CN101510085A - Fluoroplastic film defect on-line detecting control system based on process control machine - Google Patents
Fluoroplastic film defect on-line detecting control system based on process control machine Download PDFInfo
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Abstract
The invention relates to an online detection and control system of a material defect based on an industrial computer, including five modules: a production line lighting module (in the text, a fluorine plastic film is taken as an example) which is suitable for the strip-shaped material characteristics; a motion control module which conducts high-precision control to a step motor; a collecting and control module which drives a plurality of high-resolution linear arrays CCD to carry out synchronous collection; a detection processing module for carrying out an image recognition to the strip-shaped material defect; and a network monitoring module which is used for conducting real-time monitoring to a detection result panel in a factory network. The invention provides a step motor, a key technology of coordinative control of the image collection, and a key collection control technology of the synchronous collection of the plurality of high-resolution linear arrays CCD; and the invention has the advantages of fast speed, high precision and the like, and can be universally applied to the real-time automatic defect detection of the plastic film, the paper products and similar transparent (translucent), strip-shaped, wide products.
Description
Technical field
The invention belongs to stepper motor with and image acquisition Collaborative Control technical field, particularly a kind ofly be used for the vision detection system that real-time high-precision detects the band-type product quality based on the multi-thread array image sensor of industrial computer.
Background technology
Because the demand of quality testing robotization is urgent day by day, the automatic detection of fault has in recent years become the heat subject that Chinese scholars is paid close attention to always and studied, and has obtained many achievements.For example: the image identification system that when researchist of Georgia Institute of Technology discloses a kind of fabric wrapping fault has been carried out online detection, hardware is formed by three fixing ccd video cameras with through the illuminator of special arrangement, and used neural network in the software, instrument such as fuzzy logic and wavelet transformation (Dorrity JL, Vachtsevanos, C, Jasper.Annual Report-National Textile Center, 1996,31 (1): 621-626), this system will be commercially produced by the Appalachian Electronic Instrument, Limited of U.S. West Virginia.People such as J.A.Throopa then disclose a production line (D.J.Aneshansleya who has embedded the apple of the online vision detection system of fault by quality classification, W.C.Angerb and D.L.Peterson.Quality evaluation of apples based onsurface defects:development of an automated inspection system[J] .Postharvest Biology andTechnology, 2003, volume 36).
And at home, the patent of relevant defect detection has only retrieved Donghua University's disclosed 200510110244 " a kind of automatic system for assessing grade of cloth inspection objectively " in 2006, its major function is to utilize the DSP module to realize automatic cloth inspection, does not relate to the gordian technique that detects in real time at a high speed based on the multi-thread battle array ccd array image acquisition of industrial computer and drive motor control system etc.In addition, about the patent of fluoroplastic product, wherein relevant with banded winding material has 6, all uses about it again, and yet there are no report about the relevant patent of its quality testing.
The fluorine plastic film goods have its yield unique product characteristics, as: the surface does not have the decorative pattern of rule; Quality clear, colorless and level and smooth, reflective function is good; Most of film faults mostly are that said minuscule hole, light color are polluted; The production line breadth is broad etc. mostly.The fault automatic checkout system that is applicable to this kind product does not also have disclosed technical patent now as yet.
Summary of the invention
The objective of the invention is to remedy the deficiency of domestic existing Automatic Measurement Technique, provide a kind of wide cut transparent plastic film fault that is applicable to gather in real time and many line array CCDs vision detection system of handling, simultaneously in conjunction with the control platform of LabVIEW software, fault detection in real time, information stores and monitoring have been realized on the fluorine plastic film production line to this product as each module.
Innovative point of the present invention is to adopt a plurality of line array CCDs as image device, and has designed the co-ordination scheme of kinematic system and acquisition system at line array CCD line scanning characteristics.Designed the closed loop control method of stepper motor+dual coding device, and adopt with VC be intermediary, realize control based on the dual call method of LabVIEW to the motion control card dynamic link library; Designed based on the synchronous equal proportion acquisition method of many line array CCDs of idler roller encoder pulse external trigger with based on the image-pickup method of multiple buffer Ring mode; Simultaneously in real time to the gained view data handle, storage and Web publishing, thereby improve precision and the detection speed that can examine fault effectively, realize the online quality monitoring of vision of transparent (translucent) strip material.
