CN113640310A - Tile surface defect detection visual system and detection method - Google Patents
Tile surface defect detection visual system and detection method Download PDFInfo
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- CN113640310A CN113640310A CN202111207379.XA CN202111207379A CN113640310A CN 113640310 A CN113640310 A CN 113640310A CN 202111207379 A CN202111207379 A CN 202111207379A CN 113640310 A CN113640310 A CN 113640310A
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- G01N21/88—Investigating the presence of flaws or contamination
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
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- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/8851—Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges
- G01N2021/8887—Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges based on image processing techniques
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Abstract
The invention provides a tile surface defect detection visual system, which comprises a conveyor assembly, a triggering photoelectric switch, an image acquisition unit, an image processing unit and a metering wheel triggering assembly, wherein the conveyor assembly is arranged on the front side of a tile; the conveyor assembly is a structural assembly for uninterruptedly conveying the ceramic tiles to be detected; the trigger photoelectric switch is fixedly arranged on one side of the conveyor component and is electrically connected with the image acquisition unit; the image acquisition unit comprises at least two groups of independent image acquisition assemblies, and each group of image acquisition assemblies is independently and electrically connected with the metering wheel trigger assembly and the image processing unit. The system also provides a detection method adopting the system, and the defect detection of different angles is carried out on the object to be detected by adopting a plurality of groups of imaging modes, so that not only is the complexity of the algorithm reduced, but also the stability of the system detection is enhanced due to the concave-convex imaging advantage of the low-angle camera, and the concave-convex defect does not need to be subjected to a large amount of background matching or AI model training work, so that the implementation period of the project is greatly shortened, and the system is suitable for the defect detection of complex background textures.
Description
Technical Field
The invention belongs to the technical field of detection methods and equipment for surface defects of ceramic tiles, and particularly relates to a visual system and a detection method for detecting the surface defects of the ceramic tiles.
Background
China is the first major country of ceramic product production, the manufacturing industry of accompaniers is improved in high quality level, the current ceramic product production line is basically transformed in an automatic mode, but the prior technical scheme has the following problems and restricts the improvement of the productivity and the utilization rate of the prior equipment: 1. the existing production line adopts a manual visual detection method, and the detection precision and the detection requirement consistency can not meet the requirement of quality improvement of a factory, so that the complaints of terminal customers are more; 2. the employment environment of a ceramic manufacturing plant is relatively poor, the labor intensity is high, the problems of personnel mobility and recruitment become the bottleneck of production capacity expansion, and ceramic production enterprises urgently need to carry out automatic modification on the existing quality inspection stations; 3. the method is limited by the reasons of complexity of the background of the ceramic tile and variety of the type of the ceramic tile, the algorithm complexity of the current technical means is high, the effect of practical application is poor, and the inspection requirements of manufacturers cannot be met temporarily.
In addition, other visual inspection methods are adopted on a part of production lines, but the visual inspection methods all adopt a group of single industrial cameras, a complete image of the object to be detected is obtained by means of positive shooting of the cameras, then the acquired image is analyzed in a color difference mode through an image processing unit, a defect area is preselected, and the preselected area is secondarily confirmed by combining secondary filtering (adopting shapes or other models), so that only obvious defect detection can be realized, as background textures of the ceramic tile are various and are limited by randomness of digital jet printing (jet printing deviation of a nozzle exceeds +/-1 mm), but the defect size required to be detected is about 0.3mm in self detection requirements, stable defect detection is difficult to realize in both precision and stability, the algorithm complexity of the method is high, and the processing time and the stability are not matched with the existing requirements, there are currently no ceramic tile surface defect detection systems available for implementation.
Disclosure of Invention
The technical scheme is as follows: in order to solve the above-mentioned existing technical problems, and the existing technical problems that only the image acquisition and imaging can be realized, the dependence on the algorithm is extremely high, the tile has various background patterns and various defect types, and the stable defect detection is difficult to realize, the invention provides a tile surface defect detection visual system, which specifically comprises:
the system comprises a conveyor component, a triggering photoelectric switch, an image acquisition unit, an image processing unit and a metering wheel triggering component; the conveyor assembly is a structural assembly for uninterruptedly conveying the ceramic tiles to be detected; the trigger photoelectric switch is fixedly arranged on one side of the conveyor component and is electrically connected with the image acquisition unit; the image acquisition unit comprises at least two groups of independent image acquisition assemblies, and each group of image acquisition assemblies is independently and electrically connected with the metering wheel trigger assembly and the image processing unit; the metering wheel trigger assembly is fixedly arranged on one side of the conveyor assembly.
