CN108458668A - Slab edge and Head and Tail Shape automatic checkout system based on binocular vision and method - Google Patents
Slab edge and Head and Tail Shape automatic checkout system based on binocular vision and method Download PDFInfo
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Abstract
本发明提供一种基于双目视觉的板坯边部及头尾形状自动检测系统,其包括图像采集模块、图像处理模块、系统通信模块、软件交互界面以及机器视觉检测算法模块,其中:图像采集模块用于板坯侧边及头尾的图像采集;图像处理模块用于对获取的所述板坯边部和尾部实时视频图像进行图像预处理;系统通信模块用于收集工业相机采集到的板坯边部和尾部实时视频图像并发送至客户端,以及向工业相机发送采集控制信号和对机器视觉检测算法模块识别结果信号的输出进行控制;机器视觉检测算法模块包括计算模块和判断模块。本发明设备简单,安装灵活,不影响原有生产线布置及操作,设备运行可靠性高且操作简单,可避免工人在恶劣环境下工作,降低人力成本。
The invention provides a binocular vision-based automatic detection system for the shape of the edge and head and tail of a slab, which includes an image acquisition module, an image processing module, a system communication module, a software interaction interface and a machine vision detection algorithm module, wherein: image acquisition The module is used for image acquisition of the side, head and tail of the slab; the image processing module is used for image preprocessing of the acquired real-time video images of the side and tail of the slab; the system communication module is used to collect the slab captured by the industrial camera The real-time video images of the edge and tail of the blank are sent to the client, and the acquisition control signal is sent to the industrial camera and the output of the recognition result signal of the machine vision detection algorithm module is controlled; the machine vision detection algorithm module includes a calculation module and a judgment module. The invention has simple equipment, flexible installation, does not affect the layout and operation of the original production line, has high equipment operation reliability and is easy to operate, can prevent workers from working in harsh environments, and reduce labor costs.
Description
技术领域technical field
本发明专利涉及板坯热轧生产板坯边部及头尾形状检测领域,特别涉及一种基于双目视觉的板坯边部及头尾形状自动检测系统及方法。The patent of the present invention relates to the field of slab edge and head and tail shape detection in slab hot rolling production, in particular to an automatic detection system and method for slab edge and head and tail shape based on binocular vision.
背景技术Background technique
铝合金厚板热轧板坯,因大压下量轧制消除了铸造组织缺陷,将铸造组织转变为形变组织,其延续产品在深冲性能、表面质量和精度控制方面具有很大的优势,可广泛应用于航空航天、汽车、机械制造、船舶及化工等国民经济重要领域,近十几年其生产过程的自动化程度有了很大发展,但智能化还远未实现,大多关键技术环节仍然依靠人工经验。Aluminum alloy thick plate hot-rolled slabs eliminate the defects of the casting structure due to large reduction rolling, and transform the casting structure into a deformed structure. Its continuation products have great advantages in deep drawing performance, surface quality and precision control. It can be widely used in important fields of the national economy such as aerospace, automobile, machinery manufacturing, shipbuilding and chemical industry. In the past ten years, the degree of automation of the production process has been greatly developed, but the intelligence is far from being realized, and most of the key technical links are still Rely on human experience.
其中一项较为关键的问题是,铝合金厚板热轧板坯初始厚度大(500-800mm),轧制压下量无法渗透到心部,累积变形在边部和头尾易出现双鼓形缺陷,目前工业实际生产过程中是通过采用投入立辊滚边和头尾切除的方式来控制板坯形状,但是由于缺少有效的检测手段,生产过程中立辊投入时机、滚边压下量、头尾切除量等控制主要靠人工检查或生产经验来实现,不仅工人操作环境恶劣,还会影响轧制规程的制定,造成了板坯的巨大浪费,大大降低了成材率。One of the more critical issues is that the initial thickness of the hot-rolled slab of aluminum alloy thick plate is large (500-800mm), the rolling reduction cannot penetrate to the center, and the accumulated deformation is prone to double drums at the edge and head and tail. Defects. At present, in the actual industrial production process, the shape of the slab is controlled by using vertical roll hemming and head and tail cutting. However, due to the lack of effective detection methods, the timing of vertical roll input, rolling reduction, and head and tail cutting Quantity and other controls are mainly realized by manual inspection or production experience. Not only is the operating environment for workers harsh, but it also affects the formulation of rolling regulations, resulting in huge waste of slabs and greatly reducing the yield of finished products.
近年来发展起来的机器视觉技术,具有可靠性高、反应快、生产成本低等优点,可真正实现生产的智能化,因此,面对人力成本的上升以及竞争压力的增大,如何借助机器视觉技术,提高其生产效率、产品成材率和产品质量成为亟待解决的关键技术问题。The machine vision technology developed in recent years has the advantages of high reliability, fast response, and low production cost, and can truly realize the intelligentization of production. Therefore, in the face of rising labor costs and increasing competitive pressure, how to use machine vision Technology, improving its production efficiency, product yield and product quality has become a key technical problem to be solved urgently.
