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CN115631138A - Zirconium alloy plate laser cutting quality monitoring method and device - Google Patents

Zirconium alloy plate laser cutting quality monitoring method and device Download PDF

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CN115631138A
CN115631138A CN202211186427.6A CN202211186427A CN115631138A CN 115631138 A CN115631138 A CN 115631138A CN 202211186427 A CN202211186427 A CN 202211186427A CN 115631138 A CN115631138 A CN 115631138A
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计效园
王泽明
涂先猛
罗建东
吴楚澔
王伟
侯明君
王治国
秦应雄
潘喆
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Huazhong University of Science and Technology
Nuclear Power Institute of China
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Nuclear Power Institute of China
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Abstract

本发明公开了一种锆合金板材激光切割质量监检测方法与装置,属于激光切割领域。在激光切割断面的侧下方架设线阵CMOS相机,在锆合金板料激光切割完成后,通过线阵CMOS相机获取切割板料切割面与底面的图像信息,通过计算机图像矫正与图像缺陷识别分类程序,对侧拍断面不矫正、对底面图像进行矫正处理,融合成一张图片,并进行灰度化、网格划分处理,对缺陷快速地进行识别分类、标记、预警、判定、评估。本发明采用一个线阵CMOS相机将切割断面与板材底面融合至一张图中,同时对三类缺陷进行在线监检测,较现有的锆合金板料激光切割质量检测,本发明用较低的软硬件成本、开发了高的功能集成度的在线监检测方法与装置,提高了检测的可靠性与产品质量。

Figure 202211186427

The invention discloses a laser cutting quality monitoring method and device for a zirconium alloy plate, belonging to the field of laser cutting. Set up a linear array CMOS camera under the side of the laser cutting section. After the laser cutting of the zirconium alloy sheet is completed, the image information of the cutting surface and the bottom surface of the cutting sheet is obtained through the linear array CMOS camera, and the computer image correction and image defect recognition and classification programs are used. , the side shot section is not corrected, the bottom image is corrected, merged into a picture, and processed by grayscale and grid division, and quickly identify and classify, mark, warn, judge, and evaluate defects. The present invention uses a linear array CMOS camera to integrate the cutting section and the bottom surface of the plate into one image, and simultaneously monitors and detects three types of defects online. Compared with the existing laser cutting quality inspection of zirconium alloy plates, the present invention uses lower software and hardware cost, and developed an on-line monitoring method and device with high functional integration, which improved the reliability of detection and product quality.

Figure 202211186427

Description

一种锆合金板材激光切割质量监检测方法与装置A method and device for quality monitoring and detection of laser cutting of zirconium alloy plates

技术领域technical field

本发明属于激光切割技术领域,更具体地,涉及一种锆合金板材激光切割质量监检测方法与装置。The invention belongs to the technical field of laser cutting, and more specifically relates to a quality monitoring method and device for laser cutting of zirconium alloy plates.

背景技术Background technique

激光切割的工作原理是将激光器产生的激光通过光学器件引导,聚焦在材料表面使材料熔化、汽化,同时用与激光束同轴的压缩气体吹走被熔化的材料,并使激光束与材料沿一定轨迹作相对运动,从而形成一定形状的切缝。激光切割技术可用于金属和非金属材料的加工中,可大大减少加工时间,降低加工成本,提高工件质量,生产中广泛应用于金属板材的切割。锆合金塑性好,可制成管材、板材等,主要用途是石油领域、核技术领域。The working principle of laser cutting is to guide the laser generated by the laser through optical devices, focus on the surface of the material to melt and vaporize the material, and at the same time use the compressed gas coaxial with the laser beam to blow away the melted material, and make the laser beam and the material along A certain trajectory makes relative movement, thereby forming a certain shape of the slit. Laser cutting technology can be used in the processing of metal and non-metal materials, which can greatly reduce processing time, reduce processing costs, and improve workpiece quality. It is widely used in the cutting of metal sheets in production. Zirconium alloy has good plasticity and can be made into pipes, plates, etc. It is mainly used in the petroleum field and nuclear technology field.

目前对于激光切割的过程切缝环境复杂,加上激光切割的参数如激光功率、切割速度、气体流量、离焦量等的选择不合适,切割时容易产生许多缺陷,如挂渣、飞溅、切面粗糙度超标等,而使得激光切割的产品关键质量指标不合格,将对最后装配的产品使用性能造成严重影响,甚至会造成严重的安全事故。然而,传统的激光切割产品质量检测依靠人工检测,并且由于工人的疲劳,会有误判和漏判的可能,耗费了大量人力,检测结果的可靠性也有待提高。此外,传统的激光切割没有对挂渣、飞溅、表面粗糙度超标等缺陷的检测装置,不能在短时间内对锆合金板料激光切割生产的产品进行评估,只能冷却后再进行人工检测挂渣、飞溅、表面粗糙度是否达标,对激光切割产品切割质量的评估需要花费大量时间。因此,有必要开发一种高度功能集成的精准高效的激光切割质量在线监检测方法与装置。At present, the cutting environment of the laser cutting process is complicated, and the selection of laser cutting parameters such as laser power, cutting speed, gas flow, defocusing amount, etc. is not suitable, and many defects are prone to occur during cutting, such as hanging slag, spatter, cut surface If the roughness exceeds the standard, the key quality indicators of laser cutting products will not be up to standard, which will have a serious impact on the performance of the final assembled product, and even cause serious safety accidents. However, the traditional quality inspection of laser cutting products relies on manual inspection, and due to the fatigue of workers, there may be misjudgment and missed judgment, which consumes a lot of manpower, and the reliability of the inspection results needs to be improved. In addition, the traditional laser cutting does not have a detection device for defects such as dross, spatter, and surface roughness exceeding the standard. It cannot evaluate the products produced by laser cutting of zirconium alloy sheets in a short period of time. It can only be manually inspected after cooling. Whether the slag, spatter, and surface roughness are up to standard, it takes a lot of time to evaluate the cutting quality of laser cutting products. Therefore, it is necessary to develop a highly functionally integrated, accurate and efficient online monitoring method and device for laser cutting quality.