To achieve these goals, the technical solution used in the present invention is as follows:
(1) lighting module: adopt the rear-projection of CCS white strip source; Lighting module takes into full account fluorine plastic film material characteristics, adopts CCS white strip source rear-projection mode to have good stability, can overcome more effectively because the detection error that variation brought of natural light.
(2) motion-control module: adopt the GT-400 motion controller, comprise GT-400-SV-PCI-G motion control card, terminal strip and stepper motor driver, and use two incremental-rotating coders, one is installed in stepper motor coaxial (being called motor encoder), is used to produce feedback pulse and the sports cards gating pulse is compared; It two is installed on the film idler roller and (is referred to as the idler roller scrambler), is used for the linear velocity of production line is converted into pulse signal, exports to acquisition control module.
(3) acquisition control module: a plurality of SmartBlue SB4480 linear array CCD cameras are arranged in the same lengthwise position of plastic film production lines, and according to resolution and accuracy of detection division visual field, be connected to the NI-1409 image pick-up card, capture card is accepted to carry out synchronous acquisition according to multiple buffer image Ring acquisition mode after the trigger pip that motion-control module sends, and view data is left in the buffer zone.
(4) detect processing module: the film fault is carried out image recognition, extract view data from buffer zone, the image processing method of employing " from coarse to fine " extracts the every information of fault and stores, and make the user can carry out setting operation, and show the fault processing result image in real time to fault gray scale threshold values, the motor method of operation, each parameter of storage position information.
(5) network monitoring module: at the plant network environment, adopt remote panel monitoring scheme, realized that the multiple spot of a cover testing hardware platform is shared and the networking monitoring based on B/S framework and LabVIEW WEB SERVER.
Described motion-control module employing is intermediary with VC, realizes Stepping Motor Control based on the dual call method to the motion control card function of LabVIEW.
Described acquisition control module is by the quick configuration of NI Vision realization to capture card.
The defect detection of described detection processing module and interface are created among the LabVIEW realizes.
Described network monitoring module adopts the remote panel function of LabVIEW WEB SERVER to realize that client is by visit and the monitoring of browser to system's front panel.
Owing to adopted above-mentioned technical scheme, the present invention compared with prior art has following advantage and good effect:
(1) be conceived to industrial machine vision system development trend, to specific industry---the product design of plastic sheeting producer meets the dedicated test system of demand.Constructed vision detection system is not only finished the function of traditional vision system image acquisition and processing, also relate to fields such as motion control, industrial communication, coordinate and brought into play the function of multiple factory automation system, embodied the more intelligentized fusion of machine vision and industrial environment.
(2) image acquisition process and production line motion process are closely combined.Design the close-loop control scheme of a kind of " stepper motor+dual coding device ", both improved the step motor control precision, provide trigger pulse for acquisition module again; Adopt a plurality of line array CCDs as image device simultaneously, and to have designed with motion module output pulse be the vertical equal proportion acquisition scheme of film image of external trigger signal, the multiple buffer Ring acquisition method of the situation that has proposed to be applicable to that volume of transmitted data is big.
(3) system software is based on the LabVIEW platform development, proposed with VC be intermediary, based on the dual call method of LabVIEW to the motion control card dynamic link library, realized motion control based on PC and motion control card; Write plastic sheeting defect detection program, and generated and comprise Electric Machine Control, acquisition controlling, the testing result software interface in being presented at based on LabVIEW platform and NI Vision Module.Made full use of this platform graphics and melted the advantage of sending out, realized setting, the configuration of user, and had the interface of convenient, easy operating attractive in appearance each hardware and software parameter.
Description of drawings
Fig. 1 is an entire system structure principle chart of the present invention;
Fig. 2 is a system of the present invention pie graph;
Fig. 3 is a system level diagram of the present invention;
Fig. 4 is a stepper motor dual coding device close-loop control scheme design drawing of the present invention;
Fig. 5 is motor encoder feedback pulse compensation principle figure of the present invention;
Fig. 6 is the signal type conversion synoptic diagram of motion-control module of the present invention;
Fig. 7 is stepper motor S type lifting speed measured curve figure of the present invention;
Fig. 8 is that stepper motor of the present invention adds position feedback and impulse compensation front and back comparison diagram;
Fig. 9 is that the synchronous isometric map of many line array CCDs of the present invention is as acquisition scheme design figure;
Figure 10 is the principle schematic of multiple buffer image Ring continuous acquisition mode of the present invention;
Figure 11 is the process flow diagram of multiple buffer image Ring continuous acquisition mode of the present invention;
Figure 12 is the LabVIEW flow chart of defect detection of the present invention and storage;
Figure 13 is the sectional drawing that the real-time displayed map of defect detection of the present invention reaches event memory in Excel;
Figure 14 is human-computer interaction interface figure of the present invention;
Figure 15 is the remote monitoring panel synoptic diagram that shows in the client browser of the present invention;
Figure 16 is the long-range front panel Manager Feature synoptic diagram of server end of the present invention.
