋检测图像采集装置采用设置于生产线上的工业相机，通过工业相机拍照获取检测图像。
检测图像要求：无论是前后还是左右发生偏移时，图像拍照区域能够明显的反映出这种变化。合格图像为：拍照区域中间文字图案或者不规则图案，图案背景颜色单一或者其他容易与图案区分的规则颜色。不合格的例子为：图像区域无明显图案、图案为前后或者左右方向的直线或者矩形区域、图像背景颜色混乱、图案位于图像的边缘位置等。
如图3所示，图3为采集到的标准无偏移的图像，可以将此图像存储作为模板图像，然后将在包装袋生产过程中采集到的检测图像进行对比处理，如图4所示，图4为包装袋向后发生偏移的检测图像；图6为包装袋向前发生偏移的检测图像；图5为包装袋同时向后和向 前发生偏移的检测图像；从图4-6中可以看出经过与模板图像的对比，明显可以得出包装袋向前和向后偏移的偏移量，从而得到需要调整包装袋前后偏移位置的调整量。
同理，图7为向前和向右同时发生偏移的检测图像，图8为向右发生偏移的检测图像，图9为向左发生偏移的检测图像，通过与模板图像进行对比，可以得到包装袋左右偏移或左右同时向前后发生偏移时的偏移量，从而得到需要调整包装袋左右或同时前后偏移位置的调整量。
其次，将采集到的包装袋检测图像传送到大小边偏移量检测装置；通过大小边偏移量检测装置得到包装袋在生产线上的位置偏移量，所述位置偏移量包括底部封边偏移量和左右封边偏移量；本实施例通过对比包装袋检测图像与标准图像来分别得到底部封边偏移量和左右封边偏移量，具体过程如下：
将获取的标准图像存储为图像模板，通过实验标定每个像素代表的距离大小，dx，通过模板匹配算法计算出当前检测图像与标准图像在前后和左右方向的偏移像素个数，分别记为前后偏移像素个数n1和左右偏移像素个数n2，需要注意的是，这个像素个数是个矢量，有正负方向，具体定义为前正后负，左正右负，例如n1＝3表示前向偏移3个像素，n1＝-4表示后向偏移4个像素；然后用n1*dx得到底部封边偏移量，n2*dx得到左右封边偏移量。
本实施例提供的对比方法是通过移动标准图片后与偏差图片进行对比后得到偏差的像素值，然后换算成偏移距离，该方法处理速度快，效果更佳。
如图10所示，图10为向前移动方式检测图像偏移的对比效果图，通过前移不同行数与标准图片灰度值矩阵差值，图中，分别表示标准图片向前移动10行、30行、50行、70行、90行、110行、130行、150行、170行；然后再与采集到的检测图像进行对比后，得到的效果图，当标准图片和检测图像能够完全抵消时，其效果图是所有像素完全抵消，形成一张黑色的图片。
存储的图像模板按照以下方式得到：当生产线调试好后，由操作工人人工判断目前包装袋的底部封边偏移量和左右封边偏移量都处于预设阈值范围内，如果偏移量均小于该预设阈值时即可作为标准图像存储于模板库中。
然后，根据底部封边偏移量和左右封边偏移量判断包装袋是否超过合格品门限值，如果否，则包装袋为合格品；如果是，则生成不合格品检测信号；并将不合格品检测信号发送给剔除装置，且剔除不合格品。
本实施例提供的包装袋大小边缺陷自动检测不仅可以对包装袋的单面进行检测，也可以 对包装袋的双面同时进行检测，包装袋的每个检测面可以分别设置合格品门限值，即前后和左右四个门限值，同时，门限值具体设置时可以根据不同的包装袋产品的要求进行确定。
最后，将底部封边偏移量传送到前后调节装置中，通过前后调节装置按照前后偏移量来调节包装袋在生产线上的位置；将左右封边偏移量传送到左右调节装置中，通过左右调节装置按照左右偏移量来调节包装袋在生产线上的位置；
同时，通过显示装置输出检测得到的包装袋封边偏移量。
实施例2
如图2所示，本实施例提供的包装袋大小边缺陷自动检测系统，包括触发信号生成单元，检测图像采集单元、安装装置、大小边偏移量检测装置、检测结果显示装置、前后调节装置、左右调节装置、剔除装置；
所述封面缺陷检测装置设置于机架一侧，通过有线或无线的方式分别封面图像采集单元连接，所述封面图像采集单元通过安装装置设置于机架上，所述触发信号生成单元设置于机架上适于判断机架上包装袋运动状态的位置，所述触发信号生成单元将生成的信号发送到封面图像采集单元；所述封面缺陷检测装置将检测结果发送到检测结果显示装置，所述检测结果显示装置设置于机架一侧或其他便于观察的位置；所述剔除装置设置于机架上位于封面图像采集单元的后端，以适于将封面图像采集单元采集后属于次品的包装袋进行剔除操作；所述前后调节装置或左右调节装置分别设置于机架上，并实现对传输中的包装袋的位置进行左右方向和前后方向的调整。
