CN118425045A - Visual inspection system and control method, device and storage medium thereof - Google Patents
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Abstract
本发明公开一种视觉检测系统及其控制方法、装置及存储介质,涉及自动检测技术领域。本发明通过工件传感装置感应工件以复位编码器值,再基于预设的编码触发值准确触发相机进行拍摄,从而拍摄得到符合要求的工件图片,进一步通过在编码锁定值内锁定信号接收端口,避免由于同一工件拍摄期间被反复感应而将编码器值重复置零,影响后续相机拍摄,提高了系统协同性,从而提高视觉检测系统的检测效率和准确性。
The present invention discloses a visual inspection system and a control method, device and storage medium thereof, and relates to the field of automatic inspection technology. The present invention senses a workpiece through a workpiece sensing device to reset an encoder value, and then accurately triggers a camera to shoot based on a preset encoding trigger value, thereby shooting a workpiece image that meets the requirements, and further locks a signal receiving port within the encoding lock value to avoid repeated zeroing of the encoder value due to repeated sensing during the shooting of the same workpiece, which affects subsequent camera shooting, thereby improving system coordination, thereby improving the detection efficiency and accuracy of the visual inspection system.
Description
技术领域Technical Field
本发明涉及自动检测技术领域,尤其涉及一种视觉检测系统及其控制方法、装置及存储介质。The present invention relates to the field of automatic detection technology, and in particular to a visual detection system and a control method, device and storage medium thereof.
背景技术Background technique
视觉检测系统是一种用机器代替人眼进行测量和判断的自动化系统。它通过工业相机、镜头、光源等设备获取待检测物体的图像或视频,然后利用计算机视觉和图像处理算法对图像进行处理和分析,以实现对物体的识别、检测、定位等功能。视觉检测系统的核心是图像处理技术,包括图像采集、预处理、特征提取和分析等步骤。视觉检测系统是一种高效、准确的自动化检测技术,可大大提高生产效率和产品质量,降低人工成本和废品率。目前,为了提高产品视觉检测的效率,通常协同多种设备实现动态视觉检测,通常为利用传送带运载工件,传送带上设置相机云台进行按照预设姿态调节拍摄,这种跟随拍摄方式虽然能提高检测效率,但容易出现画面拍摄偏差的情况,从而降低后续图像识别检测的准确性。The visual inspection system is an automated system that uses machines to replace human eyes for measurement and judgment. It obtains images or videos of the objects to be inspected through industrial cameras, lenses, light sources and other equipment, and then uses computer vision and image processing algorithms to process and analyze the images to achieve functions such as object recognition, detection, and positioning. The core of the visual inspection system is image processing technology, including steps such as image acquisition, preprocessing, feature extraction and analysis. The visual inspection system is an efficient and accurate automated inspection technology that can greatly improve production efficiency and product quality, and reduce labor costs and scrap rates. At present, in order to improve the efficiency of product visual inspection, dynamic visual inspection is usually achieved by coordinating multiple devices. Usually, a conveyor belt is used to carry the workpiece, and a camera gimbal is set on the conveyor belt to adjust the shooting according to the preset posture. Although this follow-up shooting method can improve the detection efficiency, it is prone to picture shooting deviation, thereby reducing the accuracy of subsequent image recognition detection.
发明内容Summary of the invention
本发明旨在至少解决现有技术中存在的技术问题之一。为此,本发明提出一种视觉检测系统及其控制方法、装置及存储介质,能够提高视觉检测效率和准确性。The present invention aims to solve at least one of the technical problems existing in the prior art. To this end, the present invention provides a visual inspection system and a control method, device and storage medium thereof, which can improve the efficiency and accuracy of visual inspection.
一方面,本发明实施例提供了一种视觉检测系统,包括:第一图像采集装置、传送装置、工件传感装置和控制装置,所述第一图像采集装置、所述传送装置和所述工件传感装置均与所述控制装置连接,所述第一图像采集装置设置在所述传送装置上方,所述第一图像采集装置包括多个姿态可调节的相机,工件传感装置设置在所述第一图像采集装置的工件入口侧;On the one hand, an embodiment of the present invention provides a visual inspection system, comprising: a first image acquisition device, a conveying device, a workpiece sensing device and a control device, wherein the first image acquisition device, the conveying device and the workpiece sensing device are all connected to the control device, the first image acquisition device is arranged above the conveying device, the first image acquisition device comprises a plurality of posture-adjustable cameras, and the workpiece sensing device is arranged at a workpiece entrance side of the first image acquisition device;
所述控制装置用于:The control device is used to:
根据当前工件类型获取编码触发值、编码锁定值和相机控制程序;Obtain the code trigger value, code lock value and camera control program according to the current workpiece type;
通过信号接收端口,监测来自工件传感装置的感应信号;Monitor the sensing signal from the workpiece sensing device through the signal receiving port;
当接收到所述感应信号,则锁定所述信号接收端口,并将传送装置的编码器置零后重新计数;When the sensing signal is received, the signal receiving port is locked, and the encoder of the transmission device is reset to zero and then counted again;
当所述编码器计数达到所述编码触发值,则控制所述第一图像采集装置按照所述相机控制程序采集工件图片以进行检测;When the encoder count reaches the encoding trigger value, the first image acquisition device is controlled to acquire a workpiece image for detection according to the camera control program;
当所述编码器计数达到所述编码锁定值,则解除对所述信号接收端口的锁定。When the encoder count reaches the encoder lock value, the signal receiving port is unlocked.
