基于机器视觉的汽车零件缺陷检测技术研究
|
摘要
机器视觉技术由于其高效率、高精度、易集成等显著优点而在国内外得到了广泛应用。然而该技术虽在国外已普及于工、农、军、医等领域,在国内却尚在探索和初期发展阶段,各大高校、研究所和名企在工业检测、医学分析和交通监控等领域作了很大的努力,其产品的应用正处在快速增长的阶段。本文在了解机器视觉技术基本工作原理的基础上,查阅了大量的该技术在汽车制造和检测领域应用情况的资料,并设计了一套完整的基于机器视觉的汽车零件缺陷检测系统,实现在线零件缺陷检测。本文的主要研究内容概括如下：
介绍了机器视觉技术的基本理论、国内外的发展和研究现状,在汽车制造和检测领域的应用,以及视觉系统常用的软件平台LabVIEW软件和Vision模块。
根据设定的检测参数和技术要求,设计了一套完整的汽车零件缺陷检测系统,其内容包括照明光源、光学镜头、相机、光电开关的合理选择和布置,基于对检测台的传动速度、工件转速与相机采集速度的关系,确定了相机的参数。
深入研究了图像处理技术,内容包括图像平滑、图像分割和图像分析等,并通过分析比较,确定了合适的图像处理方法。
基于相机标定的基本原理,采用空间后方交会法编写了标定程序,采用空间前方交会法编写了坐标转换程序；通过待检测零件的几何关系利用单台相继实现了通常只有双目标定才能完成的像物坐标转换问题,大大节约了成本。
编写了一整套的基于LabVIEW的零件缺陷检测程序与用户界面程序,按照模块化的编程思想,分成图像采集模块、图像处理模块、结果保存模块、数据管理模块。以轴类零件为例,验证了缺陷检测系统的工作有效性。
通过简单的实验,对缺陷检测结果、检测精度和检测速度进行了计算,验证了系统方案的可行性,最后对误差原因进行全面分析。
Machine vision technology has been used widely at home and abroad due to its high efficiency, high precision, easy integration and some other significant advantages. However, although this technology is very popular in industry, agriculture, military and medical fields abroad, it is still in the stage of exploration in China, and great efforts have been made in industrial inspection, medical analysis and traffic monitoring mainly by colleges and universities, research institutes and enterprises. The applications of these products are grow rapidly. On bases of the understanding of the principle of machine vision technology, this paper accesses to a large number of machine vision application materials on automotive manufacturing and testing aspects, and designs a complete set of auto parts defect detection system based on this technology, which achieves on-line flaw detection of auto-parts. The main contents of this paper are summarized as below:
The technology of machine vision theory, development situation at home and abroad, application situation in automotive manufacturing industry, as well as the software platform of this system (LabVIEW software and Vision module) are introduced.
According to the preset parameters and technical requirements, a complete set of auto parts defect detection system is designed, which includes the selection and arrangements of the lighting source, optical lens, camera and photoelectric switches. The camera parameters are determined based on the relationship between the platform transmission speed, detection part rotating speed and the camera shooting speed.
Intensively studied the image processing technology, which includes image smoothing, image segmentation and image analyzing. The appropriate image processing methods are determined through analyzing and comparing the effects of these methods.
On bases of the camera calibration principle, calibration procedure is written applying the spatial intersection method, while the coordinates of the conversion procedure is written using spatial forward intersection method. By using the geometrical relations of the detecting parts, pixel-physical coordinate conversion is completed, which could only be achieved by binocular calibration otherwise and thus greatly reduces the cost.
A set of parts defect inspection procedure is written in accordance with the modular programming ideas based on LabVIEW. The procedures are divided into image acquisition module, image processing module, results storage module, data management module and interface designation module. Taking the shaft parts for example, the effectiveness of this system is verified.
By carrying simple experiments, results of defect detection, detection accuracy and speed were calculated, which verified the system feasibility. Finally, the error reasons were full analyzed.