As an improvement, the image acquisition unit comprises a first image acquisition component and a second image acquisition component; the first image acquisition assembly is used for shooting and acquiring a plane and color difference defect information image of a detection surface; and the second image acquisition assembly is used for shooting and acquiring concave-convex defect and size defect information images of the detection surface. The invention adopts a mode of combining multi-angle camera shooting, realizes the defects of plane chromatic aberration by adopting high angles, realizes the defects of concave-convex surface by adopting low angles, and effectively reduces the difficulty of algorithm realization and the system detection stability.
As an improvement, the first image acquisition assembly is fixedly arranged right above a conveying plane of the conveyor assembly; the included angle between the second image acquisition component and the surface of the ceramic tile to be detected is 1-65 degrees when the second image acquisition component shoots. According to the invention, the dark field/bright field shooting effect of the camera is realized by arranging the second image acquisition component as a low-angle camera and setting the angle between 1 and 65 degrees, so that the background is filtered in an imaging mode, the defect contrast is enhanced, the interference of the background on the detection system is reduced, and the application range of the system to different backgrounds is enhanced.
As an improvement, the device also comprises an upper computer, a marking component and a reminding component; the image acquisition unit acquires an image and transmits the image to the image processing unit; the image processing unit processes the image, the processed information comprises the information of detecting the plane, the chromatic aberration, the concave-convex defect and the size defect of the tile surface, and the processed information is transmitted to the upper computer; the upper computer displays the defect information mark and outputs the information to the marking and reminding component; the marking and reminding component sends out marking and reminding signals.
As an improvement, the first image acquisition assembly and the second image acquisition assembly are respectively and independently provided with a group of camera sets, and the light source adopts an independent or shared mode to acquire the image of the detected ceramic tile through the camera sets.
As an improvement, the image processing unit comprises an image extraction unit, an edge extraction unit, a defect classifier, a defect detection result storage unit and a grading comparison and result storage unit; the image extraction unit extracts data of the image acquired by the image acquisition unit and transmits the data to the edge extraction unit for image edge extraction; the edge extraction unit transmits the extracted data information including the data information of the plane, the chromatic aberration, the concave-convex defect and the size defect of the detected tile surface to a defect classifier; the defect classifier compares and classifies each group of defect data information including shape, size, chromatic aberration and concave-convex, and outputs the defect data information to the defect detection result storage unit according to the type required by the result; the defect detection result storage unit summarizes and stores the classified defect data and then outputs the data to the grading comparison and result storage unit; and the grading comparison and result storage unit is used for carrying out grading judgment and grading result storage on the defect information data and outputting the grading result.
Meanwhile, a method for detecting by adopting the system is also provided, and the specific steps are as follows:
conveying and detecting triggering of the tiles to be detected:
the method comprises the steps that a tile to be detected is conveyed and transported uninterruptedly through a conveyor assembly, when the tile is conveyed to a trigger photoelectric switch, the trigger photoelectric switch sends a trigger signal to an image acquisition unit to start to acquire a picture, the image acquisition unit starts to receive a pulse trigger signal of a metering wheel trigger assembly to shoot the tile to be detected, and shooting is stopped by limiting a preset shooting line number set value or triggering an end signal of the photoelectric switch, wherein the image acquisition unit comprises at least two groups of independent image acquisition assemblies which work independently;
(II) picture acquisition and imaging processing:
after each group of image acquisition assemblies shoots a picture, the acquired picture is transmitted to an image processing unit, an image extraction unit carries out data extraction on the acquired picture and transmits the extracted picture to an edge extraction unit, the edge extraction unit carries out picture edge extraction to obtain data information, and then the data information is transmitted to a defect classifier; the defect classifier is used for comparing and classifying the data information of each group of defects, which comprises the shape, the size, the concave-convex and the chromatic aberration, with preset defect information, and outputting the data information to a defect detection result storage unit according to the type required by the result; the defect detection result storage unit summarizes and stores the classified defect data and then outputs the data to the grading comparison and result storage unit; the grading comparison and result storage unit is used for carrying out grading judgment and grading result storage on the defect information data and outputting a grading result;
(III) quality grading and post-processing:
the method comprises the steps of determining defect information data, carrying out secondary filtration on suspected points, carrying out cross analysis on 2 groups of pictures obtained from different angles, eliminating misjudgment points, outputting a summary detection result, transmitting the result to an upper computer, carrying out grade division on the measured ceramic tiles by the upper computer through grading judgment and detection results and combining preset detection standards, wherein the grade comprises high grade, qualified, bad and waste products, displaying the result on a detection interface of the upper computer after the judgment is finished, and sending grading grade information to a marking and reminding component, so that automatic ceramic tile surface quality grading is realized.