发明内容Contents of the invention
本发明的目的是针对目前铝合金板热轧粗轧生产中缺少板坯形状检测装置,导致立辊投入、头尾切除时机及数值无法精确控制的问题,提供一种结构简单、实时检测且准确性高的双目视觉板坯边部及头尾形状检测系统及方法。The purpose of the present invention is to provide a simple structure, real-time detection and accurate detection device for the lack of slab shape detection device in the current production of aluminum alloy plate hot rolling and rough rolling, which leads to the problem that vertical roll input, head and tail cutting timing and numerical value cannot be accurately controlled. A highly efficient binocular vision slab edge and head and tail shape detection system and method.
本发明的目的通过以下技术方案来实现:The purpose of the present invention is achieved through the following technical solutions:
本发明提供一种基于双目视觉的板坯边部及头尾形状自动检测系统,其包括图像采集模块、图像处理模块、系统通信模块、软件交互界面以及机器视觉检测算法模块,其中:The invention provides a binocular vision-based automatic detection system for slab edge and head and tail shapes, which includes an image acquisition module, an image processing module, a system communication module, a software interaction interface and a machine vision detection algorithm module, wherein:
所述图像采集模块用于板坯侧边及头尾的图像采集,所述图像采集模块包括多个工业相机以及定位支架,所述定位支架固定在轧机出口辊道两侧,所述工业相机安装在所述定位支架上用于获取生产线板坯边部和尾部实时视频图像,每两个工业相机组成一个双目系统;The image acquisition module is used for image acquisition of the side, head and tail of the slab. The image acquisition module includes a plurality of industrial cameras and positioning brackets. The positioning brackets are fixed on both sides of the roller table at the exit of the rolling mill. The industrial cameras are installed On the positioning bracket, it is used to obtain real-time video images of the edge and tail of the production line slab, and every two industrial cameras form a binocular system;
所述图像处理模块用于对获取的所述板坯边部和尾部实时视频图像进行图像预处理,图像预处理包括板坯感兴趣区域的前景提取和图像增强,得到板坯边部及尾部图像;The image processing module is used to perform image preprocessing on the acquired real-time video images of the edge and tail of the slab, and the image preprocessing includes foreground extraction and image enhancement of the area of interest of the slab to obtain images of the edge and tail of the slab ;
所述系统通信模块用于收集工业相机采集到的板坯边部和尾部实时视频图像并发送至客户端,以及向工业相机发送采集控制信号和对机器视觉检测算法模块识别结果信号的输出进行控制;The system communication module is used to collect the real-time video images of the edge and tail of the slab collected by the industrial camera and send them to the client, and send the acquisition control signal to the industrial camera and control the output of the recognition result signal of the machine vision detection algorithm module ;
所述软件交互界面用于显示板坯边部和尾部实时视频图像以及机器视觉检测算法模块的运行结果,并实现机器视觉检测算法模块的运行参数控制;The software interaction interface is used to display the real-time video images of the edge and tail of the slab and the operation results of the machine vision detection algorithm module, and realize the control of the operation parameters of the machine vision detection algorithm module;
所述机器视觉检测算法模块包括计算模块和判断模块,The machine vision detection algorithm module includes a calculation module and a judgment module,
所述计算模块对处理后的板坯边部及头尾图像信息进行分析,得到检测板坯侧边及头尾的形状参数,The calculation module analyzes the processed slab edge and head and tail image information to obtain shape parameters for detecting the slab side and head and tail,
所述判断模块将检测板坯侧边及头尾的形状参数与预设道次变形参数进行比对,从而判断是否需要立辊投入和头尾切除以及滚边压下量和头尾切除量数值。The judging module compares the shape parameters of the detected slab side and head and tail with the preset pass deformation parameters, thereby judging whether vertical roll input, head and tail removal, rolling edge reduction, and head and tail removal are required.
优选地,所述工业相机为CCD相机。Preferably, the industrial camera is a CCD camera.
优选地,边部检测所用的两个CCD相机平行安装,所述CCD相机用于采集板坯上的图像;头尾检测的相机安装在板坯头尾位置,采集头尾的图像,为了采集良好的图像,可以将头尾的相机装在滑道上,让其和铝合金厚板有相同速度运动。Preferably, the two CCD cameras used for edge detection are installed in parallel, and the CCD cameras are used to collect images on the slab; the cameras for head and tail detection are installed at the head and tail positions of the slab to collect images of the head and tail, in order to collect good The image of the head and tail can be installed on the slide, so that it can move at the same speed as the aluminum alloy plate.
