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纸膜双层缺陷检测的视觉成像光场设计

蒋仕飞 张兆国 王法安 解开婷 王成琳 李治

蒋仕飞, 张兆国, 王法安, 解开婷, 王成琳, 李治. 纸膜双层缺陷检测的视觉成像光场设计[J]. . doi: 10.37188/CO.2023-0134
引用本文: 蒋仕飞, 张兆国, 王法安, 解开婷, 王成琳, 李治. 纸膜双层缺陷检测的视觉成像光场设计[J]. . doi: 10.37188/CO.2023-0134
JIANG Shi-fei, ZHANG Zhao-guo, WANG Fa-an, XIE Kai-ting, WANG Chen-lin, LI Zhi. Design of optical field of vision imaging for defect detection of paper and transparent film[J]. Chinese Optics. doi: 10.37188/CO.2023-0134
Citation: JIANG Shi-fei, ZHANG Zhao-guo, WANG Fa-an, XIE Kai-ting, WANG Chen-lin, LI Zhi. Design of optical field of vision imaging for defect detection of paper and transparent film[J]. Chinese Optics. doi: 10.37188/CO.2023-0134

纸膜双层缺陷检测的视觉成像光场设计

doi: 10.37188/CO.2023-0134
基金项目: 国家重点研发计划项目(No. 2022YFD2002004);云南省院士(专家)工作站项目(No. 202105AF150030);云南中烟重点项目(No. 2022ZK05);
详细信息
    作者简介:

    蒋仕飞(1987—),男,云南昭通人,博士生,工程师,2014年于昆明理工大学获得硕士学位,主要从事机器视觉及自动检测方面的研究。E-mail:20211103008@stu.kust.edu.cn

    王法安(1990—),男,河南信阳人,博士,硕士生导师,2014年于安阳工学院获得学士学位,2017年于昆明理工大学获得硕士学位,2022年于东南大学获得博士学位,主要从事智能机械装备设计制造研究等方面的研究。E-mail:wfa@kust.edu.cn

  • 中图分类号: TB811;TB858.2

Design of optical field of vision imaging for defect detection of paper and transparent film

Funds: Supported by National Key R & D Program of China (No. 2022YFD2002004); Yunnan Province Academician (Expert) Workstation Project (No. 202105AF150030); the Key project of China Tobacco Industry in Yunnan (No. 2022ZK05)
More Information
  • 摘要:

    为实现包装盒的纸质基底层和透明膜层缺陷的同步检测,开展对纸和膜缺陷同步成像特性研究。首先,分别建立了标准球面积分光场、椭球面积分光场和弧面积分光场模型,并利用COMSOL Multiphysics 5.6对三类光场进行射线仿真,对比球面积分光场下射线角度均匀性及辐照均匀性,通过正交仿真优化椭球面积分光场参数;其次,在椭球面积分光场环境、亮场前打光环境、暗场前打光环境下对包装盒成像,与此同时,对包装盒的油污、抵触、开口、泡皱、破损五项常见缺陷成像依次进行物理检测和机器视检测,验证缺陷成像的有效性。试验结果表明,在椭球面积分光场下成像,图像对纸质基底层缺陷特征、透明膜层缺陷特征均有较好的呈现效果,图像上油污、抵触、开口、泡皱、破损的物理检出率分别为96.2%、92.5%、100%、95%、92%,异常检出率分别为98.6%、97.5%、100%、100%、98.4%,缺陷类别检出率分别为97.6%、96%、100%、97%、96%。研究结果表明,椭球面积分光场光路角度和辐照强度均匀,覆透明膜包装盒的缺陷特征呈现清晰,满足工业生产的检测要求。

     

  • 图 1  亮场前打光方式对纸质基底层的成像

    Figure 1.  Imaging of paper in bright field forward lighting

    图 2  暗场前打光方式对透明膜的成像

    Figure 2.  Imaging of paper in dark field forward lighting

    图 3  曲面反射光路图

    Figure 3.  Curved surface reflection optical path diagram

    图 4  标准球面积分光场模型

    1.光罩 2.球面内腔 3.条光源 4.辐照面1. Light cover 2. spherical cavity 3. strip light source 4. irradiated surface

    Figure 4.  Structure of spherical integral light field

    图 5  椭球面内球面积分光场模型

    1.光罩 2.椭球面内腔 3.条形光 4.辐照面

    Figure 5.  Structure of ellipsoidal integral light field

    1. Light cover 2. ellipsoidal cavity 3. strip light source 4. irradiated surface

    图 6  弧面积分光场模型

    1.光罩 2.弧面内腔 3.条光源 4.辐照面

    Figure 6.  Structure of arc-area integral light field

    1. Light cover 2. cambered cavity 3. strip light source 4. irradiated surface

    图 7  射线30°向上释放的球面光场光路

    Figure 7.  Optical path of a spherical light field with rays emitted 30° upward

    图 8  射线45°向上释放的球面光场光路

    Figure 8.  Optical path of a spherical light field with rays emitted 45° upward

    图 9  射线60°向上释放的球面光场光路

    Figure 9.  Optical path of a spherical light field with rays emitted 60° upward

    图 10  射线30°向上释放的椭球面光场光路

    Figure 10.  Optical path of an ellipsoidal light field with rays emitted 30° upward

    图 11  射线45°向上释放的椭球面光场光路

    Figure 11.  Optical path of an ellipsoidal light field with rays emitted 45° upward

    图 12  射线60°向上释放的椭球面光场光路

    Figure 12.  Optical path of a ellipsoidal light field with rays emitted 60° upward