发明内容Contents of the invention

针对现有技术的缺陷,本发明的目的在于提供一种锆合金板材激光切割质量监检测方法与装置,旨在解决如何节省大量人力、提高激光切割产品检测的可靠性的问题。In view of the defects of the prior art, the purpose of the present invention is to provide a method and device for laser cutting quality monitoring of zirconium alloy plates, aiming at solving the problem of how to save a lot of manpower and improve the reliability of laser cutting product detection.

为实现上述目的,第一方面,本发明提供了一种锆合金板材激光切割质量监检测方法,该方法包括:In order to achieve the above object, in the first aspect, the present invention provides a method for monitoring and detecting the quality of laser cutting of zirconium alloy plates, the method comprising:

S1.获取锆合金板材激光切割后包含有切割面与底面的图片,对板材底面矫正后,与未矫正的切割断面图片融合成一张图片,并对图像进行灰度化与网格划分;S1. Obtain the picture including the cutting surface and the bottom surface after the laser cutting of the zirconium alloy plate, after correcting the bottom surface of the plate, merge it with the uncorrected cutting section picture into one picture, and perform grayscale and grid division on the image;

S2.计算各网格的灰度直方图的分布标准差和分布均方根高度值的比值,分别与最大可接受粗糙度对应的阈值比较,若超过,则该网格存在表面粗糙度超标缺陷,否则,该网格不存在表面粗糙度超标缺陷;S2. Calculate the ratio of the distribution standard deviation and the distribution root mean square height value of the gray histogram of each grid, and compare them with the threshold corresponding to the maximum acceptable roughness respectively. If it exceeds, the grid has a surface roughness exceeding the standard defect , otherwise, the grid does not have defects of surface roughness exceeding the standard;

S3.将各网格灰度化图片输入至卷积神经网络,得到各网格存在挂渣缺陷和飞溅缺陷的概率,并根据概率大小进行缺陷的标定;S3. Input the grayscale images of each grid into the convolutional neural network to obtain the probability of slag defects and splash defects in each grid, and calibrate the defects according to the probability;

S4.综合表面粗糙度超标、挂渣和飞溅三类缺陷的数量和面积,对板材切割质量进行评估。S4. Based on the quantity and area of the surface roughness exceeding the standard, hanging slag and splashing three types of defects, the cutting quality of the plate is evaluated.

优选地,步骤S1中,对图片进行底面矫正,包括:Preferably, in step S1, correcting the bottom surface of the picture includes:

1)基于透视变换,识别出底面与切割面的交线并延长至图片边缘;1) Based on the perspective transformation, identify the intersection line between the bottom surface and the cutting surface and extend it to the edge of the picture;

2)对于所得延长线的下方的图片进行透视变换矫正;2) Perspective transformation correction is carried out for the picture below the obtained extension line;

3)将矫正后的下方的图片沿着延长线与切割面融合,得到最终矫正图。3) Merge the corrected lower picture along the extension line with the cut surface to obtain the final corrected picture.

优选地,获得拍摄装置距离切割面的水平距离,依据三角函数关系,得出拍摄装置轴线的垂直面与板材底面的锐角夹角,作为底面矫正的角度。Preferably, the horizontal distance between the shooting device and the cutting surface is obtained, and the acute angle between the vertical plane of the axis of the shooting device and the bottom surface of the plate is obtained according to the relationship of trigonometric functions as the angle for bottom surface correction.

优选地,在将各网格灰度化图片输入至卷积神经网络之前,采用选择性搜索算法进行可疑网格图片的初筛。Preferably, before inputting each gray-scaled grid picture to the convolutional neural network, a selective search algorithm is used for preliminary screening of suspicious grid pictures.

优选地,步骤S3中,对于得到的缺陷判定结果,最大概率超过95%的,认定为存在该缺陷,并直接将该区域附加红色框标记,最大概率在75%~95%的,认为疑似存在该缺陷,并在该区域附加黄色框标记,最大概率在75%以下的区域,不加标记,最终在计算机界面通过图示展示时便于区分。Preferably, in step S3, for the defect determination results obtained, if the maximum probability exceeds 95%, it is determined that the defect exists, and the area is directly marked with a red box, and if the maximum probability is 75% to 95%, it is considered suspected to exist The defect is marked with a yellow box in this area, and the area with the maximum probability below 75% is not marked, and finally it is easy to distinguish when it is displayed on the computer interface through a diagram.

优选地,该方法还包括以下任一种处理方式:Preferably, the method also includes any of the following treatments:

处理方式一:通过对可视化显示界面弹窗与线阵CMOS监测系统进行三色灯预警与蜂鸣器警告声预警;其中,红色预警灯亮表示缺陷问题严重,缺陷数量或尺寸超出正常范围,蜂鸣器发出连续警告声;黄色预警灯亮表示切割面与底面的质量均在正常范围内,但是评分未达到优,蜂鸣器发出断续警告声;绿色预警灯亮表示缺陷情况正常,并且评分为优,无警告声;Processing method 1: Through the pop-up window of the visual display interface and the linear array CMOS monitoring system, the three-color light warning and the buzzer warning sound warning are carried out; among them, the red warning light indicates that the defect is serious, and the number or size of the defect exceeds the normal range, and the buzzer sounds The buzzer emits a continuous warning sound; the yellow warning light is on, indicating that the quality of the cutting surface and the bottom surface are within the normal range, but the score is not excellent, and the buzzer emits an intermittent warning sound; the green warning light is on, indicating that the defect is normal and the score is excellent. No warning sound;

处理方式二:对检测的缺陷进行数量统计、尺寸统计、缺陷密度统计,并与标准比较,判断在每种缺陷上是否达标。Processing method 2: Perform quantity statistics, size statistics, and defect density statistics on the detected defects, and compare with the standard to determine whether each defect meets the standard.