The invention analyzes the multi-angle image of the sample to be detected, corrects the defect classification and the misjudgment removal, and improves the missing detection and the misdetection effects caused by the threshold adjustment of a single picture.
As an improvement, the image acquisition unit comprises a first image acquisition component and a second image acquisition component; the first image acquisition assembly is used for shooting and acquiring a plane and color difference defect information image of a detection surface; and the second image acquisition assembly is used for shooting and acquiring concave-convex defect and size defect information images of the detection surface.
As an improvement, the included angle between the second image acquisition component and the surface of the ceramic tile to be detected is 1-65 degrees when the second image acquisition component shoots, and the imaging mode of shooting a dark field and/or a bright field is realized by filtering the background in the imaging mode.
As an improvement, the defect information comprises concave-convex defects, size defects, color difference defects and flatness.
Has the advantages that: compared with the prior art, the device provided by the invention overcomes the following technical problems, and makes the following improvements: (1) the method aims at the problems that the conventional imaging system can only realize the acquisition imaging of images, has extremely high dependence on an algorithm, has various ceramic tile background patterns and various defects, and is difficult to realize stable defect detection; the method divides the defects into 2 types, adopts different imaging modes aiming at the characteristics (plane/concave-convex, color and the like) of the defects, adopts a camera low-angle shooting mode (the included angle between the camera and the surface of a workpiece is less than 65 degrees) aiming at the concave-convex defects, adjusts the angle of a light source, filters out background textures through the imaging mode, enables the background textures of the ceramic tile to present uniform dark black, and images the concave-convex defects into a large amount of reflective spots, so that the contrast ratio of the defects and the background is greatly improved, the requirement of an algorithm is reduced, and the result detection is stable.
(2) Because the edging chamfer processing can be usually done to the corner of ceramic tile, the conventional shooting mode has the phenomenon of overexposure at the border position of ceramic tile, can submerge the little limit or the top layer that collapses on the ceramic tile corner like this, the present shooting mode is owing to need not consider the color formation of image, except that the defect characteristic is high bright, the ceramic tile itself is the effect in dark field, the edges and corners are clear, still can use this image to carry out size measurement, limit straightness accuracy, edge or dead angle collapse defect measurement such as bump.
(3) In order to enhance the contrast of the defect, the single-angle camera often needs to adjust the light source to a lower angle, so that the color reduction degree of a part of front images can be sacrificed, and for ceramic tile products with complex backgrounds, the defect detection stability of plane colors can be influenced.
(4) Because the background texture of the ceramic tile is various and complex, a single group of image detection has great interference and misjudgment, and certain difficulty exists in industrial floor application, the scheme combines 2 groups of cameras with different angles to respectively shoot the object to be detected, and reference information with different dimensions can be added in the aspects of defect classification and misjudgment, so that the misjudgment can be easily eliminated in the algorithm.
Drawings
FIG. 1 is a schematic structural diagram of the present invention.
FIG. 2 is a schematic diagram of the detection method of the present invention.
In the figure: the system comprises a conveyor assembly 1, a metering wheel trigger assembly 2, a ceramic tile 3, a trigger photoelectric switch 4, a first light source 5, a second light source 6, a first image acquisition assembly 7, a second image acquisition assembly 8, an image processing unit 9, an upper computer 10 and a marking and reminding assembly 11.
Detailed Description
The following examples are given to further illustrate the embodiments of the present invention. The following examples are intended to illustrate the invention but are not intended to limit the scope of the invention.
The invention adopts a multi-group imaging mode to detect the defects of the object to be detected at different angles, not only reduces the complexity of the algorithm, but also enhances the stability of system detection due to the concave-convex imaging advantage of the low-angle camera, and the concave-convex defects do not need to do a large amount of background matching or AI model training work any more, thereby greatly shortening the implementation period of the project and being suitable for the defect detection of complex background textures.
As a specific implementation mode of the invention, two groups of shooting components are adopted, the shooting components can selectively comprise a camera combined light source, one group of camera sets is a low-angle camera, the detection range of the detection of the prior technical scheme is expanded, such as edge-breaking angle detection, size detection, edge straightness detection and the like, and more flexibility is provided for the arrangement of production line equipment.
The multi-angle image analysis of the sample to be detected is adopted, the defect classification and the misjudgment removal are corrected, and the missing detection and the misdetection effects caused by the threshold adjustment of a single picture are improved.
