CN116091506B - Machine vision defect quality inspection method based on YOLOV5 - Google Patents
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Abstract
本发明公开一种基于YOLOV5的机器视觉缺陷质检方法,涉及视觉检测产品质量技术领域,步骤1,分别采集标准合格产品和不同缺陷的不合格产品多套六面照片;步骤2,分别组成合格产品六面标准图训练库和不合格产品六面图训练库;步骤3,搭建基于YOLOV5算法的质检平台;步骤4,判定待检测产品是否合格。本发明采用相同的条件通过机器视觉系统采集多张样图,作为质检平台基于深度学习YOLOV5算法的训练素材,最终质检平台经过大批量的素材训练后会大大提高质检的准确性和效率,采用四个基准特征点的模式来精简对比,在基准特征点的比对中引入了距离差异阈值的概念,对待检产品的质量管控提供反馈数据,有利于产品质量的提升。
The invention discloses a machine vision defect quality inspection method based on YOLOV5, and relates to the technical field of visual inspection product quality. Step 1, respectively collect multiple sets of six-sided photos of standard qualified products and unqualified products with different defects; Step 2, respectively compose qualified Product six-sided standard diagram training library and unqualified product six-sided diagram training library; Step 3, build a quality inspection platform based on the YOLOV5 algorithm; Step 4, determine whether the product to be tested is qualified. The present invention adopts the same conditions to collect multiple sample images through the machine vision system as the training material of the quality inspection platform based on the deep learning YOLOV5 algorithm, and the final quality inspection platform will greatly improve the accuracy and efficiency of quality inspection after being trained with a large number of materials , using the model of four reference feature points to simplify the comparison, and introducing the concept of distance difference threshold in the comparison of reference feature points, which provides feedback data for the quality control of the product to be inspected, which is conducive to the improvement of product quality.
Description
技术领域technical field
本发明涉及视觉检测产品质量技术领域,尤其是涉及一种基于YOLOV5的机器视觉缺陷质检方法。The invention relates to the technical field of visual inspection of product quality, in particular to a YOLOV5-based machine vision defect quality inspection method.
背景技术Background technique
视觉检测就是用机器代替人眼来做测量和判断。视觉检测是指通过机器视觉产品,即图像摄取装置,将被摄取目标转换成图像信号,传送给专用的图像处理系统,根据像素分布和亮度、颜色等信息,转变成数字化信号;图像系统对这些信号进行各种运算来抽取目标的特征,进而根据判别的结果来控制现场的设备动作。是用于生产、装配或包装的有价值的机制。它在检测缺陷和防止缺陷产品被配送到消费者的功能方面具有不可估量的价值。Visual inspection is to use machines instead of human eyes for measurement and judgment. Visual inspection refers to converting the ingested target into an image signal through a machine vision product, that is, an image capture device, and transmitting it to a dedicated image processing system, and converting it into a digital signal according to pixel distribution, brightness, color and other information; Various calculations are performed on the signal to extract the characteristics of the target, and then the on-site equipment actions are controlled according to the results of the discrimination. Is a valuable mechanism for production, assembly or packaging. It is invaluable in its ability to detect defects and prevent defective products from being shipped to consumers.
目前,自动化生产中越来越多地采用视觉系统采集产品的外观图片,再配合视觉算法来实现产品缺陷的质检,然而常规的做法一般只能实现对于产品上表面的缺陷质检,适用于上表面是主要使用面的产品质检,对于产品六面均有重要特征的产品适用性并不高,还是需要人工或者其他质检工序来完成其他面的缺陷质检。At present, more and more visual systems are used in automated production to collect product appearance pictures, and then cooperate with visual algorithms to realize product defect quality inspection. The surface is the product quality inspection of the main use surface, and the applicability of products with important features on all six sides of the product is not high, and manual or other quality inspection procedures are still required to complete the defect quality inspection of other surfaces.
