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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

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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]. , 2024, 17(2): 354-365. 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]. , 2024, 17(2): 354-365.doi:10.37188/CO.2023-0134
JIANG Shi-fei, ZHANG Zhao-guo, WANG Fa-an, XIE Kai-ting, WANG Cheng-lin, LI Zhi. Design of optical field of vision imaging for defect detection of paper and transparent film[J]. Chinese Optics, 2024, 17(2): 354-365. doi: 10.37188/CO.2023-0134
Citation: JIANG Shi-fei, ZHANG Zhao-guo, WANG Fa-an, XIE Kai-ting, WANG Cheng-lin, LI Zhi. Design of optical field of vision imaging for defect detection of paper and transparent film[J].Chinese Optics, 2024, 17(2): 354-365.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,博士研究生,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); Key Project of China Tobacco Industry in Yunnan (No. 2022ZK05)
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  • 摘要:

    为实现包装盒纸质基底层和透明膜层缺陷的同步检测,开展了对纸和膜缺陷的同步成像研究。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3类光场进行射线仿真,对比分析了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5项常见缺陷依次进行物理检测和机器视觉检测,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 transparent film in dark field forward lighting

    图 3曲面反射光路图

    Figure 3.Optical path diagram of curved surface reflection

    图 4标准球面积分光场模型

    Figure 4.Spherical integral light field model

    图 5椭球面内球面积分光场模型

    Figure 5.Ellipsoidal integral light field model

    图 6弧面积分光场模型

    Figure 6.Arc-area integral light field model

    图 7射线以(a)30°、(b)45°、(c)60°向上释放的球面光场光路

    Figure 7.Optical paths of a spherical light field with rays emitted upward at (a) 30°, (b) 45°, (c) 60°

    图 8在长半轴端射线以(a)30°、(b)45°、(c)60°向上释放的椭球面光场光路

    Figure 8.Optical paths of an ellipsoidal light field with rays emitted upward at the end of semi-major axis at (a) 30°, (b) 45°, (c) 60°

    图 9在短半球端射线以(a)30°、(b)45°、(c)60°向上释放的椭球面光场光路

    Figure 9.Optical paths of an ellipsoidal light field with rays emitted upward at the end of short haff-shaft at (a) 30°, (b) 45°, (c) 60°

    图 10弧面积分光场仿真结果

    Figure 10.Simulation results of arc-area integral light field

    图 11半径比与投射口距离对辐照比的响应曲面

    Figure 11.Response surface plotted by three coefficients, ie., radius radio, projection port distance, and irradiation ratio

    图 12半径比与辐照面距离对辐照比的响应曲面

    Figure 12.Response surface plotted by three coefficients, i.e., radius ratio, irradiation surface distance, and irradiation ratio

    图 13成像系统结构设计图

    Figure 13.Structural design graph of imaging system

    图 14试验设备

    Figure 14.Experiment equipment

    图 15前打光环境成像装置

    Figure 15.Imaging device of forward lighting field

    图 16包装盒缺陷图像

    Figure 16.Defect images of packaging box

    图 17不同光环境下成像缺陷比例

    Figure 17.Presentation rates of imaging defects under different light fields

    图 18PaDiM异常检测的patch 嵌入向量与定位分割

    Figure 18.Patch embedding vector and location segmentation of PaDiM abnormal detection

    图 19缺陷的异常检测和类别检测结果

    Figure 19.Abnormal detection and classification detection results of defects

    图 20缺陷检出率雷达图

    Figure 20.Radar map of defects detection rate

    表 13种光场主要参数

    Table 1.Main parameters of the three types of integrated light fields

    光场类型 光罩尺寸A
    ×B×H/mm
    半径RR1×R2×R3/mm 投射口距
    S/mm
    辐照面
    距离C/mm
    标准球面积分光场 180×180×130 85 35 20
    椭球面积
    分光场1
    180×180×110 85×65×65 35 20
    椭球面积
    分光场2
    180×180×110 65×85×65 35 20
    弧面积
    分光场
    180×130×130 85 35 20
    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)
    1 1.1 30 5
    0 1.3 35 17.5
    -1 1.5 40 30
    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/R2 S/(mm) C/( mm)
    1 1.3 40 30 80
    2 1.1 35 5 76
    3 1.5 35 5 74
    4 1.3 35 17.5 92
    5 1.1 30 17.5 76
    6 1.3 30 30 82
    7 1.5 35 30 70
    8 1.3 35 17.5 90
    9 1.3 35 17.5 90
    10 1.5 40 17.5 70
    11 1.3 30 5 86
    12 1.3 40 5 84
    13 1.3 35 17.5 92
    14 1.3 35 17.5 92
    15 1.1 40 17.5 74
    16 1.1 35 30 72
    17 1.5 30 17.5 72
    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 F P
    模型 1104.73 9 122.75 126.36 < 0.0001***
    R1:R2 18.00 1 18.00 18.53 0.0035***
    S 8.00 1 8.00 8.24 0.0240**
    C 32.00 1 32.00 32.94 0.0007***
    残差 6.80 7 0.9714
    失拟 2.00 3 0.6667 0.5556 0.6716
    误差 4.80 4 1.20
    总和 1111.53 16
    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 213 205 96.2 206 96.7 138 64.8
    抵触 80 74 92.5 76 95 54 67.5
    开口 50 50 100 50 100 38 76
    泡皱 98 93 95 64 65 93 95
    破损 125 115 92 74 59 116 92.8
    下载: 导出CSV

    表 6图像缺陷的机器视觉检测结果

    Table 6.Machine 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 213 210 98.6 208 97.6 210 98.6 210 98.6 140 65.7 140 65.7
    抵触 80 78 97.5 75 96 79 98.7 78 97.5 60 75 62 77.5
    开口 50 50 100 50 100 50 100 50 100 38 76 40 80
    泡皱 98 98 100 95 97 70 71.4 67 68 95 97 95 97
    破损 125 123 98.4 120 96 82 65.5 80 64 120 96 122 97.6
    下载: 导出CSV
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  • 收稿日期:2023-08-09
  • 修回日期:2023-09-12
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