介绍了机器视觉技术的基本理论、国内外的发展和研究现状,在汽车制造和检测领域的应用,以及视觉系统常用的软件平台LabVIEW软件和Vision模块。
根据设定的检测参数和技术要求,设计了一套完整的汽车零件缺陷检测系统,其内容包括照明光源、光学镜头、相机、光电开关的合理选择和布置,基于对检测台的传动速度、工件转速与相机采集速度的关系,确定了相机的参数。
深入研究了图像处理技术,内容包括图像平滑、图像分割和图像分析等,并通过分析比较,确定了合适的图像处理方法。
基于相机标定的基本原理,采用空间后方交会法编写了标定程序,采用空间前方交会法编写了坐标转换程序；通过待检测零件的几何关系利用单台相继实现了通常只有双目标定才能完成的像物坐标转换问题,大大节约了成本。
编写了一整套的基于LabVIEW的零件缺陷检测程序与用户界面程序,按照模块化的编程思想,分成图像采集模块、图像处理模块、结果保存模块、数据管理模块。以轴类零件为例,验证了缺陷检测系统的工作有效性。
通过简单的实验,对缺陷检测结果、检测精度和检测速度进行了计算,验证了系统方案的可行性,最后对误差原因进行全面分析。
Machine vision technology has been used widely at home and abroad due to its high efficiency, high precision, easy integration and some other significant advantages. However, although this technology is very popular in industry, agriculture, military and medical fields abroad, it is still in the stage of exploration in China, and great efforts have been made in industrial inspection, medical analysis and traffic monitoring mainly by colleges and universities, research institutes and enterprises. The applications of these products are grow rapidly. On bases of the understanding of the principle of machine vision technology, this paper accesses to a large number of machine vision application materials on automotive manufacturing and testing aspects, and designs a complete set of auto parts defect detection system based on this technology, which achieves on-line flaw detection of auto-parts. The main contents of this paper are summarized as below:
The technology of machine vision theory, development situation at home and abroad, application situation in automotive manufacturing industry, as well as the software platform of this system (LabVIEW software and Vision module) are introduced.
According to the preset parameters and technical requirements, a complete set of auto parts defect detection system is designed, which includes the selection and arrangements of the lighting source, optical lens, camera and photoelectric switches. The camera parameters are determined based on the relationship between the platform transmission speed, detection part rotating speed and the camera shooting speed.
Intensively studied the image processing technology, which includes image smoothing, image segmentation and image analyzing. The appropriate image processing methods are determined through analyzing and comparing the effects of these methods.
On bases of the camera calibration principle, calibration procedure is written applying the spatial intersection method, while the coordinates of the conversion procedure is written using spatial forward intersection method. By using the geometrical relations of the detecting parts, pixel-physical coordinate conversion is completed, which could only be achieved by binocular calibration otherwise and thus greatly reduces the cost.
A set of parts defect inspection procedure is written in accordance with the modular programming ideas based on LabVIEW. The procedures are divided into image acquisition module, image processing module, results storage module, data management module and interface designation module. Taking the shaft parts for example, the effectiveness of this system is verified.
By carrying simple experiments, results of defect detection, detection accuracy and speed were calculated, which verified the system feasibility. Finally, the error reasons were full analyzed.
引文
[1]张五一,赵强送,王冬云.机器视觉的现状及发展趋势[J].中原工学院学报,2009,19(1)： 9-15.
[2]唐向阳,张勇,李江有等.机器视觉关键技术的现状及应用展望[J].昆明理工大学学报(理工版),2004,29(2)：36-39.
[3]周富强.三维在线机器视觉检测关键技术的研究[D].天津大学博士学位论文.2000.
[4]李树杰.中国机器视觉的发展趋势[J].赤峰学院学报(自然科学版),2010,26(1)：161-162.