Example 1
The ceramic tile 3 to be detected is transported through the conveyor component 1, after the ceramic tile 3 runs to the triggering photoelectric switch 4, the camera group II of the first image acquisition component 7 and the camera group of the second image acquisition component 8 are triggered respectively through photoelectric trigger signals to start shooting, an imaging system starts receiving pulse trigger signals of the metering wheel trigger component 2, the ceramic tile 3 to be detected is shot, the shooting is stopped through the preset shooting line number limitation or the end signal triggering the photoelectric switch 4, and the image processing list is used for processing the acquired pictures of the camera I and the camera II respectively.
The first image acquisition assembly 7 and the second image acquisition assembly 8 further respectively and independently comprise a first light source 5 and a second light source 6, and the first light source and the second light source are used for performing light compensation to obtain high-quality shot pictures.
The first camera group performs algorithm analysis on the chromatic aberration plane defects: through image extraction → image edge extraction → plane and color difference defect identification → classification by a classifier, the result is obtained: the defect type, size and number are sent to the upper computer 10 of the image processing unit 9 for temporary storage.
And performing algorithm analysis on the concave-convex defects by the camera set II: through image extraction → image edge extraction → identification of concave-convex defects, size measurement, edge straightness measurement and the like → classification by a classifier, the result is obtained: the defect type, size and number are sent to the upper computer 10 of the image processing unit 9 for temporary storage.
The upper computer 10 in the image processing unit 9 receives the results of the 2 groups of cameras, performs comprehensive analysis, performs image cross analysis on suspected points, eliminates misjudged points, and outputs a summary detection result: xx defect, size xx and other information are subjected to grading judgment for the upper computer 10, the upper computer 10 grades the tested ceramic tiles (excellent, qualified, defective and the like) according to the detection results and the detection standards of manufacturers, the results are displayed on a detection interface of the upper computer after the judgment is finished, and in addition, the graded grade information is sent to the marking and reminding component 11, so that the automatic ceramic tile surface quality grading is realized.
The above-mentioned embodiments only express several embodiments of the present invention, and the description thereof is more specific and detailed, but not construed as limiting the scope of the invention. It should be noted that, for a person skilled in the art, several variations and modifications can be made without departing from the inventive concept, which falls within the scope of the present invention. Therefore, the protection scope of the present patent shall be subject to the appended claims.
Claims (10)
1. Ceramic tile surface defect detects visual system, its characterized in that: the system comprises a conveyor component (1), a trigger photoelectric switch (4), an image acquisition unit, an image processing unit (9) and a metering wheel trigger component (2); the conveyor assembly (1) is a structural assembly for uninterruptedly conveying the ceramic tiles (3) to be detected; the triggering photoelectric switch (4) is fixedly arranged on one side of the conveyor assembly (1) and is electrically connected with the image acquisition unit; the image acquisition unit comprises at least two groups of independent image acquisition assemblies, and each group of image acquisition assemblies are independently and electrically connected with the metering wheel trigger assembly (2) and the image processing unit (9); the metering wheel trigger assembly (2) is fixedly arranged on one side of the conveyor assembly (1).
2. The tile surface defect inspection vision system of claim 1, wherein: the image acquisition unit comprises a first image acquisition component (7) and a second image acquisition component (8); the first image acquisition assembly (7) is used for shooting and acquiring a plane and color difference defect information image of a detection surface; and the second image acquisition assembly (8) is used for shooting and acquiring concave-convex defect and size defect information images of the detection surface.
3. The tile surface defect inspection vision system of claim 2, wherein: the first image acquisition assembly (7) is fixedly arranged right above a conveying plane of the conveyor assembly (1); the included angle between the second image acquisition component (8) and the surface of the ceramic tile (3) to be detected is 1-65 degrees when the second image acquisition component shoots.
4. A tile surface defect inspection vision system according to any one of claims 1 to 3, wherein: the device also comprises an upper computer (10) and a marking and reminding assembly (11); wherein the image acquisition unit acquires images and transmits the images to the image processing unit (9); the image processing unit (9) processes the image, the processed information comprises the information of detecting the plane, the chromatic aberration, the concave-convex defect and the size defect of the tile surface, and the processed information is transmitted to the upper computer (10); the upper computer (10) displays the defect information mark and outputs the information to the marking and reminding component (11); the marking and reminding assembly (11) sends out marking and reminding signals.
5. The tile surface defect inspection vision system of claim 2, wherein: the first image acquisition assembly (7) and the second image acquisition assembly (8) are both independently provided with a group of camera sets, and the light source adopts an independent or shared mode to acquire images of the detected ceramic tiles through the camera sets.