根据本发明一些实施例,所述编码触发值预存于所述控制装置中,所述编码触发值通过以下步骤确定:According to some embodiments of the present invention, the coding trigger value is pre-stored in the control device, and the coding trigger value is determined by the following steps:
从接收到来自工件传感装置的感应信号开始,每隔一个编码器值控制所述第一图像采集装置按照所述相机控制程序的初始点位进行拍摄,得到多张第一图片;Starting from receiving the sensing signal from the workpiece sensing device, controlling the first image acquisition device to take pictures according to the initial point position of the camera control program at every encoder value to obtain a plurality of first pictures;
显示多张所述第一图片,以选中符合要求的第一图片,并将选中的第一图片对应的编码器值作为所述编码触发值。A plurality of the first pictures are displayed to select a first picture that meets the requirements, and an encoder value corresponding to the selected first picture is used as the encoding trigger value.
根据本发明一些实施例,所述编码锁定值预存于所述控制装置中,所述编码锁定值通过以下步骤确定:According to some embodiments of the present invention, the code lock value is pre-stored in the control device, and the code lock value is determined by the following steps:
根据所述传送装置的运行速度将编码器值转换为单位距离;converting the encoder value into a unit distance according to the operating speed of the conveyor;
获取对应工件类型的工件长度;Get the workpiece length of the corresponding workpiece type;
根据所述工件长度和所述单位距离确定编码锁定值。A coding lock value is determined according to the workpiece length and the unit distance.
根据本发明一些实施例,所述视觉检测系统还包括第二图像采集装置和机械臂,所述第一图像采集装置、传送装置和工件传感装置均设置在第一工位上,所述第二图像采集装置设置在第二工位上,所述第二图像采集装置用于采集工件上表面图像,所述第一图像采集装置用于采集工件侧面图像,所述机械臂设置于所述第一工位和所述第二工位之间,所述机械臂用于将所述第二工位上的工件搬运至所述第一工位。According to some embodiments of the present invention, the visual inspection system further includes a second image acquisition device and a robotic arm, the first image acquisition device, the conveying device and the workpiece sensing device are all arranged on the first workstation, the second image acquisition device is arranged on the second workstation, the second image acquisition device is used to acquire the upper surface image of the workpiece, the first image acquisition device is used to acquire the side image of the workpiece, the robotic arm is arranged between the first workstation and the second workstation, and the robotic arm is used to move the workpiece on the second workstation to the first workstation.
根据本发明一些实施例,所述控制装置还用于:According to some embodiments of the present invention, the control device is further used for:
通过所述第二图像采集装置获取工件上表面图像;Acquire the upper surface image of the workpiece by the second image acquisition device;
根据所述工件上表面图像确定工件类型。The type of the workpiece is determined according to the upper surface image of the workpiece.
根据本发明一些实施例,所述控制装置通过以下步骤对所述相机控制程序进行校验:According to some embodiments of the present invention, the control device verifies the camera control program through the following steps:
控制所述第一图像采集装置按照所述相机控制程序对标定工件进行图像采集,得到多张第二图片,其中,所述标定工件的关节拐点设置有标签;Controlling the first image acquisition device to acquire images of the calibration workpiece according to the camera control program to obtain a plurality of second images, wherein the joint inflection points of the calibration workpiece are provided with labels;
对多张所述第二图片分别进行标签识别得到标签识别结果;Performing label recognition on the plurality of second images respectively to obtain label recognition results;
根据所述标签识别结果对所述相机控制程序进行校验,当所述标签识别结果中的每个标签均完整,则所述相机控制程序通过校验。The camera control program is verified according to the tag recognition result. When each tag in the tag recognition result is complete, the camera control program passes the verification.
根据本发明一些实施例,所述控制装置通过以下步骤对视觉检测系统中的相机的机械状态进行校验:According to some embodiments of the present invention, the control device verifies the mechanical state of the camera in the visual inspection system through the following steps:
根据自检点位调整相机姿态,并控制所述相机对标定板进行拍摄得到标定图片;Adjust the camera posture according to the self-checking point, and control the camera to shoot the calibration plate to obtain a calibration picture;
根据所述标定图片确定标定点搜索数据;Determine calibration point search data according to the calibration image;
将所述标定点数据和模板数据进行对比,当所述标定点数据和模板数据相同,则所述相机的机械状态通过校验。The calibration point data is compared with the template data. When the calibration point data is identical to the template data, the mechanical state of the camera passes the verification.