优选地,还包括数据库生成模块,所述数据库生成模块用于根据采集图像及处理结果建立工艺规程数据库,记录生产过程中板坯边部及头尾的形状的变化过程。Preferably, a database generation module is also included, the database generation module is used to establish a process specification database according to the collected images and processing results, and record the change process of the shape of the edge and head and tail of the slab during the production process.
本发明还提供一种基于机器视觉的板坯边部及头尾形状自动化检测方法,包括以下步骤:The present invention also provides a machine vision-based automatic detection method for the edge and head and tail shapes of a slab, comprising the following steps:
S1、布置检测装置,安装CCD相机;S1. Arrange the detection device and install the CCD camera;
S2、图像视频采集,通过CCD相机进行铝合金板坯边部及头尾图像视频信息采集;S2. Image and video collection, through the CCD camera to collect the edge and head and tail image and video information of the aluminum alloy slab;
S3、图像预处理,图像预处理包括板坯感兴趣区域的前景提取和图像增强;S3. Image preprocessing, image preprocessing includes foreground extraction and image enhancement of the area of interest of the slab;
S4、计算形状参数,通过CCD相机参数标定和系统的标定,得到CCD相机坐标、图像坐标和世界坐标系的关系,然后通过双目视觉原理计算得到世界坐标系下边部及其头尾形状轮廓;S4. Calculate the shape parameters, obtain the relationship between the CCD camera coordinates, the image coordinates and the world coordinate system through the calibration of the CCD camera parameters and the system calibration, and then calculate the lower part of the world coordinate system and its head and tail shape contours through the binocular vision principle;
S5、预设道次参数比对及判断,通过拟合得到的板坯边部及其头尾形状轮廓和预设道次变形参数进行对比,达到预设道次变形参数后投入立辊进行滚滚边和切头尾。S5. Comparison and judgment of the parameters of the preset pass. The edge of the slab and its head and tail shape profile obtained by fitting are compared with the deformation parameters of the preset pass. After the deformation parameters of the preset pass are reached, the vertical roller is put into rolling Edge and cut head and tail.
优选地,S1中布置检测装置的具体步骤如下所述:Preferably, the specific steps for arranging the detection device in S1 are as follows:
S11、首先利用双目CCD相机监控板坯,通过前景提取板坯感兴趣区域,然后通过图像增强突出板坯的边部及头尾部特征;S11. First, use a binocular CCD camera to monitor the slab, extract the area of interest of the slab through the foreground, and then highlight the edge and head and tail features of the slab through image enhancement;
S12、CCD相机标定,通过标定得到CCD相机坐标系、图像坐标系和世界坐标系之间的关系;S12, CCD camera calibration, the relationship between the CCD camera coordinate system, the image coordinate system and the world coordinate system is obtained through calibration;
S13、利用双目CCD相机检测边部变形参数。S13. Using a binocular CCD camera to detect edge deformation parameters.
优选地,S4中通过双目视觉原理计算得到世界坐标系下边部及其头尾关键点坐标具体包括如下步骤:Preferably, in S4, calculating the coordinates of the lower part of the world coordinate system and its head and tail key points through the principle of binocular vision specifically includes the following steps:
S41、将成像平面设定在镜头的光心前焦距f处,左右成像面坐标原点在CCD相机光轴与平面的交点O1和O2处,空间中某点P在左成像平面和右成像平面中相应的坐标为Pl(ul,vl)和Pr(ur,vr),现假设CCD相机的图像在同一平面,即vl=vr,由几何关系得到:S41. The imaging plane is set at the front focal length f of the optical center of the lens, the coordinate origin of the left and right imaging planes is at the intersections O1 and O2 of the optical axis of the CCD camera and the plane, and a certain point P in space is imaged on the left imaging plane and the right The corresponding coordinates in the plane are P l (u l , v l ) and P r (u r , v r ), assuming that the images of the CCD camera are on the same plane, that is, v l = v r , obtained from the geometric relationship:
上式中(xc,yc,zc)为点P在左CCD相机坐标系中的坐标,b为基线距,f为两CCD相机的焦距,(ul,vl)和(ur,vr)为点P在左右两图像中的坐标;In the above formula (x c , y c , z c ) are the coordinates of point P in the coordinate system of the left CCD camera, b is the baseline distance, f is the focal length of the two CCD cameras, (u l , v l ) and (u r , v r ) is the coordinates of point P in the left and right images;
S42、定义视差为某一点在两图像中相应点的位置差:S42. Define parallax as the position difference of a certain point in corresponding points in two images:
由此可以计算出空间中某点P在左CCD相机坐标系中的坐标为:From this, the coordinates of a point P in the space in the left CCD camera coordinate system can be calculated as:
S43、令世界坐标系与左CCD相机坐标系重合,得到的(xc,yc,zc)即为世界坐标系下P点坐标。S43. Make the world coordinate system coincide with the coordinate system of the left CCD camera, and the obtained (x c , y c , z c ) are the coordinates of point P in the world coordinate system.