Embodiment
Below in conjunction with specific embodiment, further set forth the present invention.Should be understood that these embodiment only to be used to the present invention is described and be not used in and limit the scope of the invention.Should be understood that in addition those skilled in the art can make various changes or modifications the present invention after the content of having read the present invention's instruction, these equivalent form of values fall within the application's appended claims institute restricted portion equally.
The invention will be further described below in conjunction with Fig. 1-16.
This embodiment of many line array CCDs vision detection system that wide cut transparent plastic film fault is gathered in real time and handled that is applicable to comprises the following steps:
(1) as shown in Figure 1, after the former base of plastics was cut into film by cutting membrane knife, level was covered on the line conveyor, the rotation roller of step motor drive travelling belt one end, a plurality of idler rollers by production line middle part keep the pellicular water sheet straight, and the spool that is sent to the production line end carries out rolling.
(2) at lighting module, use CCS white strip source (or high frequency white spot), length is (customized) about 1.3m according to demand, adopts mode backlight.Adjust according to field demand in installation, decorating position is mainly based on the CCD photosensitive region.
(3) at motion-control module, adopt the GT-400 motion controller of solid high company, comprise GT-400-SV-PCI-G motion control card, terminal strip and stepper motor driver, control card is connected to terminal strip (terminal strip is used for connecting external signal and output etc.), and the CN1 of control card is connected with shielded cable with CN2 with CN1, the CN2 of terminal strip, to guarantee that external circuit is normal; The control card output pulse signal is exported to driver by the pin of terminal strip CN5.
Shown in Fig. 4～6, the design of " stepper motor+dual coding device " close-loop control scheme is as follows:
Motion controller, is compared by the coaxial incremental-rotating coder of stepper motor (being referred to as motor encoder in the literary composition) feedback pulse and sports cards gating pulse by the motion of setting scheme with pulse control step motor, carries out error compensation simultaneously; Another scrambler (being referred to as the idler roller scrambler in the literary composition) is installed on the film idler roller, idler roller is converted into angular velocity with the linear velocity of production line, the idler roller scrambler changes it into the TTL pulse signal again in real time, and as a plurality of line array CCD external trigger signals of acquisition control module, be connected to capture card interface box Trigger contact, external trigger signal as capture card, capture card determines and controls the collection line frequency of line array CCD according to this signal, promptly receive a pulse signal, just gather delegation's view data.
Because motion control card only provides the dynamic link library that can programme under the C language environment, therefore native system proposes a kind of method that sports cards dynamic link library secondary is called, with VC is intermediary, has realized the setting of Electric Machine Control parameter and the control of motion process under the LabVIEW platform.That is: at first set up a VC++ engineering in VC, be incorporated into GT400.h, the GT400.dll file is write each several part control function function in CPP, sets input; In LabVIEW, utilize the CLF interface node that input is set again and carry out the VC function call, thereby realization is to the control of sports cards.
This scheme proposes three gordian techniquies, the precision of emphasis resolution system in motion control and real-time two large problems:
A) in order to improve the step motor control precision, the step-out problem of stepper motor has designed the S type lifting fast mode based on motion control card when solving the startup of low speed high frequency, and results measured is referring to Fig. 7 on stepper motor;
B) in order further to improve the step motor control precision, solve the production line movement velocity variation issue that step-out or film spool change in radius cause, at the coaxial installation incremental-rotating coder of stepper motor, constitute pulse feedback, compare with encoder pulse and sports cards gating pulse that precision is higher, and carry out the compensation that control card is exported pulse in real time, results measured is referring to Fig. 8 on stepper motor;
C) can collect the higher view data of vertical precision in order to guarantee at the image capture module of defect detection system, improve the real-time of gathering simultaneously, realize the equal proportion collection of line array CCD, this programme connects scrambler on the idler roller at plastic film production lines middle part, and with the external trigger signal of encoder pulse as capture card.