另一方面,本发明实施例还提供一种视觉检测系统的控制方法,包括以下步骤:On the other hand, an embodiment of the present invention further provides a control method of a visual inspection system, comprising the following steps:
根据当前工件类型获取编码触发值、编码锁定值和相机控制程序;Obtain the code trigger value, code lock value and camera control program according to the current workpiece type;
通过信号接收端口,监测来自工件传感装置的感应信号;Monitor the sensing signal from the workpiece sensing device through the signal receiving port;
当接收到所述感应信号,则锁定所述信号接收端口,并将传送装置的编码器置零后重新计数;When the sensing signal is received, the signal receiving port is locked, and the encoder of the transmission device is reset to zero and then counted again;
当所述编码器计数达到所述编码触发值,则控制第一图像采集装置按照所述相机控制程序采集工件图片以进行检测;When the encoder count reaches the encoding trigger value, the first image acquisition device is controlled to acquire a workpiece image for detection according to the camera control program;
当所述编码器计数达到所述编码锁定值,则解除对所述信号接收端口的锁定。When the encoder count reaches the encoder lock value, the signal receiving port is unlocked.
另一方面,本发明实施例还提供一种视觉检测系统的控制装置,包括:On the other hand, an embodiment of the present invention further provides a control device for a visual inspection system, comprising:
至少一个处理器;at least one processor;
至少一个存储器,用于存储至少一个程序;at least one memory for storing at least one program;
当所述至少一个程序被所述至少一个处理器执行,使得至少一个所述处理器实现如前面所述的视觉检测系统的控制方法。When the at least one program is executed by the at least one processor, the at least one processor implements the control method of the visual inspection system as described above.
另一方面,本发明实施例还提供一种计算机可读存储介质,所述计算机可读存储介质存储有计算机可执行指令,所述计算机可执行指令用于使计算机执行如前面所述的视觉检测系统的控制方法。On the other hand, an embodiment of the present invention further provides a computer-readable storage medium, wherein the computer-readable storage medium stores computer-executable instructions, and the computer-executable instructions are used to enable a computer to execute the control method of the visual inspection system as described above.
本发明上述的技术方案至少具有如下优点或有益效果之一:通过第一图像采集装置工件入口侧的工件传感装置感应工件,当控制装置通过信号接收端口接收到感应信号,则锁定信号接收端口,并将传送装置的编码器置零后重新计数,当编码器计数达到编码触发值,则控制第一图像采集装置按照相机控制程序采集工件图片以进行检测,当编码器计数达到编码锁定值,则解除对信号接收端口的锁定。通过工件传感装置感应工件以复位编码器值,再基于预设的编码触发值准确触发相机进行拍摄,从而拍摄得到符合要求的工件图片,进一步通过在编码锁定值内锁定信号接收端口,避免由于同一工件拍摄期间被反复感应而将编码器值重复置零,影响后续相机拍摄,提高了系统协同性,从而提高视觉检测系统的检测效率和准确性。The above technical solution of the present invention has at least one of the following advantages or beneficial effects: the workpiece is sensed by the workpiece sensing device on the workpiece inlet side of the first image acquisition device, and when the control device receives the sensing signal through the signal receiving port, the signal receiving port is locked, and the encoder of the transmission device is reset to zero and then counted again, and when the encoder count reaches the encoding trigger value, the first image acquisition device is controlled to collect the workpiece image for detection according to the camera control program, and when the encoder count reaches the encoding lock value, the signal receiving port is unlocked. The workpiece is sensed by the workpiece sensing device to reset the encoder value, and then the camera is accurately triggered to shoot based on the preset encoding trigger value, so as to shoot the workpiece image that meets the requirements, and further by locking the signal receiving port within the encoding lock value, it is avoided that the encoder value is repeatedly reset to zero due to repeated sensing during the shooting of the same workpiece, which affects the subsequent camera shooting, and the system coordination is improved, thereby improving the detection efficiency and accuracy of the visual inspection system.
附图说明BRIEF DESCRIPTION OF THE DRAWINGS
图1是本发明实施例提供的视觉检测系统示意图;FIG1 is a schematic diagram of a visual inspection system provided by an embodiment of the present invention;
图2是本发明实施例提供的视觉检测系统的控制方法流程图;2 is a flow chart of a control method of a visual inspection system provided by an embodiment of the present invention;
图3是本发明实施例提供的视觉检测系统相机自检流程图;3 is a flow chart of camera self-test of a visual inspection system provided by an embodiment of the present invention;
图4是本发明实施例提供的标定板示意图;FIG4 is a schematic diagram of a calibration plate provided in an embodiment of the present invention;
图5是本发明实施例提供的视觉检测系统的控制装置结构示意图。FIG. 5 is a schematic diagram of the structure of a control device of a visual inspection system provided in an embodiment of the present invention.
具体实施方式Detailed ways
下面详细描述本发明的实施例,所述实施例的示例在附图中示出,其中自始至终相同或者类似的标号表示相同或者类似的原件或具有相同或类似功能的元件。下面通过参考附图描述的实施例是示例性的,仅用于解释本发明,而不能理解为对本发明的限制。The embodiments of the present invention are described in detail below, and examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar originals or elements with the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and cannot be understood as limiting the present invention.