所述触发信号生成单元，用于获取触发采集包装袋检测图像的触发信号，该触发信号可以预先设置为生产线在运行过程中的特定状态；该状态有利于采集到最佳的包装袋检测图像，本实施例设置的特定状态是设置在生产线上的用于切割包装袋的切刀刚好切割包装袋的短暂状态，从切刀下落到切割完成这一段时间，在该时间内包装袋是处于静止状态，在这一静止时间内采集到包装袋检测图像效果最佳，当然也可以根据实际情况来进行判断，如可根据生产线上其他部位运动状态与切刀的运动状态一致或相反来进行判断，从而使得刚好在包装袋处于静止状态时采集到的检测图像。
本实施例避免在包装袋运动过程中采集检测图像，因为在包装袋快速运动速度过程中采集的图像质量较差，或在无法准确定位采集检测图像，导致采集到的包装袋会发生变形。
本实施例所述的检测触发信号是通过光电接近开关传感器、激光对射传感器或者激光测距仪等获取的生产线的运行状态信号。将光电接近开关传感器设置于靠近切刀的位置，通过 固定装置将光电接近开关传感器设置于生产线适合安装的位置。
所述检测图像采集单元、用于采集包装袋上预设图像区域，该预设图像区域被相机拍摄，能够便于识别出包装袋位置，从而分析出包装袋所处的位置是否发生变化；本实施例的相机可以采用工业相机，通过安装装置将工业相机设置于生产线上，安装装置可以调节相机的安装位置，使得能够方便地将相机固定于生产线上需要采集检测图像的位置。
检测图像要求：无论是前后还是左右发生偏移时，图像拍照区域能够明显的反映出这种变化。合格图像为：拍照区域中间文字图案或者不规则图案，图案背景颜色单一或者其他容易与图案区分的规则颜色。不合格的例子为：图像区域无明显图案、图案为前后或者左右方向的直线或者矩形区域、图像背景颜色混乱、图案位于图像的边缘位置等。
所述大小边偏移量检测装置，用于得到包装袋在生产线上的位置偏移量；所述位置偏移量包括底部封边偏移量和左右封边偏移量；
所述大小边偏移量检测装置接收包装袋检测图像，通过对比包装袋检测图像与标准图像来分别得到底部封边偏移量和左右封边偏移量；
本实施例具体过程如下：
将获取的标准图像存储为图像模板，通过实验标定每个像素代表的距离大小，dx，通过模板匹配算法计算出当前检测图像与标准图像在前后和左右方向的偏移像素个数，分别记为前后偏移像素个数n1和左右偏移像素个数n2，需要注意的是，这个像素个数是个矢量，有正负方向，具体定义为前正后负，左正右负，例如n1＝3表示前向偏移3个像素，n1＝-4表示后向偏移4个像素；然后用n1*dx得到底部封边偏移量，n2*dx得到左右封边偏移量。
存储的图像模板按照以下方式得到：当生产线调试好后，由操作工人人工判断目前包装袋的底部封边偏移量和左右封边偏移量都处于预设阈值范围内，如果偏移量均小于该预设阈值时即可作为标准图像存储于模板库中。根据底部封边偏移量和左右封边偏移量判断包装袋是否超过合格品门限值，如果否，则包装袋为合格品；如果是，则生成不合格品检测信号；并将不合格品检测信号发送给剔除装置，且剔除不合格品。
本实施例提供的大小边偏移量检测装置是存储有包装袋检测图像分析的处理器，可以采用通用的计算机系统，笔记本电脑或其他能进行数字图像处理的智能化设备和装置。
本实施例提供的包装袋大小边缺陷自动检测不仅可以对包装袋的单面进行检测，也可以对包装袋的双面同时进行检测，包装袋的每个检测面可以分别设置合格品门限值，即前后和左右四个门限值，同时，门限值具体设置时可以根据不同的包装袋产品的要求进行确定。
所述检测结果显示装置，用于输出和显示包装袋封边的偏移量；本实施例包装袋的封边包括左右封边和底部封边；通过对比检测图像与标准图像得到位于生产线上的包装袋位置偏移量；
所述前后调节装置，通过接收到的底部封边偏移量来调节包装袋在生产线上的前后位置；
所述左右调节装置，通过接收左右封边偏移量来调节包装袋在生产线上的左右位置；
本实施例提供前后调节装置和左右调节装置可以采用用于机械装置中调节位置的纠偏系统，通过纠偏系统中的纠偏导辊与基准导辊来调节偏转角度。其中，前后调节装置未在图中标注。
所述剔除装置，用于接收大小边偏移量检测装置发送的超过合格品门限值的不合格品检测信号；并根据不合格品检测信号来启动剔除装置将不合格的包装袋剔除。