为实现上述目的,第二方面,本发明提供了一种锆合金板材激光切割质量监检测装置,该装置包括:拍摄装置、导轨、支撑连接装置和图像处理分析模块;In order to achieve the above object, in the second aspect, the present invention provides a zirconium alloy plate laser cutting quality monitoring device, the device includes: a shooting device, a guide rail, a supporting connection device and an image processing and analysis module;

所述导轨位于激光切割面的侧下方,且与激光切割的x轴平行,用于带动拍摄装置无障碍、平稳地移动,同时保证拍摄装置能同时扫描激光切割工件切割面与底面的全貌;The guide rail is located under the side of the laser cutting surface and is parallel to the x-axis of the laser cutting, and is used to drive the shooting device to move smoothly without obstacles, and at the same time to ensure that the shooting device can scan the whole picture of the cutting surface and the bottom surface of the laser cutting workpiece at the same time;

所述拍摄装置通过支撑连接装置固定在导轨上,用于根据控制信号,在锆合金板材激光切割完成后,拍摄包含有切割板料底面与切割面的图片,上传至图像处理分析模块;The photographing device is fixed on the guide rail through the supporting connection device, and is used for taking pictures including the bottom surface and the cutting surface of the cutting plate after the laser cutting of the zirconium alloy plate is completed according to the control signal, and uploading to the image processing and analysis module;

所述图像处理分析模块,用于对拍摄到的图片采用如第一方面所述的方法进行处理和分析,得到锆合金板材的缺陷位置与种类、切割质量。The image processing and analysis module is used to process and analyze the captured pictures using the method as described in the first aspect, so as to obtain the position and type of defects and the cutting quality of the zirconium alloy plate.

优选地,所述拍摄装置的仰角为45°~65°。Preferably, the elevation angle of the shooting device is 45°-65°.

优选地,所述装置还包括保护片;Preferably, the device also includes a protective sheet;

所述保护片安装于拍摄装置的镜片表面,用于根据控制信号,在激光切割过程中关闭,以隔绝拍摄装置的镜片与外界,在拍摄装置扫描收集过程中打开,以保证图像的采集。The protective sheet is installed on the surface of the lens of the shooting device, and is used to close according to the control signal during the laser cutting process to isolate the lens of the shooting device from the outside world, and to open it during the scanning and collection process of the shooting device to ensure image collection.

优选地,所述装置还包括:微型通风装置;Preferably, the device also includes: a micro ventilation device;

所述微型通风装置安装于拍摄装置的镜头外围,用于根据控制信号,在拍摄装置扫描收集过程中吹出气体,以清除拍摄装置视角内的残留烟尘。The micro-ventilator is installed on the periphery of the lens of the photographing device, and is used for blowing out gas during the scanning and collecting process of the photographing device according to the control signal, so as to remove residual smoke and dust in the viewing angle of the photographing device.

总体而言,通过本发明所构思的以上技术方案与现有技术相比,具有以下有益效果:Generally speaking, compared with the prior art, the above technical solution conceived by the present invention has the following beneficial effects:

(1)本发明提出一种锆合金板材激光切割质量监检测方法,通过一次拍摄获取切割板料底部与切割面两部分的图像信息并同时分析,减少拍摄分析次数,减少质量监检测花费的时间。对获取的图片,通过计算机矫正程序对图像进行矫正,矫正时只对底面的部分进行矫正,切割面仍保持为侧视图,将两部分融合成为一张最终的矫正图,对图像进行区域划分、选择,并通过卷积神经网络对图像的各类缺陷进行分类、判定,并将图像缺陷信息展示在计算机界面,对激光切割锆合金板材切割质量进行评定,可快速获知激光切割锆合金板料的缺陷位置与种类,并将缺陷信息反馈到激光切割系统,调整激光切割参数,对激光切割锆板质量进行监检测。(1) The present invention proposes a quality monitoring and testing method for laser cutting of zirconium alloy plates. The image information of the bottom part and the cutting surface of the cutting plate is obtained by one shot and analyzed at the same time, which reduces the number of shots and analyzes and reduces the time spent on quality monitoring and testing. . For the acquired picture, the image is corrected through the computer correction program. When correcting, only the part of the bottom surface is corrected, and the cut surface is still kept as a side view. The two parts are fused into a final correction map, and the image is divided into regions, Select, and classify and judge various defects of the image through the convolutional neural network, and display the image defect information on the computer interface, evaluate the cutting quality of the laser-cut zirconium alloy sheet, and quickly know the quality of the laser-cut zirconium alloy sheet The location and type of defects, and the defect information is fed back to the laser cutting system, the laser cutting parameters are adjusted, and the quality of the laser-cut zirconium plate is monitored and tested.

(2)本发明提出一种锆合金板材激光切割质量监检测装置,在现有激光切割质量的基础上,在激光切割缝的侧下方增设线阵CMOS相机及其运动辅助与保护装置,并借助计算机图像处理技术,实现通过一张照片对两个面的三种缺陷的监检测,并且未对加工设备整体进行大的改造,因此,节省大量人力,并提高检测的可靠性,从长远角度看节省大量成本。(2) The present invention proposes a laser cutting quality monitoring device for zirconium alloy plates. On the basis of the existing laser cutting quality, a linear array CMOS camera and its motion assistance and protection device are added below the side of the laser cutting seam, and by means of Computer image processing technology realizes the monitoring and detection of three kinds of defects on two surfaces through one photo, and does not make major changes to the overall processing equipment. Therefore, it saves a lot of manpower and improves the reliability of detection. From a long-term perspective Great cost savings.

附图说明Description of drawings

图1为本发明提供的一种锆合金板材激光切割质量监检测方法流程图。Fig. 1 is a flow chart of a quality monitoring method for laser cutting of zirconium alloy plates provided by the present invention.

图2为本发明实施例提供的相机架设示意图。Fig. 2 is a schematic diagram of camera erection provided by an embodiment of the present invention.

图3为本发明实施例提供的底面矫正示意图。Fig. 3 is a schematic diagram of bottom correction provided by an embodiment of the present invention.

图4为本发明实施例提供的缺陷标记结果示意图。Fig. 4 is a schematic diagram of defect marking results provided by an embodiment of the present invention.

具体实施方式Detailed ways

为了使本发明的目的、技术方案及优点更加清楚明白,以下结合附图及实施例,对本发明进行进一步详细说明。应当理解,此处所描述的具体实施例仅用以解释本发明,并不用于限定本发明。In order to make the object, technical solution and advantages of the present invention clearer, the present invention will be further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described here are only used to explain the present invention, not to limit the present invention.