优选地,还包括S6、生成工艺规程数据库,所述工艺规程数据库根据采集图像及处理结果建立,记录生产过程中板坯边部及头尾的形状的变化过程。Preferably, it also includes S6. Generating a process specification database, the process specification database is established according to the collected images and processing results, and records the change process of the shape of the edge and head and tail of the slab during the production process.
优选地,道次变形参数至少包括轧制过程中侧边及头尾凹陷的最大长度。Preferably, the pass deformation parameters at least include the maximum length of the side and head and tail depressions during the rolling process.
相比现有检测方法,本发明的有益效果是:Compared with existing detection methods, the beneficial effects of the present invention are:
①本发明设备简单,安装灵活,不影响原有生产线布置及操作,设备运行可靠性高且操作简单,可避免工人在恶劣环境下工作,降低人力成本。① The invention has simple equipment, flexible installation, does not affect the layout and operation of the original production line, and has high reliability and simple operation, which can prevent workers from working in harsh environments and reduce labor costs.
②本发明采用机器视觉技术,在线采集板坯边部和头尾图像,实时反馈边部和头尾变形后的轮廓形状,从而控制立辊及头尾切除的投入时机,实现滚边压下量及头尾切除量的精确控制,达到提高铝合金板坯的成材率和产品质量、增加生产经济效益的目的。②The present invention adopts machine vision technology to collect images of the edge and head and tail of the slab online, and feed back the deformed contour shape of the edge and head and tail in real time, so as to control the input timing of the vertical roller and head and tail cutting, and realize the amount of rolling edge reduction and The precise control of the head and tail cutting amount can achieve the purpose of improving the yield and product quality of aluminum alloy slabs and increasing the economic benefits of production.
③本发明可根据采集图像及处理结果建立工艺规程数据库,记录生产过程中板坯边部及头尾形状变化过程,可作为技术人员培训和工艺规程优化的参考资料。③ The present invention can establish a process specification database according to the collected images and processing results, and record the shape change process of the edge and head and tail of the slab during the production process, which can be used as reference materials for technical personnel training and process specification optimization.
附图说明Description of drawings
图1是本发明的结构示意框图;Fig. 1 is a structural schematic block diagram of the present invention;
图2是本发明的图像采集模块结构示意图;Fig. 2 is a schematic structural diagram of an image acquisition module of the present invention;
图3是本发明的双目视觉的检测原理图;Fig. 3 is the detection schematic diagram of the binocular vision of the present invention;
图4是本发明的三维结构示意图;Fig. 4 is a schematic diagram of a three-dimensional structure of the present invention;
图5为本发明的工作流程示意图;Fig. 5 is a schematic diagram of the workflow of the present invention;
图6为本发明的实施例1中的阈值分割图像;Fig. 6 is the threshold segmentation image in Embodiment 1 of the present invention;
图7为本发明的实施例1中的计算区域连接的部分;Fig. 7 is the part of the calculation area connection in Embodiment 1 of the present invention;
图8为本发明的实施例1中的提取得到的铝合金轮廓特征;Fig. 8 is the profile feature of the aluminum alloy extracted in Example 1 of the present invention;
图9为本发明的实施例1中的凸包运算后的图形;Fig. 9 is the graph after the convex hull operation in embodiment 1 of the present invention;
图10为本发明的实施例1中的“双鼓”缺口轮廓提取方法;Fig. 10 is the "double drum" gap contour extraction method in Embodiment 1 of the present invention;
图11为本发明的实施例2中的工厂实际轧制板坯变形示意图;Fig. 11 is a schematic diagram of deformation of the actual rolled slab in the factory in Embodiment 2 of the present invention;
图12为本发明的实施例2中的左相机采集的图像示意图;12 is a schematic diagram of images collected by the left camera in Embodiment 2 of the present invention;
图13为本发明的实施例2中的右相机采集的图像示意图;Fig. 13 is a schematic diagram of images collected by the right camera in Embodiment 2 of the present invention;
图14为本发明的实施例2中的视差图示意图;FIG. 14 is a schematic diagram of a disparity map in Embodiment 2 of the present invention;
图15为本发明的实施例2中的匹配分值示意图。FIG. 15 is a schematic diagram of matching scores in Embodiment 2 of the present invention.
具体实施方式Detailed ways
以下将参考附图详细说明本发明的示例性实施例、特征和方面。附图中相同的附图标记表示功能相同或相似的元件。尽管在附图中示出了实施例的各种方面,但是除非特别指出,不必按比例绘制附图。Exemplary embodiments, features, and aspects of the present invention will be described in detail below with reference to the accompanying drawings. The same reference numbers in the figures indicate functionally identical or similar elements. While various aspects of the embodiments are shown in drawings, the drawings are not necessarily drawn to scale unless specifically indicated.