[5]王鹏,赵彦玲,刘献礼等.基于LabVIEW的机器视觉系统开发与应用[J].哈尔滨理工大学学报,2004,9(5)：84-87
[6]刘金桥,吴金强.机器视觉系统发展及其应用[J].机械工程与自动化,2010(1)：215-216.
[7]施雯.机器视觉在汽车实验中的应用[J].天津汽车,2008(10)：48-50.
[8]周龙.汽车发动机连杆表面缺陷机器视觉检测系统[D].浙江工业大学硕士学位论文,2005.
[9]王振峰.图像处理技术在汽车类型自动识别中的应用研究[D].中国农业大学硕士学位论文,2000.
[10]段峰,王耀南,雷晓峰等.机器视觉技术及其应用综述[J].自动化博览,2002(3)：59-61.
[11]陈刚.机器视觉系统使生产更快捷更方便[R].机器人技术与应用
[12]杨运蛾,何哓鸣.基于图像处理的客车车厢防雨密封性检测方法研究[J].武汉工业学院学报,2007(06)：75-77.
[13]李任江,李春梅,王丽娜等.机器视觉技术在汽车纵梁装配工艺孔在线检测中的应用[J].长春工业大学学报(自然科学版),2007.9,28(3)：308-311
[14]胡兴军,唐向阳,张勇.机器视觉技术及其在汽车制造质量检测中的应用[J].MC现代零部件,2005(11)：96-100.
[15]张立斌,苏建,田云锋.汽车前轮定位参数快速检测的建模研究.公路交通科技,2003(06)：155-158
[16]Leica.3D-Laser Tracking System The Hardware. Product Information,1996.
[17]申晓彦,王鉴.用于视觉检测的光源照明系统分析[J].灯与照明,2009.9,33(3)：7-9.
[18]莫之剑,范彦斌,全燕鸣.基于机器视觉产品尺寸在线检测的实践研究[J].佛山科学技术学院学报(自然科学版),2006.1,24(1)：25-28.
[19]潘珍英.工业自动光学检测中的照明系统设计[D].厦门大学硕士学位论文,2007.
[20]王亚鹏.机器视觉系统中镜头的选用技巧[J].自动化博览,2006.2：29-31.
[21]周雪英.小议CCD摄像机的选择与使用[J].西部广播电视,1994年增刊.
[22]段德山.工件非接触检测中机器视觉的研究与应用[D].北京邮电大学硕士学位论文,2007.
[23]杨高科.基于虚拟仪器的质量检测机器视觉系统[D].西北大学硕士学位论文,2002.
[24]杨雪发.工业摄像机镜头选用与调整[J].冶金自动化,2008.S2：700-703.
[25]蒋慧海.光电开关的原理和应用[J],铜业工程,2009(2)：41-46.
[26]沈畅,王晓峰,李毅等.光电开关之我见[J].新自动化,2006.8：34-36.
[27]贾永红.数字图像处理[M].武汉：武汉大学出版社,2006.
[28]张瑞林,朱桂英.图像处理技术在织物疵点检测中的应用[J].天津工业大学学报,2006.10,25(5)
[29]朱华勇.汽车前照灯计算机检测图像处理技术的研究[D].南京林业大学硕士学位论文,2007.
[30]田村秀行著.金喜子,乔双译.计算机图像处理[M].北京：科学出版社,2004.6.
[31]舒红平,蒋建明.基于灰度最优阈值的图像分割方法及应用[J].重庆工商大学学报(自然科学版),2003(4)：80-83
[32]Brink AD. Thresholding of Digital Image Using Two-dimensional Entropies [J].Pattern Recognition,1992(8):80-83.
[33]冯文灏.近景摄影测量[M],武汉：武汉大学出版社,2002.
[34]朱庆.论CCD成像系统检校的DLT方法[J].铁路航测,1994(3)
[35]雷俊.基于虚拟仪器技术的机器视觉系统研究[D].西北工业大学硕士学位论文,2001.
[36]选择视觉软件需要考虑的10个方面National Instrument.