图1为本发明提供的一种锆合金板材激光切割质量监检测方法流程图。如图1所示,该方法包括:Fig. 1 is a flow chart of a quality monitoring method for laser cutting of zirconium alloy plates provided by the present invention. As shown in Figure 1, the method includes:

步骤S1:相机位置角度架设。Step S1: Set up the camera position and angle.

图2为本发明实施例提供的相机架设示意图。如图2所示,在锆板底部侧边安装好线阵CMOS相机,此时照相装置盖上保护镜,做好激光切割锆板的准备工作,准备进行激光切割。线阵CMOS相机的主视方向与切割面1与底面2交线垂直,并将线阵CMOS相机设置的仰角在45°~65°最佳,此角度范围内凸显了切割面的挂渣和表面粗糙的缺陷轮廓,同时能够覆盖了尺寸更大的板材底面信息,有利于后面神经网络模型对缺陷进行精准的识别与分类。Fig. 2 is a schematic diagram of camera erection provided by an embodiment of the present invention. As shown in Figure 2, a linear array CMOS camera is installed on the bottom side of the zirconium plate. At this time, the camera device is covered with a protective lens, and the preparations for laser cutting the zirconium plate are done, ready for laser cutting. The main viewing direction of the linear array CMOS camera is perpendicular to the intersection line between the cutting surface 1 and the bottom surface 2, and the elevation angle of the linear array CMOS camera is set at 45° to 65°, which highlights the dross and surface of the cutting surface The rough defect outline can also cover the bottom surface information of the larger plate, which is conducive to the accurate identification and classification of defects by the subsequent neural network model.

激光切割面侧下方安装导轨,用于线阵CMOS相机的移动,导轨安装与激光切割的x轴平行。将线阵CMOS相机通过支撑装置与导轨相连接,确保线阵CMOS相机在导轨上的运动无障碍、平稳且不会被激光损伤。A guide rail is installed under the side of the laser cutting surface for the movement of the linear array CMOS camera, and the guide rail is installed parallel to the x-axis of the laser cutting. Connect the linear array CMOS camera with the guide rail through the support device to ensure that the motion of the linear array CMOS camera on the guide rail is unobstructed, stable and will not be damaged by the laser.

步骤S2:锆合金板材激光切割。Step S2: laser cutting the zirconium alloy plate.

设置激光切割的参数,设置切割功率、切割速率、气压等参数,装夹好锆板,进行激光切割。Set the parameters of laser cutting, set cutting power, cutting speed, air pressure and other parameters, clamp the zirconium plate, and carry out laser cutting.

步骤S3:线阵CMOS图像采集与重构。Step S3: line array CMOS image acquisition and reconstruction.

待激光切割完成后,抽烟系统吸收大部分切割过程产生的烟尘后,打开照相装置的保护片,并开启通风系统,驱散线阵CMOS相机视角内的残留烟尘,开启线阵CMOS相机,线阵CMOS相机沿着预先安装的导轨对切割面与被切割件底面同时进行光学图像的采集。After the laser cutting is completed, after the smoke extraction system absorbs most of the smoke and dust generated during the cutting process, open the protective sheet of the camera device, and turn on the ventilation system to dispel the residual smoke and dust in the line-array CMOS camera angle of view, and turn on the line-array CMOS camera. The camera simultaneously collects optical images of the cutting surface and the bottom surface of the cut piece along the pre-installed guide rail.

将线阵CMOS相机的保护片能够在激光切割过程中通过套件与保护片隔绝照相装置的镜片与外界,在线阵CMOS相机扫描收集信息时通过电机牵引软绳索打开保护片,不干扰照相装置的图像信息的采集,所述保护片为玻璃片、橡胶片,保护片形状采用矩形。The protective sheet of the line array CMOS camera can be used to isolate the lens of the camera device from the outside world through the kit and the protective sheet during the laser cutting process. When the line array CMOS camera scans and collects information, the protective sheet is opened by pulling the soft rope through the motor, without disturbing the image of the camera device. For information collection, the protection sheet is a glass sheet or a rubber sheet, and the shape of the protection sheet is a rectangle.

在线阵CMOS相机周围安装小的通风驱烟系统,在照相装置图像采集过程中,清除照相装置视角内的残留烟尘,确保拍照采集的图像信息不受残留烟尘干扰。A small ventilation and smoke removal system is installed around the line array CMOS camera. During the image acquisition process of the camera device, the residual smoke and dust in the viewing angle of the camera device are removed to ensure that the image information collected by the camera is not disturbed by the residual smoke and dust.

线阵CMOS相机从板材切割起始端沿着切割轨迹方向,在导轨上通过伺服电机驱动运动至切割末端,完成整个切割面与板材底面图像信息的重构。重构后的切割面与底面均不是切割面与底面的正视图,所呈现的图像为两个梯形衔接而成。The linear CMOS camera moves from the starting end of the plate cutting along the direction of the cutting track to the end of the cutting on the guide rail driven by a servo motor, and completes the reconstruction of the image information of the entire cutting surface and the bottom surface of the plate. The reconstructed cutting surface and the bottom surface are not the front view of the cutting surface and the bottom surface, and the presented image is formed by the connection of two trapezoids.

步骤S4:底面图像矫正与断面图像融合。Step S4: Bottom image correction and cross-sectional image fusion.

由于相机摆放在切缝侧下方,采集到的图像底面与切割面均为带有角度的侧视图,需要对图像进行矫正,对切割面不进行矫正、对板材底面进行矫正,再将两部分融合得到矫正图。Since the camera is placed under the side of the cutting seam, the bottom surface of the collected image and the cutting surface are both angled side views, and the image needs to be corrected. The cutting surface is not corrected, and the bottom surface of the plate is corrected. Then the two parts Fusion to get rectified map.