在本发明的描述中,需要理解的是,涉及到方位描述,例如上、下、左、右等指示的方位或者位置关系为基于附图所示的方位或者位置关系,仅是为了便于描述本发明和简化描述,而不是指示或者暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作,因此不能理解为对本发明的限制。In the description of the present invention, it should be understood that descriptions involving orientation, such as up, down, left, right, etc., the orientations or positional relationships indicated are based on the orientations or positional relationships shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present invention.
本发明的描述中,如果有描述到第一、第二等只是用于区分技术特征为目的,而不能理解为指示或者暗示相对重要性或者隐含指明所指示的技术特征的数量或者隐含指明所指示的技术特征的先后关系。In the description of the present invention, if there is a description of first, second, etc., it is only for the purpose of distinguishing technical features, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features or implicitly indicating the sequence of the indicated technical features.
本发明实施例提供了一种视觉检测系统,参照图1,本发明实施例的视觉检测系统包括第一图像采集装置120、传送装置110、工件传感装置130和控制装置(图中未示出),第一图像采集装置、传送装置和工件传感装置均与控制装置连接,第一图像采集装置设置在传送装置上方,第一图像采集装置包括多个姿态可调节的相机,工件传感装置设置在第一图像采集装置的工件入口侧。An embodiment of the present invention provides a visual inspection system. Referring to Figure 1, the visual inspection system of the embodiment of the present invention includes a first image acquisition device 120, a conveying device 110, a workpiece sensing device 130 and a control device (not shown in the figure). The first image acquisition device, the conveying device and the workpiece sensing device are all connected to the control device. The first image acquisition device is arranged above the conveying device. The first image acquisition device includes a plurality of cameras with adjustable postures. The workpiece sensing device is arranged on the workpiece entrance side of the first image acquisition device.
在本实施例中,第一图像采集装置可以以龙门架的形式放置在传送装置上,第一图像采集装置内侧的顶部和侧部设置有多个相机和多个光照板,多个相机的角度姿态通过云台进行调整,云台可由计算机程序调节控制,相机可使用电动变焦镜头,较传统镜头,更换检测头后无需任何调试即可正常使用,无传统镜头对于镜头焦距、光圈调整的繁琐工作,确保工作站运行稳定性;多个角度可调节的光照板用于提供均匀的拍摄光源。传送装置设置有编码器,编码器可以安装于输送驱动电机位置,能够将传送的直线位移转换成周期性的电信号,再把这个电信号转变成计数脉冲,用脉冲的个数表示位移的大小。In this embodiment, the first image acquisition device can be placed on the conveying device in the form of a gantry. Multiple cameras and multiple lighting panels are arranged on the top and side of the inner side of the first image acquisition device. The angles and postures of the multiple cameras are adjusted by a pan-tilt platform, which can be adjusted and controlled by a computer program. The camera can use an electric zoom lens. Compared with traditional lenses, it can be used normally without any debugging after replacing the detection head. There is no tedious work of adjusting the focal length and aperture of the lens for traditional lenses, ensuring the stability of the workstation operation; multiple angle-adjustable lighting panels are used to provide a uniform shooting light source. The conveying device is provided with an encoder, which can be installed at the position of the conveying drive motor, and can convert the transmitted linear displacement into a periodic electrical signal, and then convert this electrical signal into a counting pulse, and the number of pulses is used to represent the size of the displacement.
在本实施例中,工件传感装置可以是红外传感器,红外传感器红外发射器、红外接收器和处理器组成,如图1所示,红外发射器和红外接收器分别设置在第一图像采集装置的工件入口侧的两边,在无遮挡情况下红外接收器一直接收红外发射器发出的红外线,此时处理器不产生感应信号,而当工件按照图示方向经过红外传感器时,由于红外线被遮挡,红外接收器接收不到红外线,此时处理器产生感应信号。可以理解的是,工件传感器也可以是其他类型的位置传感器,能够感应工件位置即可。In this embodiment, the workpiece sensing device can be an infrared sensor, which is composed of an infrared transmitter, an infrared receiver and a processor. As shown in FIG1 , the infrared transmitter and the infrared receiver are respectively arranged on both sides of the workpiece entrance side of the first image acquisition device. In the absence of shielding, the infrared receiver always receives the infrared rays emitted by the infrared transmitter. At this time, the processor does not generate a sensing signal. When the workpiece passes through the infrared sensor in the direction shown in the figure, the infrared receiver cannot receive the infrared rays because the infrared rays are blocked. At this time, the processor generates a sensing signal. It can be understood that the workpiece sensor can also be other types of position sensors that can sense the position of the workpiece.