[37]Robert H.bishop著,桥瑞萍,林欣等.LabVIEW 7实用教程[M].北京：电子工业出版社,2005.8.
[38]2005-2006 National Instruments Corporation. LabVIEW Help.371361B-01, August 2006.
[39]Gary W.Johnson, Richrad Jennings著.武嘉澍,陆劲昆译.LabVIEW图形编程.北京：北京大学出版社,2002
[40]基于LabVIEW的虚拟仪器和虚拟实验
[41]虚拟仪器与LabVIEW简介
[42]黄晓.基于LabVIEW和IMAQ Vision的几何尺寸非接触测量系统的研究[D].武汉理工大学硕士学位论文,2007.
[43]National Instruments Corporation. IMAQ Vision for LabVIEW User Manual.2003.
[44]National Instruments Corporation. IMAQ Vision Concepts Manual.2003.
[45]National Instruments Corporation. NI-IMAQ User Manual.2003.
[46]National Instruments Corporation. NI-IMAQ VI Reference Help, 2003.
[47]杨灿.基于LabVIEW的汽车行驶跑偏测试系统研究开发[D].武汉理工大学硕士学位论文,2010.
[48]崔淑娟.车辆跑偏在线自动检测系统的图像处理技术[D].武汉理工大学硕士学位论文,2010.
[49]周熊,叶平LabVIEW中利用LabSQL对数据库访问的实现[J].国外电子测量技术,2007,(07)
[50]陈锡辉,张银鸿.LabVIEW 8.20程序设计从入门到精通[M].北京：清华大学出版社,2007.7
[2]唐向阳,张勇,李江有等.机器视觉关键技术的现状及应用展望[J].昆明理工大学学报(理工版),2004,29(2)：36-39.
[3]周富强.三维在线机器视觉检测关键技术的研究[D].天津大学博士学位论文.2000.
[4]李树杰.中国机器视觉的发展趋势[J].赤峰学院学报(自然科学版),2010,26(1)：161-162.
[5]王鹏,赵彦玲,刘献礼等.基于LabVIEW的机器视觉系统开发与应用[J].哈尔滨理工大学学报,2004,9(5)：84-87
[6]刘金桥,吴金强.机器视觉系统发展及其应用[J].机械工程与自动化,2010(1)：215-216.
[7]施雯.机器视觉在汽车实验中的应用[J].天津汽车,2008(10)：48-50.
[8]周龙.汽车发动机连杆表面缺陷机器视觉检测系统[D].浙江工业大学硕士学位论文,2005.
[9]王振峰.图像处理技术在汽车类型自动识别中的应用研究[D].中国农业大学硕士学位论文,2000.
[10]段峰,王耀南,雷晓峰等.机器视觉技术及其应用综述[J].自动化博览,2002(3)：59-61.
[11]陈刚.机器视觉系统使生产更快捷更方便[R].机器人技术与应用
[12]杨运蛾,何哓鸣.基于图像处理的客车车厢防雨密封性检测方法研究[J].武汉工业学院学报,2007(06)：75-77.
[13]李任江,李春梅,王丽娜等.机器视觉技术在汽车纵梁装配工艺孔在线检测中的应用[J].长春工业大学学报(自然科学版),2007.9,28(3)：308-311
[14]胡兴军,唐向阳,张勇.机器视觉技术及其在汽车制造质量检测中的应用[J].MC现代零部件,2005(11)：96-100.
[15]张立斌,苏建,田云锋.汽车前轮定位参数快速检测的建模研究.公路交通科技,2003(06)：155-158
[16]Leica.3D-Laser Tracking System The Hardware. Product Information,1996.
[17]申晓彦,王鉴.用于视觉检测的光源照明系统分析[J].灯与照明,2009.9,33(3)：7-9.
[18]莫之剑,范彦斌,全燕鸣.基于机器视觉产品尺寸在线检测的实践研究[J].佛山科学技术学院学报(自然科学版),2006.1,24(1)：25-28.