S4.1:板材底面图像矫正:矫正过程采取基于底面与切割面几何交线改进的透视变换:透视变换是将原有投影面绕迹线旋转一定角度,得到矫正好的正视图,本方法基于透视变换,先识别出底面与切割面的交线并延长至图片边缘,对于所得延长线的下方的图片进行透视变换矫正,由于透视变换会对图像进行延伸和缩放,被拉长和放大的部分会像素会有原来的连续变为不连续,这里采用双线性内插法,用待求取像素的四个相邻像素的灰度在两个方向上作线性插入,得到最终需要的矫正图。由于切割面的检测需要关注粗糙度值,进行矫正容易对粗糙度的检测造成影响,且切割面矫正对挂渣的检测影响不大,故可以选择不对切割面进行矫正。S4.1: Image correction of the bottom surface of the plate: the correction process adopts the improved perspective transformation based on the geometric intersection of the bottom surface and the cutting surface: the perspective transformation is to rotate the original projection surface around the trace line at a certain angle to obtain the corrected front view. This method is based on Perspective transformation, first identify the intersection line between the bottom surface and the cutting surface and extend it to the edge of the picture, and perform perspective transformation correction on the picture below the obtained extension line, because the perspective transformation will extend and zoom the image, the part that is elongated and enlarged The pixels will change from continuous to discontinuous. Here, the bilinear interpolation method is used, and the gray levels of the four adjacent pixels of the pixel to be obtained are linearly interpolated in two directions to obtain the final corrected image. . Since the detection of the cutting surface needs to pay attention to the roughness value, the correction will easily affect the detection of the roughness, and the correction of the cutting surface has little effect on the detection of dross, so you can choose not to correct the cutting surface.

具体矫正计算中,在校正前图像上任取一点(x,y,1),其对应校正后图像上的点(x′,y′,1),设变换矩阵为H,则转换关系如下所示:In the specific correction calculation, a point (x, y, 1) is randomly selected on the image before correction, which corresponds to a point (x′, y′, 1) on the image after correction, and the transformation matrix is H, then the transformation relationship is as follows :

Figure BDA0003866807410000071
Figure BDA0003866807410000071

由于所切割锆板底面宽度远大于板料厚度,底面占据绝大部分检测区域,相机的摆放角度需要更偏向底面成像。导轨安装完成后,相机到工件加工底面可以确定的高度可以确定,导轨与激光切割x轴平行,加工程序加载完成后,可以获得相机距离切割面的水平距离。图3为本发明实施例提供的底面矫正示意图。如图3所示,依据三角函数关系,可以得出相机轴线与切割面与底面交线的夹角,此夹角即底面矫正的角度θ。Since the width of the bottom surface of the cut zirconium plate is much larger than the thickness of the sheet, the bottom surface occupies most of the detection area, and the camera placement angle needs to be more biased towards the bottom surface for imaging. After the guide rail is installed, the height from the camera to the bottom surface of the workpiece can be determined. The guide rail is parallel to the x-axis of the laser cutting. After the processing program is loaded, the horizontal distance between the camera and the cutting surface can be obtained. Fig. 3 is a schematic diagram of bottom correction provided by an embodiment of the present invention. As shown in Figure 3, according to the relationship of trigonometric functions, the angle between the camera axis and the intersection line between the cutting surface and the bottom surface can be obtained, and this angle is the angle θ of bottom surface correction.

S4.2:板材底面与切割面图像融合:将矫正后的底面图像与线阵CMOS相机直接拍摄到的图像放置于一张图像中,板材底面与切割面通过其交界线加以区分,矫正后的底面图像呈现矩形,但是未经过矫正处理的切割面图像是梯形,矩形的顶边与梯形的底边重合,并在重合线上重构虚线加以视觉区分。S4.2: Image fusion of the bottom surface of the plate and the cutting surface: put the corrected bottom surface image and the image directly captured by the line array CMOS camera into one image, and distinguish the bottom surface of the plate from the cutting surface by their boundary line, and the corrected image The bottom surface image is rectangular, but the cut surface image without correction is trapezoidal. The top edge of the rectangle coincides with the bottom edge of the trapezoid, and the dotted line is reconstructed on the coincident line for visual distinction.

步骤S5:缺陷识别分类、预警、标记、判定和评估。Step S5: Defect identification and classification, early warning, marking, judgment and evaluation.

在对缺陷的识别与分类中,基于锆合金板材激光切割质量监检测方法与装置,输入计算机的图像通过灰度化处理转化成灰度图像,其中,采用但不限于加权平均法对RGB三色图像进行灰度处理,得到像素值在[0,255]范围内的灰度图像。所用算法为I(x,y)=a*I_R(x,y)+b*I_G(x,y)+c*I_B(x,y),其中,a+b+c=1。In the identification and classification of defects, based on the quality monitoring method and device for laser cutting of zirconium alloy plates, the image input into the computer is converted into a grayscale image through grayscale processing. The image is grayscale processed to obtain a grayscale image with pixel values in the range [0, 255]. The algorithm used is I(x,y)=a*I_R(x,y)+b*I_G(x,y)+c*I_B(x,y), where a+b+c=1.

S5.1:缺陷识别分类:对于表面粗糙度的检测,切割面表面粗糙度是大范围连续的,工件的表面粗糙度与图像灰度直方图分布的标准差和均方根相关,具体的表面粗糙度随着图像灰度直方图的分布标准差与分布均方根高度值之比的增加而增大,每种金属所对应的比值也有差异,具体需要针对正常激光切割锆合金表面通过拍摄,分析灰度直方图,获得灰度直方图的分布标准差S与分布均方根高度值H,通过计算比值S/H确定阈值,选取100张图用于测试确定阈值,在100张图的测试结果中,在粗糙度在正常范围的数据中,选取对应的S/H最大值作为阈值。将矫正后的图片切割成小块区域的图片分析灰度直方图,依据预先通过测试得到的最大可接受粗糙度对应的阈值,判定该区域表面粗糙度是否超标,判定标准为计算值比阈值大的则表面粗糙度超标。本实施例中,锆合金板料激光切割表面粗糙度值设定的标准为Ra 3.2。S5.1: Defect identification classification: For the detection of surface roughness, the surface roughness of the cutting surface is continuous in a large range, and the surface roughness of the workpiece is related to the standard deviation and root mean square of the image gray histogram distribution. The specific surface The roughness increases with the ratio of the distribution standard deviation of the gray histogram of the image to the root mean square height value of the distribution. The ratio corresponding to each metal is also different. It needs to be photographed for the normal laser-cut zirconium alloy surface. Analyze the grayscale histogram, obtain the distribution standard deviation S and the distribution root mean square height value H of the grayscale histogram, determine the threshold by calculating the ratio S/H, select 100 images for testing to determine the threshold, and test the 100 images In the result, in the data whose roughness is in the normal range, the corresponding maximum value of S/H is selected as the threshold. Cut the corrected picture into small areas to analyze the gray histogram of the picture, and judge whether the surface roughness of the area exceeds the standard according to the threshold value corresponding to the maximum acceptable roughness obtained through the test in advance. The judgment standard is that the calculated value is greater than the threshold value The surface roughness exceeds the standard. In this embodiment, the standard for setting the surface roughness value of the laser-cut zirconium alloy sheet is Ra 3.2.