参照图2,控制装置用于执行以下步骤:Referring to FIG. 2 , the control device is used to perform the following steps:
步骤S201,根据当前工件类型获取编码触发值、编码锁定值和相机控制程序;Step S201, obtaining a code trigger value, a code lock value and a camera control program according to the current workpiece type;
步骤S202,通过信号接收端口,监测来自工件传感装置的感应信号;Step S202, monitoring the sensing signal from the workpiece sensing device through the signal receiving port;
步骤S203,当接收到感应信号,则锁定信号接收端口,并将传送装置的编码器置零后重新计数;Step S203, when the sensing signal is received, the signal receiving port is locked, and the encoder of the transmission device is reset to zero and counted again;
步骤S204,当编码器计数达到编码触发值,则控制第一图像采集装置按照相机控制程序采集工件图片以进行检测;Step S204, when the encoder count reaches the encoding trigger value, the first image acquisition device is controlled to acquire a workpiece image for detection according to the camera control program;
步骤S205,当编码器计数达到编码锁定值,则解除对信号接收端口的锁定。Step S205: when the encoder count reaches the encoder lock value, the signal receiving port is unlocked.
在本实施例中,控制装置接收来自工件传感装置的感应信号的端口为信号接收端口,控制装置可以将信号接收端口配置为锁定状态或者解除锁定状态。在信号接收端口锁定状态下,控制装置不对工件传感装置的感应信号进行监测。In this embodiment, the port of the control device receiving the sensing signal from the workpiece sensor device is the signal receiving port, and the control device can configure the signal receiving port to be locked or unlocked. When the signal receiving port is locked, the control device does not monitor the sensing signal of the workpiece sensor device.
在本实施例中,工件经过工件传感装置时,工件传感装置产生感应信号,控制装置监测到感应信号后,将编码器值置零并重新计数,同时锁定信号接收端口,以避免后续同一工件的多次触发。当编码器计数至预设的编码触发值时,表明此时工件已经运送至符合第一图像采集装置拍摄的位置,则控制第一图像采集装置按照相机控制程序采集视角合适的工件图片,以对工件进行视觉检测。当编码器计数至预设的编码锁定值时,表明当前工件已经完全通过工件传感装置,则可以解除对信号接收端的锁定,以对下一个进入第一图像采集装置的工件进行监测。可以理解的是,本实施例中的相机控制程序用于控制第一图像采集装置中的多个相机按照预设时间间隔和点位(或称角度)进行拍摄。In this embodiment, when the workpiece passes through the workpiece sensing device, the workpiece sensing device generates a sensing signal. After the control device detects the sensing signal, it resets the encoder value to zero and recounts, and locks the signal receiving port at the same time to avoid multiple triggering of the same workpiece in the future. When the encoder counts to the preset encoding trigger value, it indicates that the workpiece has been transported to a position that meets the shooting of the first image acquisition device. Then, the first image acquisition device is controlled to capture a workpiece image with a suitable viewing angle according to the camera control program to perform visual inspection of the workpiece. When the encoder counts to the preset encoding lock value, it indicates that the current workpiece has completely passed through the workpiece sensing device, and the signal receiving end can be unlocked to monitor the next workpiece entering the first image acquisition device. It can be understood that the camera control program in this embodiment is used to control multiple cameras in the first image acquisition device to shoot at preset time intervals and points (or angles).
根据本发明一些实施例,编码触发值预存于控制装置中,编码触发值通过以下步骤确定:According to some embodiments of the present invention, the coding trigger value is pre-stored in the control device, and the coding trigger value is determined by the following steps:
步骤S301,从接收到来自工件传感装置的感应信号开始,每隔一个编码器值控制第一图像采集装置按照相机控制程序的初始点位进行拍摄,得到多张第一图片;Step S301, starting from receiving the sensing signal from the workpiece sensing device, controlling the first image acquisition device to shoot according to the initial point position of the camera control program at every encoder value to obtain multiple first pictures;
步骤S302,显示多张第一图片,以选中符合要求的第一图片,并将选中的第一图片对应的编码器值作为编码触发值。Step S302 , displaying multiple first pictures to select a first picture that meets the requirements, and using the encoder value corresponding to the selected first picture as the encoding trigger value.
在本实施例中,在实际视觉检测过程中,工件跟随传送装置运动,需要为不同类型的工件配置对应的拍摄角度和拍摄时机,以获得最佳拍摄视角的工件图片。在启动相机控制程序后,相机可以按照相机控制程序的初始点位开始进行拍摄,从而实现自动控制拍摄角度和拍摄时机,而启动相机控制程序的时机可以由编码器值是否达到编码触发值决定,预设的编码触发值可以通过以下方式确定:In this embodiment, during the actual visual inspection process, the workpiece moves with the conveyor, and it is necessary to configure corresponding shooting angles and shooting times for different types of workpieces to obtain workpiece images with the best shooting angle. After starting the camera control program, the camera can start shooting according to the initial point position of the camera control program, thereby automatically controlling the shooting angle and shooting time, and the timing of starting the camera control program can be determined by whether the encoder value reaches the encoding trigger value, and the preset encoding trigger value can be determined by the following method:
从接收到来自工件传感装置的感应信号开始,每隔一个编码器值控制第一图像采集装置按照相机控制程序的初始点位进行拍摄得到多张相机角度相同但工件位置不同的工件图片,即第一图片。在终端上显示多张第一图片,以使工作人员根据从多张第一图片中选择初始点位下最佳视角的图片,并将选中的第一图片对应的编码器值作为编码触发值,然后将该编码触发值与工件类型关联存储在控制装置中。Starting from receiving the sensing signal from the workpiece sensing device, the first image acquisition device is controlled to shoot at the initial point of the camera control program at every encoder value to obtain multiple workpiece images with the same camera angle but different workpiece positions, namely, the first images. Multiple first images are displayed on the terminal so that the staff can select the image with the best viewing angle at the initial point from the multiple first images, and use the encoder value corresponding to the selected first image as the encoding trigger value, and then store the encoding trigger value in association with the workpiece type in the control device.