发明内容Contents of the invention
为了解决上述采用视觉技术对自动化中的产品进行质检时不能满足一次性对六面进行缺陷质检的技术问题,本发明提供一种基于YOLOV5的机器视觉缺陷质检方法。采用如下的技术方案:In order to solve the above-mentioned technical problem that the quality inspection of products in automation using visual technology cannot satisfy the defect quality inspection of six sides at one time, the present invention provides a machine vision defect quality inspection method based on YOLOV5. Adopt the following technical solutions:
一种基于YOLOV5的机器视觉缺陷质检方法,包括以下具体步骤:A method for quality inspection of machine vision defects based on YOLOV5, comprising the following specific steps:
步骤1,采集标准合格产品的多套六面照片,采集不同缺陷的不合格产品多套六面照片;Step 1, collect multiple sets of six-sided photos of standard qualified products, and collect multiple sets of six-sided photos of unqualified products with different defects;
步骤2,对标准合格产品和不合格产品的六面照片分别运行图像拼接算法重新生成标准合格产品六面图和不合格产品六面图,标准合格产品六面图包含标准合格产品六个面所有外观特征,不合格产品六面图包含不合格产品六个面所有外观特征,多张标准合格产品六面图组成合格产品六面标准图训练库,多张不合格产品六面图组成不合格产品六面图训练库;
步骤3,搭建基于YOLOV5算法的质检平台,并采用步骤2中生成的合格产品六面标准图训练库和不合格产品六面图训练库训练质检平台;
步骤4,判定待检测产品是否合格,采用机器视觉系统获取待检测产品的六面待检图,运行图像拼接算法将六面待检图拼接成一张产品待检图,将产品待检图输入到质检平台,质检平台采用YOLOV5算法采集产品待检图的特征,通过相似度比较,当产品待检图与标准合格产品六面图的相似度IOU值大于设定相似度阈值时,输出产品合格的判定;Step 4, determine whether the product to be inspected is qualified, use the machine vision system to obtain the six-sided inspection image of the product to be inspected, run the image stitching algorithm to stitch the six-sided inspection image into a product inspection image, and input the product inspection image to The quality inspection platform, the quality inspection platform uses the YOLOV5 algorithm to collect the characteristics of the product to be inspected, and compares the similarity. When the similarity IOU value between the product to be inspected and the six-sided image of the standard qualified product is greater than the set similarity threshold, the product is output qualified determination;
当产品六面待检图与标准合格产品六面图的相似度IOU值小于或等于设定相似度阈值时,输出产品不合格的判定。When the similarity IOU value between the six-sided image of the product to be inspected and the six-sided image of the standard qualified product is less than or equal to the set similarity threshold, the judgment of unqualified product is output.
通过采用上述技术方案,传统的基于视觉检测的产品缺陷质检通常只采集顶部视图,或者立体视图来进行质检,不能适用于六面均有重要特征的待检产品,这里分别采集检测产品的六面待检图进行拼接后来一次性完成六个面的缺陷质检,一次拍摄完成六面质检,大大提高了视觉质检的效率,能够适用于六面均有重要特征的待检产品;By adopting the above-mentioned technical solution, the traditional product defect quality inspection based on visual inspection usually only collects top view or three-dimensional view for quality inspection, which cannot be applied to products to be inspected with important features on all six sides. Here, the inspection products are collected separately. After splicing the six-sided pictures to be inspected, the six-sided defect quality inspection is completed at one time, and the six-sided quality inspection is completed in one shot, which greatly improves the efficiency of visual quality inspection and can be applied to products to be inspected with important features on all six sides;
为了满足质检需求,首先对标准合格产品和不合格产品均采用相同的条件通过机器视觉系统采集多张样图,作为质检平台基于深度学习YOLOV5算法的训练素材,标准合格产品和不合格产品的素材采集后也需要进行拼接操作,最终质检平台经过大批量的素材训练后会大大提高质检的准确性和效率;In order to meet the requirements of quality inspection, first of all, the same conditions are used for standard qualified products and unqualified products to collect multiple samples through the machine vision system, as the training material of the quality inspection platform based on deep learning YOLOV5 algorithm, standard qualified products and unqualified products The splicing operation is also required after the material is collected, and the final quality inspection platform will greatly improve the accuracy and efficiency of quality inspection after a large number of material training;
质检平台实质上是一种视觉服务器,其中搭载了各种视觉算法,质检平台采用YOLOV5算法采集产品待检图的特征,通过相似度比较,当产品待检图与标准合格产品六面图的相似度IOU值大于设定相似度阈值时,输出产品合格的判定,这种判定方式是先对比标准合格产品六面图,也就是优先合格推定,更适合合格率大于90%的产品缺陷质检,能大大提高缺陷质检效率。The quality inspection platform is essentially a visual server, which is equipped with various visual algorithms. The quality inspection platform uses the YOLOV5 algorithm to collect the characteristics of the product to-be-inspected image, and compares the similarity. When the IOU value of the similarity degree is greater than the set similarity threshold, the judgment of product qualification is output. This judgment method is to compare the six-sided diagram of standard qualified products first, that is, the priority qualification presumption, which is more suitable for product defect quality with a pass rate greater than 90%. Inspection can greatly improve the efficiency of defect quality inspection.