    图 13  射线30°向上释放的椭球面光场光路

    Figure 13.  Optical path of an ellipsoidal light field with rays emitted 30° upward

    图 14  射线45°向上释放的椭球面光场光路

    Figure 14.  Optical path of an ellipsoidal light field with rays emitted 45° upward

    图 15  射线60°向上释放的椭球面光场光路

    Figure 15.  Optical path of an ellipsoidal light field with rays emitted 60° upward

    图 16  射线30°向上释放的弧面光场光路

    Figure 16.  Optical path of an arc light field with rays emitted 30° upward

    图 17  射线45°向上释放的弧面光场光路

    Figure 17.  Optical path of an arc light field with rays emitted 45° upward

    图 18  射线60°向上释放的弧面光场光路

    Figure 18.  Optical path of an arc light field with rays emitted 60° upward

    图 19  半径比与投射口距离对辐照比的响应曲面

    Figure 19.  Response surface of radius ratio and projection port distance

    图 20  半径比与辐照面距离对辐照比的响应曲面

    Figure 20.  Response surface plotted by three coefficients, i.e., radius ratio, irradiation surface distance, and irradiation ratio

    图 21  成像结构设计

    1.光罩 2.光源 3.连接板 4.相机 5.光路反射腔

    Figure 21.  Imaging structure design

    1. Light cover 2. strip light source 3. plate for joining 4. camera 5. cavity for light reflection

    图 22  试验设备

    1.盒入口 2.第一成像装置 3.横向通道 4.翻转装置 5.纵向通道 6.第二成像装置

    Figure 22.  Equipment for experiment

    1. Entrance of the packaging box 2. Frontal imaging device 3. transversal transfer channel 4. turnover device of packaging box 5. longitudinal transfer channel 6. backside imaging device

    图 23  前打光环境成像装置

    Figure 23.  Imaging device in forward lighting field

    图 24  包装盒缺陷图像

    Figure 24.  Packaging box defect images

    图 25  不同光环境下成像缺陷呈现比例

    Figure 25.  Presentation rate of imaging defects in different light field

    图 26  padim异常检测的patch 嵌入向量与定位分割

    Figure 26.  Patch embedding vector and location segmentation of PaDiM abnormal detection

    图 27  缺陷的异常检测和类别检测结果

    Figure 27.  Abnormal detection and classification detection results of defects

    图 28  缺陷检出率雷达图

    Figure 28.  Radar map of defects detection rate

    表  1  弧面积分光场主要尺寸

    Table  1.   Main dimensions of the integrated light field on a curved surface

    光场类型光罩尺寸A
    ×B×H/mm
    半径R&R1×R2×R3/mm投射口距
    离S/mm
    辐照面
    距离C/mm
    标准球面积分光场180×180×130853520
    椭球面积
    分光场1
    180×180×11085×65×653520
    椭球面积
    分光场2
    180×180×11065×85×653520
    弧面积
    分光场
    180×130×130853520
    下载: 导出CSV

    表  2  因素水平表

    Table  2.   Coding table of experimental factors and levels

    水平因素
    半径比(R1/R2)投射口距离S/(mm)辐照面距离C/( mm)
    11.1305
    01.33517.5
    -11.54030
    下载: 导出CSV

    表  3  试验方案与结果

    Table  3.   Experimental scheme and results

    序号因素辐照比Q/%
    R1/R2S/(mm)C/( mm)
    11.3403080
    21.135576
    31.535574
    41.33517.592
    51.13017.576
    61.3303082
    71.5353070
    81.33517.590
    91.33517.590
    101.54017.570
    111.330586
    121.340584
    131.33517.592
    141.33517.592
    151.14017.574
    161.1353072
    171.53017.572
    下载: 导出CSV

    表  4  方差分析

    Table  4.   Variance analysis

    变异来源平方和自由度均方FP
    模型1104.739122.75126.36< 0.0001***
    R1:R218.00118.0018.530.0035***
    S8.0018.008.240.0240**
    C32.00132.0032.940.0007***
    残差6.8070.9714
    失拟2.0030.66670.55560.6716
    误差4.8041.20
    总和1111.5316
    注:**表示影响显著(P<0.05),***表示影响极显著(P<0.01)
    下载: 导出CSV

    表  5  缺陷检出数量统计

    Table  5.   Statistics on detected defects

    缺陷类别缺陷数量椭球面积分光场环境亮场前打光环境暗场前打光环境
    缺陷检出数量缺陷检出率/%缺陷检出数量缺陷检出率/%缺陷检出数量缺陷检出率/%
    油污21320596.220696.713864.8
    抵触807492.576955467.5
    开口5050100501003876
    泡皱98939564659395
    破损12511592745911692.8
    下载: 导出CSV

    表  6  图像缺陷的视觉检测结果

    Table  6.   Vision detection results of image defects

    缺陷
    类别
    缺陷
    数量
    椭球面积分光场环境亮场前打光环境暗场前打光环境
    异常检
    出数量
    异常检
    出率/%
    类别检出
    数量
    类别
    检出率/%
    异常检
    出数量
    异常检
    出率/%
    类别检出
    数量
    类别
    检出率/%
    异常检
    出数量
    异常检
    出率/%
    类别检出
    数量
    类别
    检出率/%
    油污21321098.620897.621098.621098.614065.714065.7
    抵触807897.575967998.77897.560756277.5
    开口505010050100501005010038764080
    泡皱989810095977071.4676895979597
    破损12512398.4120968265.580641209612297.6
    下载: 导出CSV
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  • 网络出版日期:  2023-12-05

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