根据本发明一些实施例,编码锁定值预存于控制装置中,编码锁定值通过以下步骤确定:According to some embodiments of the present invention, the code lock value is pre-stored in the control device, and the code lock value is determined by the following steps:
步骤S401,根据传送装置的运行速度将编码器值转换为单位距离;Step S401, converting the encoder value into a unit distance according to the running speed of the conveying device;
步骤S402,获取对应工件类型的工件长度;Step S402, obtaining the workpiece length of the corresponding workpiece type;
步骤S403,根据工件长度和单位距离确定编码锁定值。Step S403, determining the encoding lock value according to the workpiece length and the unit distance.
在本实施例中,工件传感装置是安装在一定高度的,原理是当有工件阻挡感应器的对射时会给系统发出信号,由于工件形状不规则,工件存在高度起伏,使工件多次触发,从而让系统误识别有多个不同的工件进入导致异常。本实施例根据传送速度将现场的编码器值转换成毫米单位的单位距离,然后将工件长度除以单位距离得到编码锁定值。在实际视觉检测过程中,将可以在感应到工件时编码从0开始计数,截至到编码锁定值期间,不再接收红外传感器信号,形成信号互锁。In this embodiment, the workpiece sensor device is installed at a certain height. The principle is that when a workpiece blocks the sensor's radiation, a signal will be sent to the system. Due to the irregular shape of the workpiece and the height fluctuations of the workpiece, the workpiece is triggered multiple times, causing the system to mistakenly identify that multiple different workpieces have entered, resulting in an abnormality. In this embodiment, the encoder value at the scene is converted into a unit distance in millimeters according to the transmission speed, and then the workpiece length is divided by the unit distance to obtain the encoding lock value. In the actual visual inspection process, the code can be counted from 0 when the workpiece is sensed, and the infrared sensor signal is no longer received during the period of the encoding lock value, forming a signal interlock.
根据本发明一些实施例,视觉检测系统还包括第二图像采集装置和机械臂,第一图像采集装置、传送装置和工件传感装置均设置在第一工位上,第二图像采集装置设置在第二工位上。第二图像采集装置用于采集工件上表面图像,第一图像采集装置用于采集工件侧面图像,机械臂设置于第一工位和所述第二工位之间,机械臂用于将第二工位上的工件搬运至第一工位。According to some embodiments of the present invention, the visual inspection system further includes a second image acquisition device and a robotic arm, the first image acquisition device, the conveying device and the workpiece sensing device are all arranged on the first station, and the second image acquisition device is arranged on the second station. The second image acquisition device is used to acquire an image of the upper surface of the workpiece, the first image acquisition device is used to acquire an image of the side surface of the workpiece, the robotic arm is arranged between the first station and the second station, and the robotic arm is used to transport the workpiece on the second station to the first station.
工件进入第二工位后,由第二工位上方的第二图像采集装置拍摄工件上表面图像,拍摄完成后由机械臂将第二工位上的工件抓取到第一工位的传送装置上。工件由传送装置运送,经过工件感应装置后进入第一图像采集装置,由第一图像采集装置中的相机拍摄工件侧面图片。通过第一图像采集装置和第二图像采集装置的配合,能够高效地完成工件各个表面的图像采集工作。After the workpiece enters the second station, the second image acquisition device above the second station captures the image of the upper surface of the workpiece. After the capture is completed, the robot arm grabs the workpiece on the second station and places it on the conveying device of the first station. The workpiece is transported by the conveying device, passes through the workpiece sensing device, and enters the first image acquisition device. The camera in the first image acquisition device captures the side image of the workpiece. Through the cooperation of the first image acquisition device and the second image acquisition device, the image acquisition work of each surface of the workpiece can be completed efficiently.
根据本发明一些实施例,本申请实施例的控制装置还用于:According to some embodiments of the present invention, the control device of the embodiment of the present application is also used for:
步骤S501,通过第二图像采集装置获取工件上表面图像;Step S501, acquiring an image of the upper surface of the workpiece by a second image acquisition device;
步骤S502,根据工件上表面图像确定工件类型。Step S502, determining the type of the workpiece according to the upper surface image of the workpiece.
在本实施例中,在第一工位进行视觉检测控制时,需要先根据当前第一工位上的工件类型获取对应的编码触发值、编码锁定值和相机控制程序,而工件类型可以通过第二图像采集装置采集到的上表面图像,利用基于卷积神经网络的图像分类模型对上表面图像进行分类识别得到。In this embodiment, when visual inspection control is performed at the first workstation, it is necessary to first obtain the corresponding coding trigger value, coding lock value and camera control program according to the type of workpiece currently on the first workstation, and the workpiece type can be obtained by classifying and identifying the upper surface image captured by the second image acquisition device using an image classification model based on a convolutional neural network.