下面结合附图对本发明专利具体实施方式做进一步说明:Below in conjunction with accompanying drawing, the specific embodiment of patent of the present invention is described further:
本发明提供一种基于双目视觉的板坯边部及头尾形状自动检测系统,如图1、图2及图4所示,其包括图像采集模块10、图像处理模块11、系统通信模块12、软件交互界面13以及机器视觉检测算法模块14,其中:The present invention provides a binocular vision-based automatic detection system for slab edge and head and tail shapes, as shown in Figure 1, Figure 2 and Figure 4, which includes an image acquisition module 10, an image processing module 11, and a system communication module 12 , software interaction interface 13 and machine vision detection algorithm module 14, wherein:
图像采集模块10用于板坯侧边及头尾的图像采集,图像采集模块10包括多个工业相机以及定位支架6,定位支架6固定在轧机出口辊道两侧,工业相机安装在定位支架6上用于获取生产线板坯边部和尾部实时视频图像,每两个工业相机组成一个双目系统。The image acquisition module 10 is used for image acquisition of the side, head and tail of the slab. The image acquisition module 10 includes a plurality of industrial cameras and positioning brackets 6. The positioning brackets 6 are fixed on both sides of the roll table at the exit of the rolling mill, and the industrial cameras are installed on the positioning brackets 6. It is used to obtain real-time video images of the edge and tail of the slab on the production line, and every two industrial cameras form a binocular system.
图像处理模块11用于对获取的所述板坯边部和尾部实时视频图像进行图像预处理,图像预处理包括板坯感兴趣区域的前景提取和图像增强,得到板坯边部和尾部图像。The image processing module 11 is used to perform image preprocessing on the acquired real-time video images of the edge and tail of the slab. The image preprocessing includes foreground extraction and image enhancement of the region of interest of the slab to obtain images of the edge and tail of the slab.
系统通信模块12用于收集工业相机采集到的板坯边部和尾部实时视频图像并发送至客户端15,以及向工业相机发送采集控制信号和对机器视觉检测算法模块识别结果信号的输出进行控制。The system communication module 12 is used to collect the real-time video images of the edge and tail of the slab collected by the industrial camera and send it to the client 15, and send the collection control signal to the industrial camera and control the output of the recognition result signal of the machine vision detection algorithm module .
软件交互界面13用于显示板坯边部和尾部图像以及算法运行结果和实现算法运行参数控制。The software interaction interface 13 is used to display the images of the edge and tail of the slab, the results of the algorithm operation, and realize the control of the algorithm operation parameters.
机器视觉检测算法模块14用于将板坯边部和尾部图像进行分析,机器视觉检测算法模块14包括计算模块141和判断模块142。The machine vision detection algorithm module 14 is used to analyze the edge and tail images of the slab, and the machine vision detection algorithm module 14 includes a calculation module 141 and a judgment module 142 .
计算模块141利用采集到的板坯边部及头尾图像信息分析,得到检测板坯侧边及头尾的形状参数。The calculation module 141 analyzes the collected slab edge and head and tail image information to obtain the shape parameters of the detected slab side and head and tail.
判断模块142将计算结果与预设道次变形参数进行比对,从而判断是否需要立辊投入和头尾切除以及滚边压下量和头尾切除量数值。The judging module 142 compares the calculation result with the preset deformation parameters of the pass, so as to judge whether vertical roll input, head and tail cutting, and rolling edge reduction and head and tail cutting are needed.
道次变形参数就是轧制过程中侧边及头尾“凹陷”的最大临界长度,还有其它参数,但是长度最明显,其它参数可以作为辅助,例如轧制过程中“凹陷”区域缺口的宽度。假设“凹陷”最大临界长度设为200mm,当实际长度大于200mm时则认为其对于整个板坯的后续轧制成材率有影响,所以需要滚边及切头尾操作。简单讲道次变形参数就是根据实际经验人为的设定一个值,当轧制过程中达到这个值时发出滚边和切头尾判断。The pass deformation parameter is the maximum critical length of the "sag" of the side and head and tail during the rolling process, and there are other parameters, but the length is the most obvious, and other parameters can be used as auxiliary, such as the width of the notch in the "sag" area during the rolling process . Assuming that the maximum critical length of "sag" is set to 200mm, when the actual length is greater than 200mm, it is considered to have an impact on the subsequent rolling yield of the entire slab, so hemming and head and tail cutting operations are required. Simply speaking, the deformation parameter of the pass is to set a value artificially based on actual experience. When this value is reached during the rolling process, the judgment of rolling edge and cutting head and tail will be issued.