6. The tile surface defect inspection vision system of claim 1, wherein: the image processing unit (9) comprises an image extraction unit, an edge extraction unit, a defect classifier, a defect detection result storage unit and a grading comparison and result storage unit; the image extraction unit extracts data of the image acquired by the image acquisition unit and transmits the data to the edge extraction unit for image edge extraction; the edge extraction unit transmits the extracted data information including the data information of the plane, the chromatic aberration, the concave-convex defect and the size defect of the detected tile surface to a defect classifier; the defect classifier compares and classifies each group of defect data information including shape, size, chromatic aberration and concave-convex, and outputs the defect data information to the defect detection result storage unit according to the type required by the result; the defect detection result storage unit summarizes and stores the classified defect data and then outputs the data to the grading comparison and result storage unit; and the grading comparison and result storage unit is used for carrying out grading judgment and grading result storage on the defect information data and outputting the grading result.
7. The detection method of the tile surface defect detection vision system is characterized by comprising the following steps: the tile surface defect detection vision system of claim 6 is used for detecting the tile (3) to be detected, and comprises the following steps:
conveying and detecting triggering of the tiles to be detected:
the method comprises the steps that a ceramic tile (3) to be detected is conveyed and transported uninterruptedly through a conveyor assembly (1), when the ceramic tile (3) is conveyed to a trigger photoelectric switch (4), the trigger photoelectric switch (4) sends a trigger signal to an image acquisition unit to start to acquire pictures, the image acquisition unit starts to receive a pulse trigger signal of a metering wheel trigger assembly (2) to shoot the ceramic tile (3) to be detected, and shooting is stopped through a preset shooting line number set value limit or an end signal of the trigger photoelectric switch (4), wherein the image acquisition unit comprises at least two groups of independent image acquisition assemblies which work independently;
(II) picture acquisition and imaging processing:
after each group of image acquisition assemblies shoots pictures, the acquired pictures are transmitted to an image processing unit (9), the image extraction unit carries out data extraction on the acquired pictures and transmits the data to an edge extraction unit, the edge extraction unit carries out picture edge extraction to obtain data information, and then the data information is transmitted to a defect classifier; the defect classifier is used for comparing and classifying the data information of each group of defects, which comprises the shape, the size, the concave-convex and the chromatic aberration, with preset defect information, and outputting the data information to a defect detection result storage unit according to the type required by the result; the defect detection result storage unit summarizes and stores the classified defect data and then outputs the data to the grading comparison and result storage unit; the grading comparison and result storage unit is used for carrying out grading judgment and grading result storage on the defect information data and outputting a grading result;
(III) quality grading and post-processing:
the determined defect information data and suspected points are subjected to secondary filtering, pictures obtained from 2 groups of different angles are subjected to cross analysis, misjudgment points are eliminated, a summary detection result is output, the result is transmitted to an upper computer (10), the upper computer (10) performs grade division on the tested tiles by combining a preset detection standard through grading judgment and detection results, the grade comprises high grade, qualified, bad and waste, the result is displayed on a detection interface of the upper computer (10) after judgment is completed, and grading grade information is sent to a marking and reminding component (11), so that automatic tile surface quality grading is realized.
8. The method of inspecting a tile surface defect inspection vision system according to claim 7, wherein: the image acquisition unit comprises a first image acquisition component (7) and a second image acquisition component (8); the first image acquisition assembly (7) is used for shooting and acquiring a plane and color difference defect information image of a detection surface; and the second image acquisition assembly (8) is used for shooting and acquiring concave-convex defect and size defect information images of the detection surface.
9. The method of inspecting a tile surface defect inspection vision system according to claim 8, wherein: an included angle between the second image acquisition component (8) and the surface of the ceramic tile (3) to be detected is 1-65 degrees when the second image acquisition component shoots, and an imaging mode of shooting a dark field and/or a bright field is realized by a mode of filtering a background in an imaging mode.
10. The method of inspecting a tile surface defect inspection vision system according to claim 7, wherein: the defect information comprises concave-convex defects, size defects, color difference defects and flatness.
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| CN202211237871.6A CN115508381A (en) | 2021-10-18 | 2022-10-11 | Tile defect detection device adopting laser and camera composite detection mode and classification method |
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| CN114308721A (en) * | 2021-12-17 | 2022-04-12 | 深圳市杰普特光电股份有限公司 | Optical detection method, system and storage medium |
| CN117250201A (en) * | 2023-11-08 | 2023-12-19 | 深圳市洪发建筑工程有限公司 | Swimming pool brick layer defect detection method and system |
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