[19]潘珍英.工业自动光学检测中的照明系统设计[D].厦门大学硕士学位论文,2007.
[20]王亚鹏.机器视觉系统中镜头的选用技巧[J].自动化博览,2006.2：29-31.
[21]周雪英.小议CCD摄像机的选择与使用[J].西部广播电视,1994年增刊.
[22]段德山.工件非接触检测中机器视觉的研究与应用[D].北京邮电大学硕士学位论文,2007.
[23]杨高科.基于虚拟仪器的质量检测机器视觉系统[D].西北大学硕士学位论文,2002.
[24]杨雪发.工业摄像机镜头选用与调整[J].冶金自动化,2008.S2：700-703.
[25]蒋慧海.光电开关的原理和应用[J],铜业工程,2009(2)：41-46.
[26]沈畅,王晓峰,李毅等.光电开关之我见[J].新自动化,2006.8：34-36.
[27]贾永红.数字图像处理[M].武汉：武汉大学出版社,2006.
[28]张瑞林,朱桂英.图像处理技术在织物疵点检测中的应用[J].天津工业大学学报,2006.10,25(5)
[29]朱华勇.汽车前照灯计算机检测图像处理技术的研究[D].南京林业大学硕士学位论文,2007.
[30]田村秀行著.金喜子,乔双译.计算机图像处理[M].北京：科学出版社,2004.6.
[31]舒红平,蒋建明.基于灰度最优阈值的图像分割方法及应用[J].重庆工商大学学报(自然科学版),2003(4)：80-83
[32]Brink AD. Thresholding of Digital Image Using Two-dimensional Entropies [J].Pattern Recognition,1992(8):80-83.
[33]冯文灏.近景摄影测量[M],武汉：武汉大学出版社,2002.
[34]朱庆.论CCD成像系统检校的DLT方法[J].铁路航测,1994(3)
[35]雷俊.基于虚拟仪器技术的机器视觉系统研究[D].西北工业大学硕士学位论文,2001.
[36]选择视觉软件需要考虑的10个方面National Instrument.
[37]Robert H.bishop著,桥瑞萍,林欣等.LabVIEW 7实用教程[M].北京：电子工业出版社,2005.8.
[38]2005-2006 National Instruments Corporation. LabVIEW Help.371361B-01, August 2006.
[39]Gary W.Johnson, Richrad Jennings著.武嘉澍,陆劲昆译.LabVIEW图形编程.北京：北京大学出版社,2002
[40]基于LabVIEW的虚拟仪器和虚拟实验
[41]虚拟仪器与LabVIEW简介
[42]黄晓.基于LabVIEW和IMAQ Vision的几何尺寸非接触测量系统的研究[D].武汉理工大学硕士学位论文,2007.
[43]National Instruments Corporation. IMAQ Vision for LabVIEW User Manual.2003.
[44]National Instruments Corporation. IMAQ Vision Concepts Manual.2003.
[45]National Instruments Corporation. NI-IMAQ User Manual.2003.
[46]National Instruments Corporation. NI-IMAQ VI Reference Help, 2003.
[47]杨灿.基于LabVIEW的汽车行驶跑偏测试系统研究开发[D].武汉理工大学硕士学位论文,2010.
[48]崔淑娟.车辆跑偏在线自动检测系统的图像处理技术[D].武汉理工大学硕士学位论文,2010.
[49]周熊,叶平LabVIEW中利用LabSQL对数据库访问的实现[J].国外电子测量技术,2007,(07)
[50]陈锡辉,张银鸿.LabVIEW 8.20程序设计从入门到精通[M].北京：清华大学出版社,2007.7
© 2004-2018 中国地质图书馆版权所有 京ICP备05064691号 京公网安备11010802017129号 地址：北京市海淀区学院路29号 邮编：100083 电话：办公室：(+86 10)66554848；文献借阅、咨询服务、科技查新：66554700 |