本实施例提供的剔除装置包括传输机构、剔除通道和剔除机构，剔除通道包括传输机构上的空隙，剔除机构位于剔除通道上方，剔除机构接到剔除信号后将包装袋从剔除通道向下剔除。所述剔除机构包括下压模块和/或导向模块，当剔除机构接到剔除信号后，剔除机构向下伸出，导向模块将包装袋导向至剔除通道，下压模块朝向剔除通道下压包装袋。
同时，也可以根据实际情况选择合适的剔除装置，如申请号为CN201920918097.2，名称为一种用于片状物料的机械式次品剔除装置中说记载的剔除装置。
以上所述实施例仅是为充分说明本发明而所举的较佳的实施例，本发明的保护范围不限于此。本技术领域的技术人员在本发明基础上所作的等同替代或变换，均在本发明的保护范围之内。本发明的保护范围以权利要求书为准。
Claims (13)
- 包装袋大小边缺陷自动检测方法，其特征在于：包括以下步骤：获取用于触发采集包装袋检测图像的包装袋静止状态信号；通过得到的包装袋静止状态信号触发包装袋检测图像采集装置；通过包装袋检测图像采集装置获取包装袋检测图像；通过对比采集到的包装袋检测图像与标准图像来获取包装袋封边的偏移量。
- 如权利要求1所述的方法，其特征在于：还包括以下步骤：根据封边偏移量判断包装袋是否超过合格品门限值，如果否，则包装袋为合格品；如果是，则包装袋为不合格品并剔除。
- 如权利要求1所述的方法，其特征在于：所述包装袋封边的偏移量是通过以下步骤获取：获取标准图像，并标定标准图像中每个像素所代表的距离；通过对比当前检测图像与标准图像得到在预设方向上的偏移像素数；通过每个像素所代表的距离和偏移像素数计算得到封边在预设方向上的偏移量。
- 如权利要求1所述的方法，其特征在于：所述包装袋封边在预设方向上的偏移量包括底部封边偏移量或左右封边偏移量。
- 如权利要求1所述的方法，其特征在于：还包括以下步骤：将所述偏移量传送到用于调节包装袋在生产线上位置的调节装置中，并根据偏移量调节包装袋在生产线上的位置。
- 如权利要求4所述的方法，其特征在于：还包括以下步骤：将所述底部封边偏移量传送到用于调节包装袋前后位置的前后调节装置中，并根据底部封边偏移量调节包装袋在生产线上的前后位置；或将所述左右封边偏移量传送到用于调节包装袋左右位置的左右调节装置中，并根据左右封边偏移量调节包装袋在生产线上的左右位置。
- 包装袋大小边缺陷自动检测系统，其特征在于：包括触发信号生成单元(1)、检测图像采集单元(2)和大小边偏移量检测装置(4)；所述触发信号生成单元(1)，用于获取触发采集包装袋检测图像的包装袋静止状态信号；所述检测图像采集单元(2)，用于在包装袋静止状态信号触发控制作用下采集包装袋检测图像；所述大小边偏移量检测装置(4)，用于通过对比采集到的包装袋检测图像与标准图像来获取包装袋封边的偏移量。
- 如权利要求7所述的系统，其特征在于：还包括剔除装置(8)；所述剔除装置与大小边偏移量检测装置(4)通信连接，所述大小边偏移量检测装置(4)根据包装袋偏移量与合格品门限值比较得到不合格品的剔除信号，所述剔除信号驱动剔除装置剔除对应的不合格品。
- 如权利要求7所述的系统，其特征在于：所述大小边偏移量检测装置(4)设置有包装袋封边偏移量生成单元，所述包装袋封边偏移量生成单元通过对比当前检测图像与标准图像得到包装袋在预设方向上的偏移量。
- 如权利要求9所述的系统，其特征在于：所述包装袋封边在预设方向上的偏移量包括底部封边偏移量或左右封边偏移量。
- 如权利要求7所述的系统，其特征在于：还包括包装袋位置调节装置，所述包装袋位置调节装置设置于生产线上，所述包装袋位置调节装置与大小边偏移量检测装置通信连接，接收所述大小边偏移量检测装置发送的偏移量，并根据偏移量调节包装袋在生产线上的位置。
- 如权利要求11所述的系统，其特征在于：所述包装袋位置调节装置为左右调节装置(7)，所述左右调节装置设置于生产线上，所述左右调节装置与大小边偏移量检测装置通信连接，接收所述大小边偏移量检测装置发送的偏移量，并根据偏移量调节包装袋在生产线上的左右位置；或所述包装袋位置调节装置为前后调节装置(6)，所述前后调节装置设置于生产线上，所述前后调节装置与大小边偏移量检测装置通信连接，接收所述大小边偏移量检测装置发送的偏移量，并根据偏移量调节包装袋在生产线上的前后位置。
- 如权利要求7所述的系统，其特征在于：还包括检测结果显示装置(5)，所述检测结果显示装置(5)与大小边偏移量检测装置通信连接，用于输出和显示包装袋封边的偏移量。
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