(4) in acquisition control module, a plurality of line array CCDs vertically are fixed on the plastic sheeting top side by side, and being connected to NI PCI-1409 capture card (connecting IMAQ-A6822 expansion interface box), the pulse signal of the control module of autokinesis in the future idler roller scrambler also is connected to interface box.
As shown in Figure 9, the synchronous isometric map of many line array CCDs is as follows as acquisition scheme design:
At first, for the capable collection of line array CCD, in case frequency acquisition and production line motion frequency are inconsistent, will make the view data generation longitudinal stretching or the compression that collect, native system is realized based on the vertical equal proportion collection of the line array CCD of external trigger with the trigger condition of idler roller encoder pulse signal as the capture card acquired signal by motion module and acquisition module co-ordination; Secondly, because the fault accuracy requirement is high and the film web face width, make that the image data amount that finally collects is very big, if the speed of image processing section does not catch up with picking rate, will take place still untreated data in the image buffer by newly adopt into the phenomenon that view data covered, native system has been realized the co-ordination of acquisition module and detection module by multiple buffer image Ring continuous acquisition mode, under the Ring mode, create a buffer zone tabulation, and open up a series of and the buffer areas that are associated of tabulation, data in a buffer zone are just when processed, the view data that newly collects can be updated in the other buffer zone and go, shown in Figure 10～11.
(5) detecting processing module, extract the view data of specifying line number from buffer zone at every turn after, just in LabVIEW, it is carried out the single treatment process.Because the image data amount that collects in the unit interval is very big, and the part that in fact former plastic sheeting comprises fault is few, and comparatively disperses, therefore for the pressure of mitigation system buffer memory, reduce the memory space of handling back information simultaneously, adopt the method for " thick earlier back is thin ":
At first, because plastic sheeting and fault gray feature are widely different, therefore rough detection adopts the simplest gray threshold method based on standard frame, the standard drawing picture frame that is about to film picture frame to be detected and no fault carries out gray scale relatively, this two width of cloth image is subtracted computing, obtain both gray scale differences, compare with setting threshold again, film to be detected is made judgement.If the picture frame that is made of setting row view data that takes out from buffer zone is respectively I at every turn
1, I
2..., and standard frame is I, and each two field picture is calculated its gray difference at each pixel i place and standard frame I respectively:
E
m(i)＝|I
m(i)-I(i)|
I wherein
m(i), I (i) represent respectively the m two field picture at the locational gray-scale value of i and standard frame image at the locational gray-scale value of i.If diversity factor E
m(i) less than the threshold value that sets, judge that then two field picture does not have fault for this reason, give up the line data that constitutes this frame, only line number is added up, to remember the lengthwise position of current line on film; Otherwise judge that two field picture has fault for this reason, enter examining and survey process.
Secondly, the two field picture that is judged to be fault is carried out examining.The method that we carry out gray level threshold segmentation after by image sharpening is determined the lateral attitude and the area size of fault.If containing the picture frame of fault is I
m, according to certain criterion at I
mIn find eigenwert T, be two parts with image segmentation.
Use the sub-VI of IMAQ count object, in its front panel, set the gray threshold parameter, and obtain the most effective threshold value of cutting apart film background and printing ink fault by continuous adjustment.The data stream of being exported by this sub-VI after handling is for comprising the fault upper left corner and lower right corner horizontal stroke, ordinate position, the fault centre coordinate, the binding of data such as fault area size bunch, with data wherein remove be bundled to the sky array after, after being converted to uniform data format, deposit the Excel file in.Finally, after each view data was handled, the fault position was all irised out by red frame, is presented on the man-machine interface.LabVIEW program and result are shown in Figure 12～14 and table one.
(6) in network monitoring module, shown in Figure 15～16, by following conceptual design: at server end, use the LabVIEW8.2 version, utilize instrument〉〉 Web issue instrument (the LabVIEW Web Server) information issuing the front panel of VI or wish to see in client.Write Document Title or the HTML content that is used for webpage before and after the plate figure this moment in front, and the IP address that can visit is set; At client's device end, the free engine LabVIEW Run-Time Engine about the 23M that installation NI provides uses modal IE browser, imports the web page address that server provides, and realizes the network monitor of real-time testing process.Simultaneously, server end uses long-range front panel connection manager, conversely the client that is connected to this webpage is in real time monitored and is managed, and write down this process.