对于挂渣与飞溅的检测,首先将图片划分成多个边长84×84像素的网格,并对区域进行筛选,选出所有可疑的区域,这里选用了选择性搜索算法,其具体步骤是:首先对输入的图片通过双阈值初始化进行划分,推荐目标区域,从相邻区域的纹理特征、重叠等方面,计算图像中相邻子区域之间的相似度,最后通过不断合并相邻相似区域,得到更小数量的目标区域,从而缩小目标搜索范围,相比传统的滑动窗口穷尽检测法,该方法减少了冗余区域,提高了检测效率。For the detection of slag and splash, first divide the picture into multiple grids with a side length of 84×84 pixels, and screen the areas to select all suspicious areas. Here, a selective search algorithm is selected, and the specific steps are as follows: : First, divide the input image by double-threshold initialization, recommend the target area, calculate the similarity between adjacent sub-areas in the image from the texture features and overlap of adjacent areas, and finally merge adjacent similar areas continuously , to obtain a smaller number of target areas, thereby narrowing the target search range. Compared with the traditional sliding window exhaustive detection method, this method reduces redundant areas and improves detection efficiency.

将得到的可疑区域裁剪成多张42×42像素的图片,通过线阵CMOS相机拍摄的缺陷为0.1mm级别,42×42像素照片可以将缺陷包括在其中,运用卷积神经网络,输入裁剪处的42×42像素图片,通过4~6层的卷积、池化、激活等处理,将缺陷处的特征提取出来,在卷积层与全连通层之间,通过扁平化处理,实现卷积与全连接层之间的过渡,输入到3层的全连接,最后使用Softmax激活函数,输出判定图像存在各种类型缺陷的概率值。Crop the obtained suspicious area into multiple 42×42 pixel pictures. The defect taken by the line array CMOS camera is 0.1mm level, and the 42×42 pixel photo can include the defect. Using the convolutional neural network, input the cropped The 42×42 pixel picture, through 4~6 layers of convolution, pooling, activation, etc., extracts the features of the defect, and realizes the convolution through flattening between the convolution layer and the fully connected layer. The transition between the fully connected layer is input to the fully connected layer 3, and finally the Softmax activation function is used to output the probability value for determining the existence of various types of defects in the image.

神经网络的训练从已切割完成的产品获取,通过对已切割完成的产品拍照输入,所输入的数据为1000个含挂渣缺陷的42×42像素图片、1000个含飞溅缺陷的42×42像素图片,将得到的数据的80%用于CNN卷积神经网络的训练,其他20%用于预测,当预测值准确度达99%以上,可认为经过训练的神经网络可靠,可用于实际生产。The training of the neural network is obtained from the cut products. The input data are 1000 42×42 pixel pictures containing slag defects and 1000 42×42 pixel pictures containing splash defects. For pictures, 80% of the obtained data is used for the training of the CNN convolutional neural network, and the other 20% is used for prediction. When the accuracy of the predicted value reaches more than 99%, it can be considered that the trained neural network is reliable and can be used in actual production.

S5.2:缺陷预警:通过对可视化显示界面弹窗与线阵CMOS监测系统进行三色灯预警与蜂鸣器警告声预警。红色预警灯亮表示缺陷问题严重,缺陷数量或尺寸超出正常范围,蜂鸣器发出连续警告声;黄色预警灯亮表示切割面与底面的质量均在正常范围内,但是评分未达到优,蜂鸣器发出断续警告声;绿色预警灯亮表示缺陷情况正常,并且评分为优,无警告声。S5.2: Defect early warning: through the pop-up window of the visual display interface and the linear array CMOS monitoring system, the three-color light early warning and the buzzer warning sound early warning. If the red warning light is on, it means that the defect is serious. If the number or size of the defects exceeds the normal range, the buzzer will sound a continuous warning; Intermittent warning sound; the green warning light is on, indicating that the defect is normal, and the score is excellent, and there is no warning sound.

S5.3:缺陷标记:将缺陷区域标定的区域在通过计算机界面展示,对于缺陷区域用红色。对得到缺陷判定结果,最大概率超过95%的直接将该区域附加红色框标记、最大概率在75%~95%的附加黄色框标记、最大概率在75%以下的区域,由于只对两种缺陷进行检测,缺陷最大值定不小于50%,当输出的某种缺陷最大概率值不满足远大于另一种,认为不是缺陷概率并不加标记。最终在计算机界面通过图示展示时便于区分。图4为本发明实施例提供的缺陷标记结果示意图。如图4所示,小圆圈表示挂渣缺陷,椭圆形表示飞溅缺陷,方框表示粗糙度超标缺陷。S5.3: Defect marking: display the marked area of the defect area through the computer interface, and use red for the defect area. For the defect judgment results obtained, the area with the maximum probability exceeding 95% is directly marked with a red frame, the area with the maximum probability between 75% and 95% is marked with a yellow frame, and the area with the maximum probability below 75% is only for two types of defects. For detection, the maximum defect value must not be less than 50%. When the output maximum probability value of a certain defect is not satisfied and is much greater than another, it is considered not to be a defect probability and will not be marked. Finally, it is easy to distinguish when the computer interface is displayed graphically. Fig. 4 is a schematic diagram of defect marking results provided by an embodiment of the present invention. As shown in Figure 4, small circles represent dross defects, ovals represent splash defects, and squares represent roughness defects.