可选的,步骤2中,采用YOLOV5目标检测算法检测多套不合格产品六面照片的缺陷特征,并形成缺陷特征对比库。Optionally, in
可选的,YOLOV5目标检测算法模型的yolov5深度学习网络使用缺陷特征对比库数据进行迭代训练,将缺陷特征对比库中的图片宽高等比例缩放并填充灰色边缘至224×224大小输入,训练图像样本经过Focus网络结构提取三个有效特征层分别为(52,52,256)、(26,26,512)和(13,13,1024),并基于三个有效特征层进行构建第四特征FPN层。Optionally, the yolov5 deep learning network of the YOLOV5 target detection algorithm model uses the data of the defect feature comparison library for iterative training, scales the width and height of the pictures in the defect feature comparison library, and fills the gray edges to a size of 224×224. Input, training image samples Three effective feature layers are extracted through the Focus network structure, namely (52, 52, 256), (26, 26, 512) and (13, 13, 1024), and the fourth feature FPN layer is constructed based on the three effective feature layers.
通过采用上述技术方案,缺陷特征对比库的中的缺陷特征经过YOLOV5目标检测算法进行抓取后,就会直接获得缺陷特征为基础的特征层,最终按照缺陷特征的大小分为三个有效特征层,其中特征层为(52,52,256)的训练图像样本对应小目标,特征层为(26,26,512)检测粒度网格对应中目标,特征层为(13,13,1024)的检测粒度网格对应大目标,对该3个初始的特征层进行卷积处理操作之后可以得到第四特征FPN层。By adopting the above technical solution, after the defect features in the defect feature comparison library are captured by the YOLOV5 target detection algorithm, the feature layer based on the defect feature will be directly obtained, and finally divided into three effective feature layers according to the size of the defect feature , where the feature layer is (52,52,256) training image samples corresponding to small targets, the feature layer is (26,26,512) corresponding to the target in the detection granularity grid, and the feature layer is (13,13,1024) corresponding to the detection granularity grid For large targets, the fourth feature FPN layer can be obtained after performing convolution processing on the three initial feature layers.
可选的,将三个有效特征层(52,52,256)、(26,26,512)和(13,13,1024)的特征通过3×3卷积的方式提取不同特征进行融合,在融合得到的特征图上再进行预测得到第四特征FPN层。Optionally, the features of the three effective feature layers (52, 52, 256), (26, 26, 512) and (13, 13, 1024) are extracted by 3×3 convolution to fuse different features, and the features obtained in the fusion Prediction is then performed on the graph to obtain the fourth feature FPN layer.
通过采用上述技术方案,Focus网络结构将w-h平面上的信息转换到通道维度,再通过3×3卷积的方式提取不同特征。采用这种方式可以减少下采样带来的信息损失,使第四特征FPN层代表的特征更加精准。By adopting the above technical solution, the Focus network structure converts the information on the w-h plane to the channel dimension, and then extracts different features through 3×3 convolution. In this way, the information loss caused by downsampling can be reduced, and the features represented by the fourth feature FPN layer are more accurate.
可选的,采样第四特征FPN层上的至少四个基准特征点,所述基准特征点是指小于3像素点的特征区域,特征区域中的明暗变化程度大于50%,将四个基准特征点分别提取并构建基于四个基准特征点的缺陷快速比对层,并采用距离检测算法测得四个基准特征点之间的相互距离,并将距离数据作为缺陷快速比对层的附加对比项。Optionally, at least four reference feature points on the fourth feature FPN layer are sampled, the reference feature points refer to a feature area less than 3 pixels, and the degree of light and shade change in the feature area is greater than 50%, the four reference feature points Points are extracted respectively and a defect rapid comparison layer based on four reference feature points is constructed, and the distance detection algorithm is used to measure the mutual distance between the four reference feature points, and the distance data is used as an additional comparison item of the defect rapid comparison layer .
可选的,采用明暗检测算法对第四特征FPN层进行明暗度变化检测。Optionally, a lightness detection algorithm is used to perform lightness change detection on the fourth feature FPN layer.
通过采用上述技术方案,因为大多数不合格产品中的缺陷特征量会较多,因此我们采用四个基准特征点的模式来精简对比,四个基准特征点加上位置距离关系数据就能够准确地定位该缺陷特征,这类似于指纹特征点识别的原理,而缺陷特征最大的特征就是明暗变化,因此采用明暗检测算法来实现明暗度变化检测能快速获得四个基准特征点。By adopting the above-mentioned technical scheme, because most of the defect features in unqualified products will be more, we use the mode of four reference feature points to simplify the comparison, and the four reference feature points plus the position distance relationship data can accurately Locating the defect feature is similar to the principle of fingerprint feature point recognition, and the biggest feature of the defect feature is the change of light and shade. Therefore, using the light and dark detection algorithm to detect the change of light and shade can quickly obtain four reference feature points.