优选地,还包括数据库生成模块,所述数据库生成模块用于根据采集图像及处理结果建立工艺规程数据库,记录生产过程中板坯边部及头尾的形状的变化过程。Preferably, a database generation module is also included, the database generation module is used to establish a process specification database according to the collected images and processing results, and record the change process of the shape of the edge and head and tail of the slab during the production process.
本发明还提供一种基于机器视觉的板坯边部及头尾形状自动化检测方法,包括以下步骤:The present invention also provides a machine vision-based automatic detection method for the edge and head and tail shapes of a slab, comprising the following steps:
S1、布置检测装置,安装CCD相机;S1. Arrange the detection device and install the CCD camera;
S2、图像视频采集,通过CCD相机进行铝合金板坯边部及头尾图像视频信息采集;S2. Image and video collection, through the CCD camera to collect the edge and head and tail image and video information of the aluminum alloy slab;
S3、图像预处理,图像预处理包括板坯感兴趣区域的前景提取和图像增强;S3. Image preprocessing, image preprocessing includes foreground extraction and image enhancement of the area of interest of the slab;
S4、计算形状参数,通过CCD相机参数标定和系统的标定,得到CCD相机坐标、图像坐标和世界坐标系的关系,然后通过双目视觉原理计算得到世界坐标系下边部及其头尾关键点坐标,通过拟合得到板坯边部及其头尾形状轮廓;S4. Calculate the shape parameters, obtain the relationship between the CCD camera coordinates, the image coordinates and the world coordinate system through the calibration of the CCD camera parameters and the system calibration, and then calculate the lower part of the world coordinate system and its head and tail key point coordinates through the binocular vision principle , get the slab edge and its head and tail shape profile by fitting;
S5、预设道次变形参数比对及判断,通过拟合得到的板坯边部及其头尾形状轮廓和预设道次变形参数进行对比,达到预设道次变形参数后投入立辊进行滚边和切头尾。S5. Comparison and judgment of the deformation parameters of the preset pass. The edge of the slab and its head and tail shape profile obtained by fitting are compared with the deformation parameters of the preset pass. After the deformation parameters of the preset pass are reached, the vertical roller is put into Piping and cutting head and tail.
S6、生成工艺规程数据库,所述工艺规程数据库根据采集图像及处理结果建立,记录生产过程中板坯边部及头尾形状变化过程。S6. Generate a process specification database. The process specification database is established according to the collected images and processing results, and records the shape change process of the edge and head and tail of the slab during the production process.
轧制过程每个道次会有不同的变形参数,数据库可以把这些变形参数记录下来,以便用于后续分析。例如,可以将每个道次边部和头尾“凹陷”变形的长度和轮廓记录下来,利用特征匹配等数字图象处理方法进行分析和自学习,最终实现轧制过程中板坯边部和头尾“凹陷”轮廓特征的在线实时预测,优化工艺。Each pass of the rolling process will have different deformation parameters, and the database can record these deformation parameters for subsequent analysis. For example, the length and contour of the "sag" deformation at the edge and head and tail of each pass can be recorded, and digital image processing methods such as feature matching can be used for analysis and self-learning, and finally the edge and tail of the slab during the rolling process can be realized. Online real-time prediction of head and tail "sag" profile features to optimize process.
按照附图2示意图进行装置各部件结构连接,附图2以及图4中包括待检测铝合金板坯2、左CCD相机3、右CCD相机5以及定位支架6。According to the schematic diagram of Figure 2, the structural connection of the various components of the device is carried out. Figure 2 and Figure 4 include the aluminum alloy slab to be inspected 2, the left CCD camera 3, the right CCD camera 5 and the positioning bracket 6.
基于双目机器视觉的板坯边部及头尾形状自动化检测系统操作过程如下:The operation process of the slab edge and head and tail shape automatic detection system based on binocular machine vision is as follows:
(1)该装置布置如图2和图4所示,首先利用双目CCD相机监控铝合金板坯,通过前景提取感兴趣区域(运动的铝合金板坯),然后通过图像增强突出铝合金板坯的边部特征,方便后期检测。(1) The arrangement of the device is shown in Figure 2 and Figure 4. First, the binocular CCD camera is used to monitor the aluminum alloy slab, and the region of interest (moving aluminum alloy slab) is extracted through the foreground, and then the aluminum alloy plate is highlighted through image enhancement The edge features of the billet are convenient for later detection.
(2)CCD相机标定。通过标定得到CCD相机坐标系、图像坐标系和世界坐标系之间的关系。(2) CCD camera calibration. The relationship between the CCD camera coordinate system, the image coordinate system and the world coordinate system is obtained through calibration.
(4)利用平行双目视觉成像原理得到图像的视差图,利用视差图计算铝合金边部凹陷距离。(4) Obtain the disparity map of the image by using the principle of parallel binocular vision imaging, and use the disparity map to calculate the concave distance of the aluminum alloy edge.