根据本发明一些实施例,控制装置通过以下步骤对相机控制程序进行校验:According to some embodiments of the present invention, the control device verifies the camera control program through the following steps:
步骤S601,控制第一图像采集装置按照相机控制程序对标定工件进行图像采集,得到多张第二图片,其中,标定工件的关节拐点设置有标签;Step S601, controlling the first image acquisition device to acquire images of the calibration workpiece according to the camera control program to obtain a plurality of second images, wherein the joint inflection points of the calibration workpiece are provided with labels;
步骤S602,对多张第二图片分别进行标签识别得到标签识别结果;Step S602, performing label recognition on the plurality of second images respectively to obtain label recognition results;
步骤S603,根据标签识别结果对相机控制程序进行校验,当所述标签识别结果中的每个标签均完整,则相机控制程序通过校验。Step S603, verifying the camera control program according to the tag recognition result, and when each tag in the tag recognition result is complete, the camera control program passes the verification.
在本实施例中,工位人员根据工件拍摄需求对第一图像采集装置中的各个相机进行多点位配置,根据配置好的各个相机的各个点位数据形成相机控制程序。生成相机控制程序后,需要对相机控制程序进行校验,以确保通过该相机控制程序的控制能够实现各个工件的全覆盖。在对相机控制程序进行校验时,可以在对应类型的工件的关节拐点处粘贴标签(例如二维码),然后将该工件作为标定工件。将标定工件送入传送装置后控制第一图像采集装置按照相机控制程序对标定工件进行图像采集得到多张各个相机在各个点位下的第二图片,通过图像处理技术提取出多张第二图片中的标签得到标签识别结果,当标签识别结果中包含所有标定工件上的标签,且每个标签均完整,则相机控制程序通过校验,反之相机控制程序校验失败,需要重新调整相机控制程序。In this embodiment, the station personnel configure each camera in the first image acquisition device at multiple points according to the workpiece shooting requirements, and form a camera control program according to the data of each point of each configured camera. After the camera control program is generated, the camera control program needs to be verified to ensure that the full coverage of each workpiece can be achieved through the control of the camera control program. When verifying the camera control program, a label (such as a QR code) can be pasted at the joint inflection point of the corresponding type of workpiece, and then the workpiece is used as a calibration workpiece. After the calibration workpiece is sent into the conveying device, the first image acquisition device is controlled to perform image acquisition on the calibration workpiece according to the camera control program to obtain multiple second pictures of each camera at each point, and the labels in the multiple second pictures are extracted by image processing technology to obtain label recognition results. When the label recognition results contain all the labels on the calibration workpiece, and each label is complete, the camera control program passes the verification, otherwise the camera control program fails to verify and the camera control program needs to be readjusted.
根据本发明一些实施例,控制装置通过以下步骤对视觉检测系统中的相机的机械状态进行校验:According to some embodiments of the present invention, the control device verifies the mechanical state of the camera in the visual inspection system through the following steps:
步骤S701,根据自检点位调整相机姿态,并控制相机对标定板进行拍摄得到标定图片;Step S701, adjusting the camera posture according to the self-checking point, and controlling the camera to shoot the calibration plate to obtain a calibration picture;
步骤S702,根据标定图片确定标定点搜索数据;Step S702, determining calibration point search data according to the calibration image;
步骤S703,将标定点数据和模板数据进行对比,当标定点数据和模板数据相同,则相机的机械状态通过校验。Step S703, comparing the calibration point data with the template data. When the calibration point data and the template data are identical, the mechanical state of the camera passes the verification.