可选的,机器视觉缺陷质检方法还包括步骤41,产品缺陷特征输出,在对产品待检图与标准合格产品六面图件相似度对比前先进行缺陷特征遍历,调用缺陷特征对比库的缺陷快速比对层对产品待检图进行遍历,若匹配成功四个基准特征点的特征,匹配相似度IOU值大于0.9,且四个基准特征点之间的相互距离差异小于距离差异阈值,则质检平台直接判定产品不合格,同时将缺陷位置进行框选处理,并基于框选标示进行显示。Optionally, the machine vision defect quality inspection method also includes step 41, outputting product defect features, performing defect feature traversal before comparing the similarity between the product to-be-inspected image and the standard qualified product six-sided image, and calling the defect feature comparison library. The defect rapid comparison layer traverses the image of the product to be inspected. If the features of the four reference feature points are successfully matched, the matching similarity IOU value is greater than 0.9, and the mutual distance difference between the four reference feature points is less than the distance difference threshold, then The quality inspection platform directly determines that the product is unqualified, and at the same time frames the defect location and displays it based on the frame selection mark.
可选的,所述距离差异值是指产品待检图任意两个基准特征点之间距离值与缺陷快速比对层中对应两个基准特征点之间距离值做差值的绝对值计算,然后将绝对值与缺陷快速比对层中对应两个基准特征点之间距离值做比值运算,设产品待检图任意两个基准特征点之间距离值为S,缺陷快速比对层中对应两个基准特征点之间距离值S1,距离差异阈值为D,则,距离差异阈值设0.05~0.1。Optionally, the distance difference value refers to the absolute value calculation of the difference between the distance value between any two reference feature points in the product to-be-inspected map and the distance value between the corresponding two reference feature points in the defect rapid comparison layer, Then, the absolute value is compared with the distance between two corresponding reference feature points in the defect rapid comparison layer, and the distance value between any two reference feature points in the product to-be-inspected image is set as S, and the corresponding value in the defect rapid comparison layer is The distance between two reference feature points is S1, and the distance difference threshold is D, then , and the distance difference threshold is set to 0.05-0.1.
通过采用上述技术方案,质检平台做出待检产品在不合格判断的同时需要标示出具体的缺陷位置和缺陷类型,这样的产品缺陷质检才会对产品的生产做出积极的反馈,更加有利于产品合格率的提升;By adopting the above technical solution, the quality inspection platform needs to mark the specific defect location and defect type while making the unqualified judgment of the product to be inspected. Only such product defect quality inspection will give positive feedback to the production of the product, which is more Conducive to the improvement of product qualification rate;
具体的,为了标示出具体的缺陷位置和缺陷类型,首先要基于缺陷快速比对层来进行缺陷特征相似度的比对,如果相似度IOU值大于0.9,则确定了缺陷种类,然后进行位置数据的比对,这里引入了距离差异阈值的概念,距离差异阈值实际上是一种缺陷位置定位的密钥,能够匹配成功则完成了缺陷位置的定位,最终质检平台输出待检产品不合格的判断,同时对不合格的区域进行框选标示,并标示缺陷类型,从而对待检产品的质量管控提供反馈数据,有利于产品质量的提升。Specifically, in order to mark the specific defect location and defect type, the defect feature similarity must be compared based on the defect quick comparison layer. If the similarity IOU value is greater than 0.9, the defect type is determined, and then the position data The comparison of the distance difference threshold is introduced here. The distance difference threshold is actually a key for defect location location. If the matching is successful, the defect location location is completed. Finally, the quality inspection platform outputs the unqualified product to be inspected. Judgment, and at the same time, mark the unqualified area and mark the defect type, so as to provide feedback data for the quality control of the product to be inspected, which is conducive to the improvement of product quality.
一种机器视觉系统,用于获取待检测产品的六面待检图,包括用于支撑待检产品的透明平台、底部相机、龙门架和顶部相机模组,所述透明平台设置在待检产品生产线的出口处,所述底部相机设置在透明平台的下方,用于拍摄待检产品的底视图,所述龙门架设置在透明平台的上方,所述顶部相机模组包括前部相机、后部相机、左侧相机、右侧相机和俯视相机,所述前部相机、后部相机、左侧相机、右侧相机和俯视相机分别挂载在龙门架上,分别用于拍摄待检测产品的前部视图、后部视图、左侧视图、右侧视图和俯视图,底部相机、前部相机、后部相机、左侧相机、右侧相机和俯视相机分别与质检平台通信连接。A machine vision system used to obtain six-sided images of products to be inspected, including a transparent platform for supporting products to be inspected, a bottom camera, a gantry and a top camera module, the transparent platform is set on the product to be inspected At the exit of the production line, the bottom camera is set under the transparent platform to take a bottom view of the product to be inspected, the gantry is set above the transparent platform, and the top camera module includes a front camera, a rear Camera, left camera, right camera and overlooking camera, the front camera, rear camera, left camera, right camera and overlooking camera are respectively mounted on the gantry, and are respectively used to photograph the front of the product to be inspected. The front view, the rear view, the left view, the right view and the top view, the bottom camera, the front camera, the rear camera, the left camera, the right camera and the top view camera are respectively connected to the quality inspection platform.