(5)计算得到的边部凹陷长度和预设道次设定的凹陷轮廓长度进行对比,当计算得到的长度达到预设定的长度时,进行投入滚边和切头尾。(5) Compare the calculated length of the edge depression with the length of the concave contour set by the preset pass, and when the calculated length reaches the preset length, put in the hemming and cut the head and tail.
附图3是双目平行视觉成像原理图。事实上CCD相机成像平面在镜头的光心之后,为了方便计算,将成像平面设定在镜头的光心前f(焦距)处。左右成像面坐标原点在CCD相机光轴与平面的交点O1和O2处。空间中某点P在左成像平面和右成像平面中相应的坐标为Pl(ul,vl)和Pr(ur,vr)。如果两CCD相机内部参数相同,且安装位置在同一平面,则两个成像平面在同一平面。现假设CCD相机的图像在同一平面,即vl=vr,由几何关系得到:Accompanying drawing 3 is the schematic diagram of binocular parallel vision imaging. In fact, the imaging plane of the CCD camera is behind the optical center of the lens. For the convenience of calculation, the imaging plane is set at f (focal length) in front of the optical center of the lens. The coordinate origin of the left and right imaging surfaces is at the intersections O1 and O2 of the optical axis of the CCD camera and the plane. The corresponding coordinates of a point P in space in the left and right imaging planes are P l (u l , v l ) and P r (u r , v r ). If the internal parameters of the two CCD cameras are the same and the installation positions are on the same plane, then the two imaging planes are on the same plane. Now assume that the images of the CCD camera are on the same plane, that is, v l =v r , obtained from the geometric relationship:
上式中(xc,yc,zc)为点P在左CCD相机坐标系中的坐标,b为基线距,f为两CCD相机的焦距,(ul,vl)和(ur,vr)为点P在左右两图像中的坐标。In the above formula (x c , y c , z c ) are the coordinates of point P in the coordinate system of the left CCD camera, b is the baseline distance, f is the focal length of the two CCD cameras, (u l , v l ) and (u r , v r ) are the coordinates of point P in the left and right images.
视差定义为某一点在两图像中相应点的位置差:Parallax is defined as the positional difference of a point at corresponding points in two images:
由此可以计算出空间中某点P在左CCD相机坐标系中的坐标为:From this, the coordinates of a point P in the space in the left CCD camera coordinate system can be calculated as:
令世界坐标系与左CCD相机坐标系重合,得到的(xc,yc,zc)即为世界坐标系下P点坐标。在二台CCD相机内外部参数一致的前提下,对于某台CCD相机像平面上任意一点,只要在另一台CCD相机平面找到其对应匹配点,就可以计算出该点的三维坐标。Let the world coordinate system coincide with the coordinate system of the left CCD camera, and the obtained (x c , y c , z c ) is the coordinate of point P in the world coordinate system. On the premise that the internal and external parameters of the two CCD cameras are consistent, for any point on the image plane of a certain CCD camera, as long as the corresponding matching point is found on the plane of another CCD camera, the three-dimensional coordinates of the point can be calculated.
实施例一:铝合金板坯头尾的测量。Example 1: Measurement of the head and tail of the aluminum alloy slab.
(1)、感兴趣区域设置。(1) Area of interest setting.
ROI为RegionOfInterest的缩写,即为感兴趣区域。对于需要提取特征的图像,我们的感兴趣区域为铝合金板,其它的例如工厂背景、轧辊、辊道等我们并不关心,所以设置的感兴趣区域只需把铝合金板包括起来即可。需要注意现场采集的图像是彩色图像,ROI区域设置之前需要把彩色图像转化为灰度图。ROI is the abbreviation of RegionOfInterest, that is, the region of interest. For the image that needs to extract features, our area of interest is the aluminum alloy plate, and we don’t care about other things such as factory background, rolls, roller tables, etc., so the set area of interest only needs to include the aluminum alloy plate. It should be noted that the image collected on site is a color image, and the color image needs to be converted into a grayscale image before the ROI area is set.
(2)图像阈值分割(2) Image threshold segmentation
阈值分割的基本思想是:对于给定灰度图像f(x,y),对于给定灰度范围[Z1,Z2],t∈[Z1,Z2],如果:The basic idea of threshold segmentation is: for a given grayscale image f(x,y), for a given grayscale range [Z 1 ,Z 2 ], t∈[Z 1 ,Z 2 ], if:
则称ft(x,y)为图像f(x,y)以t为门限的二值图像。本文采取的阈值门限为97,阈值分割后的图像如下图6所示。Then f t (x, y) is called the binary image of the image f(x, y) with t as the threshold. The threshold threshold used in this paper is 97, and the image after threshold segmentation is shown in Figure 6 below.