S5.4:缺陷判定:与标准比较,看单个缺陷是否达标。对检测的缺陷进行数量统计、尺寸统计、缺陷密度统计,挂渣数量不能超过4个、密度不能超过2mm2/dm2,飞溅数量不能超过10、密度不能超过3mm2/dm2,表面粗糙度超标区域不能超过12mm2S5.4: Defect judgment: compare with the standard to see whether a single defect meets the standard. Perform quantity statistics, size statistics, and defect density statistics on the detected defects. The number of dross cannot exceed 4, the density cannot exceed 2mm 2 /dm 2 , the number of splashes cannot exceed 10, and the density cannot exceed 3mm 2 /dm 2 . The area exceeding the standard cannot exceed 12mm 2 .

S5.5:缺陷评估:结合实测尺寸与表面粗糙度超标区域面积,挂渣、飞溅的尺寸、数量等质量指标,对板材质量进行综合性评估:依据表面粗糙度、挂渣、飞溅等的关键性指标,通过加权平均得出综合质量评分:将上述挂渣、飞溅、表面粗糙度质量评定标准定为60分,无缺陷定为满分100分,一种缺陷的各项质量指标数据在该缺陷评分中比例相等,各项指标分数按标准值为60分,无缺陷为100分,分数随质量数据均匀分布,对总体质量的评分通过上述三种缺陷分数按照1∶1∶1的比例加权计算,并依次将质量划分为4个等级:90分及以上为优、75及以上为良、60分以上为合格、60分以下为不合格。并且对于某一项数据已超过标准值,划分到不合格等级。S5.5: Defect evaluation: combined with the actual measured size and the area of the area where the surface roughness exceeds the standard, the size and quantity of dross and splash, comprehensively evaluate the quality of the plate: based on the key factors such as surface roughness, dross, and splash The comprehensive quality score is obtained by weighted average: the above-mentioned slag, splash, and surface roughness quality evaluation standards are set as 60 points, and no defect is set as a full score of 100 points. The proportions in the scoring are equal, the scores of each index are 60 points according to the standard value, and 100 points for no defect, the scores are evenly distributed with the quality data, and the overall quality score is calculated by weighting the above three defect scores according to the ratio of 1:1:1 , and divide the quality into 4 grades in turn: 90 points and above are excellent, 75 points and above are good, 60 points and above are qualified, and below 60 points are unqualified. And for a certain item of data that has exceeded the standard value, it is classified as unqualified.

进一步地,在对激光切割产品的评判完成后,可以将检测出的问题反馈给激光切割系统,及时对激光切割参数进行调整,提高产品质量,达到监测产品质量的目的。Furthermore, after the evaluation of laser cutting products is completed, the detected problems can be fed back to the laser cutting system, and the laser cutting parameters can be adjusted in time to improve product quality and achieve the purpose of monitoring product quality.

本领域的技术人员容易理解,以上所述仅为本发明的较佳实施例而已,并不用以限制本发明,凡在本发明的精神和原则之内所作的任何修改、等同替换和改进等,均应包含在本发明的保护范围之内。It is easy for those skilled in the art to understand that the above descriptions are only preferred embodiments of the present invention, and are not intended to limit the present invention. Any modifications, equivalent replacements and improvements made within the spirit and principles of the present invention, All should be included within the protection scope of the present invention.

Claims (10)