通过采用上述技术方案,传统的机器视觉系统只能获取产品上方的画面,采用上述结构可以完成检测产品的前部视图、后部视图、左侧视图、右侧视图和俯视图的获取,为后续质检一次性提供同一状态下的六面待检图,因为是一次同时拍摄,所以光影条件一致,更加有利于后续质检平台做出质检结果判断。By adopting the above-mentioned technical scheme, the traditional machine vision system can only obtain the picture above the product, and the above-mentioned structure can complete the acquisition of the front view, rear view, left view, right view and top view of the inspected product. The inspection provides six pictures to be inspected in the same state at one time. Because it is shot at the same time, the light and shadow conditions are consistent, which is more conducive to the subsequent quality inspection platform to judge the quality inspection results.
综上所述,本发明包括以下至少一种有益技术效果:In summary, the present invention includes at least one of the following beneficial technical effects:
本发明能提供一种基于YOLOV5的机器视觉缺陷质检方法,对标准合格产品和不合格产品均采用相同的条件通过机器视觉系统采集多张样图,作为质检平台基于深度学习YOLOV5算法的训练素材,最终质检平台经过大批量的素材训练后会大大提高质检的准确性和效率,采用四个基准特征点的模式来精简对比,四个基准特征点加上位置距离关系数据就能够准确地定位该缺陷特征,采用明暗检测算法来实现明暗度变化检测能快速获得四个基准特征点,在基准特征点的比对中引入了距离差异阈值的概念,同时对不合格的区域进行框选标示,并标示缺陷类型,对待检产品的质量管控提供反馈数据,有利于产品质量的提升。The present invention can provide a machine vision defect quality inspection method based on YOLOV5, adopting the same conditions for standard qualified products and unqualified products to collect multiple sample images through the machine vision system, as a quality inspection platform based on deep learning YOLOV5 algorithm training Material, the final quality inspection platform will greatly improve the accuracy and efficiency of quality inspection after a large number of material training, using the model of four benchmark feature points to simplify the comparison, four benchmark feature points plus position distance relationship data can be accurate To accurately locate the defect feature, use the light and dark detection algorithm to realize the light and dark change detection, and quickly obtain four reference feature points. In the comparison of the reference feature points, the concept of distance difference threshold is introduced, and the unqualified area is selected at the same time. Mark and mark the type of defect, and provide feedback data for the quality control of the product to be inspected, which is conducive to the improvement of product quality.
附图说明Description of drawings
图1是本发明一种基于YOLOV5的机器视觉缺陷质检方法的流程示意图;Fig. 1 is a schematic flow chart of a machine vision defect quality inspection method based on YOLOV5 of the present invention;
图2是本发明一种机器视觉系统的电器件连接原理示意图;Fig. 2 is a schematic diagram of the electrical device connection principle of a machine vision system of the present invention;
图3是本发明一种基于YOLOV5的机器视觉缺陷质检方法缺陷快速比对层的效果示意图。Fig. 3 is a schematic diagram of the effect of a defect rapid comparison layer of a machine vision defect quality inspection method based on YOLOV5 in the present invention.
附图标记说明:1、底部相机;2、前部相机;3、后部相机;4、左侧相机;5、右侧相机;6、俯视相机;100、质检平台。Explanation of reference numerals: 1. Bottom camera; 2. Front camera; 3. Rear camera; 4. Left camera; 5. Right camera; 6. Looking down camera; 100. Quality inspection platform.
实施方式Implementation
以下结合附图对本发明作进一步详细说明。The present invention will be described in further detail below in conjunction with the accompanying drawings.
本发明实施例公开一种基于YOLOV5的机器视觉缺陷质检方法。The embodiment of the present invention discloses a machine vision defect quality inspection method based on YOLOV5.
参照图1-图3,一种基于YOLOV5的机器视觉缺陷质检方法,包括以下具体步骤:Referring to Figure 1-Figure 3, a machine vision defect quality inspection method based on YOLOV5 includes the following specific steps:
步骤1,采集标准合格产品的多套六面照片,采集不同缺陷的不合格产品多套六面照片;Step 1, collect multiple sets of six-sided photos of standard qualified products, and collect multiple sets of six-sided photos of unqualified products with different defects;
步骤2,对标准合格产品和不合格产品的六面照片分别运行图像拼接算法重新生成标准合格产品六面图和不合格产品六面图,标准合格产品六面图包含标准合格产品六个面所有外观特征,不合格产品六面图包含不合格产品六个面所有外观特征,多张标准合格产品六面图组成合格产品六面标准图训练库,多张不合格产品六面图组成不合格产品六面图训练库;
步骤3,搭建基于YOLOV5算法的质检平台100,并采用步骤2中生成的合格产品六面标准图训练库和不合格产品六面图训练库训练质检平台100;
步骤4,判定待检测产品是否合格,采用机器视觉系统获取待检测产品的六面待检图,运行图像拼接算法将六面待检图拼接成一张产品待检图,将产品待检图输入到质检平台100,质检平台100采用YOLOV5算法采集产品待检图的特征,通过相似度比较,当产品待检图与标准合格产品六面图的相似度IOU值大于设定相似度阈值时,输出产品合格的判定;Step 4, determine whether the product to be inspected is qualified, use the machine vision system to obtain the six-sided inspection image of the product to be inspected, run the image stitching algorithm to stitch the six-sided inspection image into a product inspection image, and input the product inspection image to The
当产品六面待检图与标准合格产品六面图的相似度IOU值小于或等于设定相似度阈值时,输出产品不合格的判定。When the similarity IOU value between the six-sided image of the product to be inspected and the six-sided image of the standard qualified product is less than or equal to the set similarity threshold, the judgment of unqualified product is output.