(3)铝合金厚板的轮廓特征提取(3) Contour feature extraction of aluminum alloy thick plate
阈值分割后,计算阈值后连接在一起的范围,结果如图7所示,不同的范围用不同的颜色表示,然后选择具有目标特征的区域。本文的目标特征为区域面积,由图7明显看出需要提取的铝合金厚板轮廓的面积远大于其他区域的面积,所以设置目标特征为面积大于100000像素(具体数值根据程序调整),提取得到的铝合金的轮廓特征如图8所示。After threshold segmentation, calculate the ranges connected together after thresholding, the result is shown in Figure 7, different ranges are represented by different colors, and then select the area with the target feature. The target feature in this paper is the area area. It is obvious from Figure 7 that the area of the aluminum alloy thick plate contour that needs to be extracted is much larger than the area of other areas, so the target feature is set to an area greater than 100,000 pixels (the specific value is adjusted according to the program), and the extraction is obtained The contour characteristics of the aluminum alloy are shown in Fig. 8.
(4)、“双鼓”长度的测量(4), the measurement of the length of "double drum"
特征提取后,接着需要测量“双鼓”的长度,其具体思路为先把提取的铝合金的轮廓进行凸包运算,得到的图形与提取的轮廓特征求差,得到“双鼓”的缺口形状,然后求缺口的最小外接矩形,最小外接矩形的宽度即为“双鼓”的长度。After the feature extraction, the length of the "double drum" needs to be measured. The specific idea is to perform a convex hull calculation on the extracted aluminum alloy profile, and then calculate the difference between the obtained graph and the extracted contour features to obtain the notch shape of the "double drum" , and then find the minimum circumscribed rectangle of the gap, the width of the minimum circumscribed rectangle is the length of the "double drum".
(4.1)凸包运算(4.1) Convex hull operation
凸包是计算机几何的基本结构,在许多图形图像相关领域得到了广泛应用。一个凸多边形就是没有任何凹陷的多边形,凸包运算后就是把凹陷的部分用图形填充。凸包运算后得到的图形如图9所示。The convex hull is the basic structure of computer geometry and has been widely used in many graphics and image related fields. A convex polygon is a polygon without any depression. After the convex hull operation, the concave part is filled with graphics. The graph obtained after the convex hull operation is shown in Figure 9.
3.2“双鼓”缺口轮廓提取与测量3.2 "Double drum" notch contour extraction and measurement
凸包得到的图形与提取的轮廓特征进行求差运算,如图10所示,得到“双鼓”缺口的轮廓。The graph obtained by the convex hull is subtracted from the extracted contour features, as shown in Figure 10, and the contour of the "double drum" gap is obtained.
得到的缺口轮廓的最小外接矩形,其宽度即为“双鼓”的长度,长度值为174.065像素。通过摄像机标定可以测得“双鼓”的真实距离为200mm。The width of the minimum circumscribed rectangle of the obtained notch outline is the length of the "double drum", and the length value is 174.065 pixels. Through camera calibration, it can be measured that the real distance of the "double drum" is 200mm.
实施例二:铝合金板坯边部的测量。Embodiment 2: Measurement of the edge of the aluminum alloy slab.
实际轧制的过程中铝合金厚板边部变形如图11所示,利用铝型材的中间凹槽模拟轧制过程中的边部的变形。The edge deformation of the aluminum alloy thick plate during the actual rolling process is shown in Figure 11. The middle groove of the aluminum profile is used to simulate the edge deformation during the rolling process.
图12和图13是用双目相机分别采集的图像,图14是生成的视差图,图15是匹配分值,用到的软件是halocn13。通过得到的视差图的灰度值可以计算铝型材中间凹槽的深度,该深度代表铝合金板坯热轧边部变形深度,当该深度达到设定值的时候,就投入立辊滚边。Figure 12 and Figure 13 are images collected by binocular cameras, Figure 14 is the generated disparity map, Figure 15 is the matching score, and the software used is halocn13. The depth of the middle groove of the aluminum profile can be calculated by the gray value of the obtained disparity map, which represents the deformation depth of the hot-rolled edge of the aluminum alloy slab. When the depth reaches the set value, it is put into the vertical roll hemming.
最后应说明的是:以上所述的各实施例仅用于说明本发明的技术方案,而非对其限制;尽管参照前述实施例对本发明进行了详细的说明,本领域的普通技术人员应当理解:其依然可以对前述实施例所记载的技术方案进行修改,或者对其中部分或全部技术特征进行等同替换;而这些修改或替换,并不使相应技术方案的本质脱离本发明各实施例技术方案的范围。Finally, it should be noted that: the above-described embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand : It is still possible to modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements to some or all of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the technical solutions of the various embodiments of the present invention range.
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