1.一种锆合金板材激光切割质量监检测方法,其特征在于,该方法包括:1. A zirconium alloy plate laser cutting quality monitoring and detection method is characterized in that the method comprises: S1.获取锆合金板材激光切割后包含有切割面与底面的图片,对板材底面矫正后,与未矫正的切割断面图片融合成一张图片,并对图像进行灰度化与网格划分;S1. Obtain the picture including the cutting surface and the bottom surface after the laser cutting of the zirconium alloy plate, after correcting the bottom surface of the plate, merge it with the uncorrected cutting section picture into one picture, and perform grayscale and grid division on the image; S2.计算各网格的灰度直方图的分布标准差和分布均方根高度值的比值,分别与最大可接受粗糙度对应的阈值比较,若超过,则该网格存在表面粗糙度超标缺陷,否则,该网格不存在表面粗糙度超标缺陷;S2. Calculate the ratio of the distribution standard deviation and the distribution root mean square height value of the gray histogram of each grid, and compare them with the threshold corresponding to the maximum acceptable roughness respectively. If it exceeds, the grid has a surface roughness exceeding the standard defect , otherwise, the grid does not have defects of surface roughness exceeding the standard; S3.将各网格灰度化图片输入至卷积神经网络,得到各网格存在挂渣缺陷和飞溅缺陷的概率,并根据概率大小进行缺陷的标定;S3. Input the grayscale images of each grid into the convolutional neural network to obtain the probability of slag defects and splash defects in each grid, and calibrate the defects according to the probability; S4.综合表面粗糙度超标、挂渣和飞溅三类缺陷的数量和面积,对板材切割质量进行评估。S4. Based on the quantity and area of the surface roughness exceeding the standard, hanging slag and splashing three types of defects, the cutting quality of the plate is evaluated. 2.如权利要求1所述的方法,其特征在于,步骤S1中,对图片进行底面矫正,包括:2. The method according to claim 1, characterized in that, in step S1, correcting the bottom surface of the picture includes: 1)基于透视变换,识别出底面与切割面的交线并延长至图片边缘;1) Based on the perspective transformation, identify the intersection line between the bottom surface and the cutting surface and extend it to the edge of the picture; 2)对于所得延长线的下方的图片进行透视变换矫正;2) Perspective transformation correction is carried out for the picture below the obtained extension line; 3)将矫正后的下方的图片沿着延长线与切割面融合,得到最终矫正图。3) Merge the corrected lower picture along the extension line with the cut surface to obtain the final corrected picture. 3.如权利要求2所述的方法,其特征在于,获得拍摄装置距离切割面的水平距离,依据三角函数关系,得出拍摄装置轴线的垂直面与板材底面的锐角夹角,作为底面矫正的角度。3. The method according to claim 2, wherein the horizontal distance between the camera and the cutting surface is obtained, and according to the relationship of trigonometric functions, the angle between the vertical plane of the axis of the camera and the bottom surface of the sheet is obtained as the acute angle of the bottom surface. angle. 4.如权利要求1至3任一项所述的方法,其特征在于,在将各网格灰度化图片输入至卷积神经网络之前,采用选择性搜索算法进行可疑网格图片的初筛。4. The method according to any one of claims 1 to 3, characterized in that, before inputting each grayscale image of each grid into the convolutional neural network, a selective search algorithm is used for preliminary screening of suspicious grid images . 5.如权利要求1所述的方法,其特征在于,步骤S3中,对于得到的缺陷判定结果,最大概率超过95%的,认定为存在该缺陷,并直接将该区域附加红色框标记,最大概率在75%~95%的,认为疑似存在该缺陷,并在该区域附加黄色框标记,最大概率在75%以下的区域,不加标记,最终在计算机界面通过图示展示时便于区分。5. The method according to claim 1, characterized in that, in step S3, for the obtained defect determination result, if the maximum probability exceeds 95%, it is determined that the defect exists, and the area is directly marked with a red frame, the maximum If the probability is between 75% and 95%, it is considered that the defect is suspected to exist, and a yellow frame mark is attached to the area, and the area with the maximum probability below 75% is not marked, and finally it is easy to distinguish when it is displayed on the computer interface through graphics. 6.如权利要求1所述的方法,其特征在于,该方法还包括以下任一种处理方式:6. The method according to claim 1, further comprising any of the following processing methods: 处理方式一:通过对可视化显示界面弹窗与线阵CMOS监测系统进行三色灯预警与蜂鸣器警告声预警;其中,红色预警灯亮表示缺陷问题严重,缺陷数量或尺寸超出正常范围,蜂鸣器发出连续警告声;黄色预警灯亮表示切割面与底面的质量均在正常范围内,但是评分未达到优,蜂鸣器发出断续警告声;绿色预警灯亮表示缺陷情况正常,并且评分为优,无警告声;Processing method 1: Through the pop-up window of the visual display interface and the linear array CMOS monitoring system, the three-color light warning and the buzzer warning sound warning are carried out; among them, the red warning light indicates that the defect is serious, and the number or size of the defect exceeds the normal range, and the buzzer sounds The buzzer emits a continuous warning sound; the yellow warning light is on, indicating that the quality of the cutting surface and the bottom surface are within the normal range, but the score is not excellent, and the buzzer emits an intermittent warning sound; the green warning light is on, indicating that the defect is normal and the score is excellent. No warning sound; 处理方式二:对检测的缺陷进行数量统计、尺寸统计、缺陷密度统计,并与标准比较,判断在每种缺陷上是否达标。Processing method 2: Perform quantity statistics, size statistics, and defect density statistics on the detected defects, and compare with the standard to determine whether each defect meets the standard. 7.一种锆合金板材激光切割质量监检测装置,其特征在于,该装置包括:拍摄装置、导轨、支撑连接装置和图像处理分析模块;7. A zirconium alloy plate laser cutting quality monitoring device, characterized in that the device comprises: a photographing device, a guide rail, a supporting connection device and an image processing and analysis module; 所述导轨位于激光切割面的侧下方,且与激光切割的x轴平行,用于带动拍摄装置无障碍、平稳地移动,同时保证拍摄装置能同时扫描激光切割工件切割面与底面的全貌;The guide rail is located under the side of the laser cutting surface and is parallel to the x-axis of the laser cutting, and is used to drive the shooting device to move smoothly without obstacles, and at the same time to ensure that the shooting device can scan the whole picture of the cutting surface and the bottom surface of the laser cutting workpiece at the same time; 所述拍摄装置通过支撑连接装置固定在导轨上,用于根据控制信号,在锆合金板材激光切割完成后,拍摄包含有切割板料底面与切割面的图片,上传至图像处理分析模块;The photographing device is fixed on the guide rail through the supporting connection device, and is used for taking pictures including the bottom surface and the cutting surface of the cutting plate after the laser cutting of the zirconium alloy plate is completed according to the control signal, and uploading to the image processing and analysis module; 所述图像处理分析模块,用于对拍摄到的图片采用如权利要求1至6任一项所述的方法进行处理和分析,得到锆合金板材的缺陷位置与种类、切割质量。The image processing and analysis module is used to process and analyze the captured pictures by the method according to any one of claims 1 to 6, so as to obtain the defect position and type and cutting quality of the zirconium alloy plate. 8.如权利要求7所述的装置,其特征在于,所述拍摄装置的仰角为45°~65°。8. The device according to claim 7, wherein the elevation angle of the photographing device is 45°-65°. 9.如权利要求7所述的装置,其特征在于,所述装置还包括保护片;9. The device of claim 7, further comprising a protective sheet; 所述保护片安装于拍摄装置的镜片表面,用于根据控制信号,在激光切割过程中关闭,以隔绝拍摄装置的镜片与外界,在拍摄装置扫描收集过程中打开,以保证图像的采集。The protective sheet is installed on the surface of the lens of the shooting device, and is used to close according to the control signal during the laser cutting process to isolate the lens of the shooting device from the outside world, and to open it during the scanning and collection process of the shooting device to ensure image collection. 10.如权利要求7所述的装置,其特征在于,所述装置还包括:微型通风装置;10. The device according to claim 7, further comprising: a micro ventilation device; 所述微型通风装置安装于拍摄装置的镜头外围,用于根据控制信号,在拍摄装置扫描收集过程中吹出气体,以清除拍摄装置视角内的残留烟尘。The micro-ventilator is installed on the periphery of the lens of the photographing device, and is used for blowing out gas during the scanning and collecting process of the photographing device according to the control signal, so as to remove residual smoke and dust in the viewing angle of the photographing device.
CN202211186427.6A 2022-09-27 2022-09-27 Zirconium alloy plate laser cutting quality monitoring method and device Pending CN115631138A (en)

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