传统的基于视觉检测的产品缺陷质检通常只采集顶部视图,或者立体视图来进行质检,不能适用于六面均有重要特征的待检产品,这里分别采集检测产品的六面待检图进行拼接后来一次性完成六个面的缺陷质检,一次拍摄完成六面质检,大大提高了视觉质检的效率,能够适用于六面均有重要特征的待检产品;The traditional quality inspection of product defects based on visual inspection usually only collects the top view or three-dimensional view for quality inspection, which cannot be applied to products to be inspected with important features on all six sides. After splicing, the defect quality inspection of six sides is completed at one time, and the quality inspection of six sides is completed in one shot, which greatly improves the efficiency of visual quality inspection and can be applied to products to be inspected with important features on all six sides;
为了满足质检需求,首先对标准合格产品和不合格产品均采用相同的条件通过机器视觉系统采集多张样图,作为质检平台基于深度学习YOLOV5算法的训练素材,标准合格产品和不合格产品的素材采集后也需要进行拼接操作,最终质检平台经过大批量的素材训练后会大大提高质检的准确性和效率;In order to meet the requirements of quality inspection, first of all, the same conditions are used for standard qualified products and unqualified products to collect multiple samples through the machine vision system, as the training material of the quality inspection platform based on deep learning YOLOV5 algorithm, standard qualified products and unqualified products The splicing operation is also required after the material is collected, and the final quality inspection platform will greatly improve the accuracy and efficiency of quality inspection after a large number of material training;
质检平台100实质上是一种视觉服务器,其中搭载了各种视觉算法,质检平台100采用YOLOV5算法采集产品待检图的特征,通过相似度比较,当产品待检图与标准合格产品六面图的相似度IOU值大于设定相似度阈值时,输出产品合格的判定,这种判定方式是先对比标准合格产品六面图,也就是优先合格推定,更适合合格率大于90%的产品缺陷质检,能大大提高缺陷质检效率。The
步骤2中,采用YOLOV5目标检测算法检测多套不合格产品六面照片的缺陷特征,并形成缺陷特征对比库。In
YOLOV5目标检测算法模型的yolov5深度学习网络使用缺陷特征对比库数据进行迭代训练,将缺陷特征对比库中的图片宽高等比例缩放并填充灰色边缘至224×224大小输入,训练图像样本经过Focus网络结构提取三个有效特征层分别为(52,52,256)、(26,26,512)和(13,13,1024),并基于三个有效特征层进行构建第四特征FPN层。The yolov5 deep learning network of the YOLOV5 target detection algorithm model uses the data of the defect feature comparison library for iterative training, scales the width and height of the pictures in the defect feature comparison library and fills the gray edges to a size of 224×224 input, and the training image samples pass through the Focus network structure Three effective feature layers are extracted (52, 52, 256), (26, 26, 512) and (13, 13, 1024), and the fourth feature FPN layer is constructed based on the three effective feature layers.
缺陷特征对比库的中的缺陷特征经过YOLOV5目标检测算法进行抓取后,就会直接获得缺陷特征为基础的特征层,最终按照缺陷特征的大小分为三个有效特征层,其中特征层为(52,52,256)的训练图像样本对应小目标,特征层为(26,26,512)检测粒度网格对应中目标,特征层为(13,13,1024)的检测粒度网格对应大目标,对该3个初始的特征层进行卷积处理操作之后可以得到第四特征FPN层。After the defect features in the defect feature comparison library are captured by the YOLOV5 target detection algorithm, the feature layer based on the defect feature will be directly obtained, and finally divided into three effective feature layers according to the size of the defect feature, where the feature layer is ( 52, 52, 256) training image samples correspond to small targets, the feature layer is (26, 26, 512) detection granularity grid corresponding to the medium target, and the feature layer is (13, 13, 1024) detection granularity grid corresponds to large targets, for the 3 The fourth feature FPN layer can be obtained after the initial feature layer is subjected to convolution processing.