Though disclose the present invention with its preferred form, for the person of ordinary skill of the art, under the condition that does not depart from the design of the present invention that proposes by claims and scope, can also carry out many improvement.
Table one:
Annotate: Center x represents the x coordinate position of fault central point in current frame image;
Center y represents the y coordinate position of fault central point in current frame image;
Left x represents the x coordinate position of fault high order end in current frame image;
Top y represents the y coordinate position of fault top in current frame image;
Right x represents the x coordinate position of fault low order end in current frame image;
Area represents fault area size.
Claims (5)
1. the fluorine plastic film fault online detection and control system based on industrial computer is characterized in that, comprises following five modules: lighting module; Motion-control module; Acquisition control module; Detect processing module; Network monitoring module.
(1) lighting module: adopt CCS white strip source, direct current supply, the rear-projection illumination is fit to specific properties such as the transparent no texture of fluorine plastic film, smooth surface;
(2) motion-control module: adopt stepper motor dual coding device close-loop control scheme, compare, carry out error compensation simultaneously, guarantee control accuracy by motor encoder feedback pulse and sports cards gating pulse that stepper motor is coaxial; Change the production line movement velocity into the TTL pulse signal in real time by the idler roller scrambler, and, be connected to the capture card interface box, thereby guarantee to collect high precision synchronous isometric map picture as a plurality of line array CCD external trigger signals of acquisition control module;
(3) acquisition control module: as gathering the row signal, the triggering collection card carries out the line scanning collection to the film image with the idler roller encoder pulse, and gives industrial computer (PC) with the image data transmission that collects, and is temporarily stored in the buffer area of industrial computer system;
(4) detect processing module: extract view data from buffer zone, adopt the image processing method of " from coarse to fine " to extract the every information of fault, be stored in the Excel file and check at any time in order to the technician, simultaneously by software interface to user's display process result;
(5) network monitoring module: adopting the B/S network architecture, is the NI application server with the industrial computer, will detect data and utilize remote panel to be published in the plant network, and the technician of client can be monitored real-time testing result by browser.
2. a kind of strip material fault online detection and control system according to claim 1 based on industrial computer, it is characterized in that: described motion-control module used a kind of with VC++ as intermediary, the dual call method of the dynamic link library file that on the LabVIEW platform, motion control card is provided.This method is called the sports cards function library and is write motion control program in the VC++ environment, realize patterned funcall by the function parameter transmission then in LabVIEW, has utilized the rapidity of C programmer and the convenient characteristic of LabVIEW front panel simultaneously.
3. a kind of strip material fault online detection and control system according to claim 1 based on industrial computer, it is characterized in that: described acquisition control module has adopted multiple buffer image Ring continuous acquisition mode, and realizes quick configuration to capture card by the sub-VI that NI Vision provides.Under this acquisition mode, create a buffer zone tabulation, and open up a series of and the buffer areas that are associated of tabulation, data in a buffer zone are just when processed, the view data that newly collects can be updated in the other buffer zone and go, the big and not high contradiction of image processing speed of image acquisition data volume when this mode has been alleviated the wide cut requirements for high precision.The sub-VI that utilizes NI Vision to provide simultaneously only needs parameters such as collection position, trigger signal types are selected, but with regard to the configuration of efficient quick ground realization to acquisition mode.
4. a kind of fluorine plastic film fault online detection and control system according to claim 1 based on industrial computer, it is characterized in that: take into full account line array CCD line scanning characteristics, Collaborative Control image acquisition process and production line motion process, with the output signal of motion module input signal as acquisition module, promptly with the external trigger signal of idler roller scrambler output pulse as capture card, guarantee to collect the higher view data of vertical precision at the image capture module of defect detection system, improve the real-time of gathering simultaneously, realize the equal proportion collection of line array CCD.
5. a kind of fluorine plastic film fault online detection and control system according to claim 1 based on industrial computer, it is characterized in that: at the plant network environment, designed industrial network monitoring modular, realized that the multiple spot of a cover testing hardware platform is shared and the networking monitoring based on B/S framework and LabVIEW WEB SERVER.
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