将三个有效特征层(52,52,256)、(26,26,512)和(13,13,1024)的特征通过3×3卷积的方式提取不同特征进行融合,在融合得到的特征图上再进行预测得到第四特征FPN层。The features of the three effective feature layers (52, 52, 256), (26, 26, 512) and (13, 13, 1024) are extracted and fused by 3×3 convolution, and then performed on the fused feature map The prediction gets the fourth feature FPN layer.
Focus网络结构将w-h平面上的信息转换到通道维度,再通过3×3卷积的方式提取不同特征。采用这种方式可以减少下采样带来的信息损失,使第四特征FPN层代表的特征更加精准。The Focus network structure converts the information on the w-h plane to the channel dimension, and then extracts different features through 3×3 convolution. In this way, the information loss caused by downsampling can be reduced, and the features represented by the fourth feature FPN layer are more accurate.
采样第四特征FPN层上的至少四个基准特征点,基准特征点是指小于3像素点的特征区域,特征区域中的明暗变化程度大于50%,将四个基准特征点分别提取并构建基于四个基准特征点的缺陷快速比对层,并采用距离检测算法测得四个基准特征点之间的相互距离,并将距离数据作为缺陷快速比对层的附加对比项。Sampling at least four reference feature points on the fourth feature FPN layer. The reference feature point refers to a feature area less than 3 pixels, and the degree of light and shade change in the feature area is greater than 50%. The four reference feature points are extracted respectively and constructed based on The defect rapid comparison layer of the four reference feature points, and the distance detection algorithm is used to measure the mutual distance between the four reference feature points, and the distance data is used as an additional comparison item of the defect rapid comparison layer.
采用明暗检测算法对第四特征FPN层进行明暗度变化检测。A light and dark detection algorithm is used to detect changes in light and dark on the fourth feature FPN layer.
因为大多数不合格产品中的缺陷特征量会较多,因此我们采用四个基准特征点的模式来精简对比,四个基准特征点加上位置距离关系数据就能够准确地定位该缺陷特征,这类似于指纹特征点识别的原理,而缺陷特征最大的特征就是明暗变化,因此采用明暗检测算法来实现明暗度变化检测能快速获得四个基准特征点。Because there are many defect features in most unqualified products, we use the model of four reference feature points to simplify the comparison. The four reference feature points plus the position and distance relationship data can accurately locate the defect feature. Similar to the principle of fingerprint feature point recognition, the biggest feature of defect features is the change of light and shade. Therefore, using the light and shade detection algorithm to detect the change of light and shade can quickly obtain four reference feature points.
机器视觉缺陷质检方法还包括步骤41,产品缺陷特征输出,在对产品待检图与标准合格产品六面图件相似度对比前先进行缺陷特征遍历,调用缺陷特征对比库的缺陷快速比对层对产品待检图进行遍历,若匹配成功四个基准特征点的特征,匹配相似度IOU值大于0.9,且四个基准特征点之间的相互距离差异小于距离差异阈值,则质检平台100直接判定产品不合格,同时将缺陷位置进行框选处理,并基于框选标示进行显示。The machine vision defect quality inspection method also includes step 41, outputting product defect features, performing defect feature traversal before comparing the similarity between the product to-be-inspected image and the standard qualified product six-sided image, and calling the defect quick comparison of the defect feature comparison library The layer traverses the image of the product to be inspected. If the features of the four reference feature points are successfully matched, the matching similarity IOU value is greater than 0.9, and the mutual distance difference between the four reference feature points is less than the distance difference threshold, the
距离差异值是指产品待检图任意两个基准特征点之间距离值与缺陷快速比对层中对应两个基准特征点之间距离值做差值的绝对值计算,然后将绝对值与缺陷快速比对层中对应两个基准特征点之间距离值做比值运算,设产品待检图任意两个基准特征点之间距离值为S,缺陷快速比对层中对应两个基准特征点之间距离值S1,距离差异阈值为D,则,距离差异阈值设0.05~0.1。The distance difference value refers to the absolute value calculation of the difference between the distance value between any two reference feature points in the product to-be-inspected map and the distance value between the corresponding two reference feature points in the defect quick comparison layer, and then the absolute value and the defect In the rapid comparison layer, the ratio operation is performed on the distance value corresponding to two reference feature points, and the distance between any two reference feature points in the product to-be-inspected image is set as S, and the distance between the two reference feature points in the defect rapid comparison layer is distance value S1, and the distance difference threshold is D, then , and the distance difference threshold is set to 0.05-0.1.
质检平台100做出待检产品在不合格判断的同时需要标示出具体的缺陷位置和缺陷类型,这样的产品缺陷质检才会对产品的生产做出积极的反馈,更加有利于产品合格率的提升;The
具体的,为了标示出具体的缺陷位置和缺陷类型,首先要基于缺陷快速比对层来进行缺陷特征相似度的比对,如果相似度IOU值大于0.9,则确定了缺陷种类,然后进行位置数据的比对,这里引入了距离差异阈值的概念,距离差异阈值实际上是一种缺陷位置定位的密钥,能够匹配成功则完成了缺陷位置的定位,最终质检平台100输出待检产品不合格的判断,同时对不合格的区域进行框选标示,并标示缺陷类型,从而对待检产品的质量管控提供反馈数据,有利于产品质量的提升。Specifically, in order to mark the specific defect location and defect type, the defect feature similarity must be compared based on the defect quick comparison layer. If the similarity IOU value is greater than 0.9, the defect type is determined, and then the position data For comparison, the concept of distance difference threshold is introduced here. The distance difference threshold is actually a key to locate the defect location. If the matching is successful, the location of the defect location is completed. Finally, the
一种机器视觉系统,用于获取待检测产品的六面待检图,包括用于支撑待检产品的透明平台、底部相机1、龙门架和顶部相机模组,透明平台设置在待检产品生产线的出口处,底部相机1设置在透明平台的下方,用于拍摄待检产品的底视图,龙门架设置在透明平台的上方,顶部相机模组包括前部相机2、后部相机3、左侧相机4、右侧相机5和俯视相机6,前部相机2、后部相机3、左侧相机4、右侧相机5和俯视相机6分别挂载在龙门架上,分别用于拍摄待检测产品的前部视图、后部视图、左侧视图、右侧视图和俯视图,底部相机1、前部相机2、后部相机3、左侧相机4、右侧相机5和俯视相机6分别与质检平台100通信连接。A machine vision system used to obtain the six-sided image of the product to be inspected, including a transparent platform for supporting the product to be inspected, a bottom camera 1, a gantry and a top camera module, and the transparent platform is set on the production line of the product to be inspected At the exit, the bottom camera 1 is set under the transparent platform to take the bottom view of the product to be inspected, the gantry is set above the transparent platform, and the top camera module includes the
传统的机器视觉系统只能获取产品上方的画面,采用上述结构可以完成检测产品的前部视图、后部视图、左侧视图、右侧视图和俯视图的获取,为后续质检一次性提供同一状态下的六面待检图,因为是一次同时拍摄,所以光影条件一致,更加有利于后续质检平台100做出质检结果判断。The traditional machine vision system can only obtain the picture above the product. The above structure can complete the acquisition of the front view, rear view, left view, right view and top view of the inspected product, and provide the same state for the subsequent quality inspection at one time. The following picture of the six sides to be inspected is taken at the same time, so the light and shadow conditions are consistent, which is more conducive to the follow-up
本发明实施例一种基于YOLOV5的机器视觉缺陷质检方法的实施原理为:The implementation principle of a machine vision defect quality inspection method based on YOLOV5 in the embodiment of the present invention is as follows:
具体的某工业生产线的产品质检场景下,某时刻加工完成后的待检产品从工业流水线输送到透明平台指定位置,底部相机1、前部相机2、后部相机3、左侧相机4、右侧相机5和俯视相机6同时拍摄待检图片传输给质检平台100。In a specific product quality inspection scenario of an industrial production line, the product to be inspected after processing at a certain moment is transported from the industrial assembly line to the designated position on the transparent platform, the bottom camera 1, the
质检平台100运行图像拼接算法将六面待检图拼接成一张产品待检图,将产品待检图输入到质检平台100,The
先进行缺陷特征遍历,调用缺陷特征对比库的缺陷快速比对层对产品待检图进行遍历,对于表面裂痕的缺陷特征匹配成功四个基准特征点的特征,匹配相似度IOU值均大于0.9,且四个基准特征点之间的相互距离差异均小于距离差异阈值0.05,则质检平台100直接判定产品不合格,同时将缺陷位置进行框选处理,质检平台100的显示器基于框选标示进行显示,同时显示缺陷种类为裂痕,工作人员发现上述不合格产品后,对缺陷进行分析,后对工艺进行调整,对产品合格率的提升起到反馈的作用。First perform defect feature traversal, call the defect quick comparison layer of the defect feature comparison library to traverse the product to-be-inspected image, and for the defect features of surface cracks, the features of the four reference feature points are successfully matched, and the matching similarity IOU values are all greater than 0.9. And the mutual distance differences between the four reference feature points are all less than the distance difference threshold value of 0.05, then the
以上均为本发明的较佳实施例,并非以此限制本发明的保护范围,故:凡依本发明的结构、形状、原理所做的等效变化,均应涵盖于本发明的保护范围之内。All the above are preferred embodiments of the present invention, not to limit the protection scope of the present invention, so: all equivalent changes made according to the structure, shape and principle of the present invention should be covered by the protection scope of the present invention Inside.
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