在本实施例中,参照图3,视觉检测系统对相机进行自检的过程如下:In this embodiment, referring to FIG. 3 , the process of the visual inspection system performing self-inspection on the camera is as follows:
通过IO信号判断是否设置系统自检指令,如果没有设置系统自检指令,则进入正常视觉检测流程;如果设置系统自检指令,则视觉系统根据自检点位调整相机姿态,并控制相机对标定板进行拍摄得到标定图片;示例性地,参照图4,标定板由五个基准圆点组成,且圆点区域与背景颜色互为反色;五个基准圆点之中四个基准圆点在标定板中心的4个角,第五个基准点位于下侧基准圆点的旁边;将标定板中心最下方的基准点设置坐标原点;坐标原点指向旁边基准点的方向,设置为X方向;坐标原点指向最上方基准点的方向,设置为Y方向;It is determined through the IO signal whether the system self-check instruction is set. If the system self-check instruction is not set, the normal visual inspection process is entered; if the system self-check instruction is set, the visual system adjusts the camera posture according to the self-check point, and controls the camera to shoot the calibration plate to obtain a calibration picture; exemplarily, referring to Figure 4, the calibration plate is composed of five reference dots, and the dot area and the background color are opposite to each other; four of the five reference dots are located at the four corners of the center of the calibration plate, and the fifth reference point is located next to the lower reference dot; the lowest reference point in the center of the calibration plate is set as the coordinate origin; the direction of the coordinate origin pointing to the adjacent reference point is set as the X direction; the direction of the coordinate origin pointing to the uppermost reference point is set as the Y direction;
根据标定图片确定标定点搜索数据,并将标定点数据和模板数据进行对比;Determine the calibration point search data according to the calibration image, and compare the calibration point data with the template data;
当标定点数据和模板数据不相同,则可以确定相机存在松动或者移动等机械状态异常情况;其中,可以先通过标定点数据和模板数据判断是否拍摄角度偏移,如果拍摄角度偏移表明相机松动,则进行弹窗报警,如果拍摄角度不偏移表明相机不松动,则进一步判断是否相机移位,如果相机移位则平移所有检测点的搜索框。When the calibration point data and the template data are different, it can be determined that the camera has mechanical abnormalities such as being loose or moving. Among them, the calibration point data and the template data can be used to first determine whether the shooting angle is offset. If the shooting angle offset indicates that the camera is loose, a pop-up alarm will be issued. If the shooting angle is not offset, indicating that the camera is not loose, further determine whether the camera is displaced. If the camera is displaced, translate the search box of all detection points.
本发明实施例还提供一种视觉检测系统的控制方法,本发明实施例的视觉检测系统的控制方法与上述控制装置执行的方法相同,具体如下:The embodiment of the present invention further provides a control method for a visual inspection system. The control method for a visual inspection system in the embodiment of the present invention is the same as the method performed by the above control device, and is specifically as follows:
根据当前工件类型获取编码触发值、编码锁定值和相机控制程序;Obtain the code trigger value, code lock value and camera control program according to the current workpiece type;
通过信号接收端口,监测来自工件传感装置的感应信号;Monitor the sensing signal from the workpiece sensing device through the signal receiving port;
当接收到感应信号,则锁定信号接收端口,并将传送装置的编码器置零后重新计数;When receiving the induction signal, the signal receiving port is locked, and the encoder of the transmission device is reset to zero and counted again;
当编码器计数达到编码触发值,则控制第一图像采集装置按照相机控制程序采集工件图片以进行检测;When the encoder count reaches the encoding trigger value, the first image acquisition device is controlled to acquire a workpiece image for detection according to the camera control program;
当编码器计数达到编码锁定值,则解除对信号接收端口的锁定。When the encoder count reaches the encoder lock value, the signal receiving port is unlocked.
可以理解的是,上述视觉检测系统的控制装置执行的方法实施例中的内容均适用于本实施例中,本系统实施例所具体实现的功能与上述控制装置执行的方法实施例相同,并且达到的有益效果与上述控制装置执行的方法实施例所达到的有益效果也相同。It can be understood that the contents of the method embodiment executed by the control device of the above-mentioned visual detection system are all applicable to the present embodiment, the functions specifically implemented by the present system embodiment are the same as those of the method embodiment executed by the above-mentioned control device, and the beneficial effects achieved are also the same as those achieved by the method embodiment executed by the above-mentioned control device.
参照图5,图5是本发明一个实施例提供的视觉检测系统的控制装置的示意图。本发明实施例的视觉检测系统的控制装置包括一个或多个控制处理器和存储器,图5中以一个控制处理器及一个存储器为例。Referring to Fig. 5, Fig. 5 is a schematic diagram of a control device of a visual inspection system provided by an embodiment of the present invention. The control device of the visual inspection system of the embodiment of the present invention includes one or more control processors and a memory, and Fig. 5 takes one control processor and one memory as an example.
控制处理器和存储器可以通过总线或者其他方式连接,图5中以通过总线连接为例。The control processor and the memory may be connected via a bus or other means, and FIG5 takes the connection via a bus as an example.
存储器作为一种非暂态计算机可读存储介质,可用于存储非暂态软件程序以及非暂态性计算机可执行程序。此外,存储器可以包括高速随机存取存储器,还可以包括非暂态存储器,例如至少一个磁盘存储器件、闪存器件、或其他非暂态固态存储器件。在一些实施方式中,存储器可选包括相对于控制处理器远程设置的存储器,这些远程存储器可以通过网络连接至该视觉检测系统的控制装置。上述网络的实例包括但不限于互联网、企业内部网、局域网、移动通信网及其组合。The memory, as a non-transient computer-readable storage medium, can be used to store non-transient software programs and non-transient computer executable programs. In addition, the memory may include a high-speed random access memory, and may also include a non-transient memory, such as at least one disk storage device, a flash memory device, or other non-transient solid-state storage device. In some embodiments, the memory may optionally include a memory remotely arranged relative to the control processor, and these remote memories may be connected to the control device of the visual inspection system via a network. Examples of the above-mentioned network include, but are not limited to, the Internet, an intranet, a local area network, a mobile communication network, and combinations thereof.
本领域技术人员可以理解,图5中示出的装置结构并不构成对视觉检测系统的控制装置的限定,可以包括比图示更多或更少的部件,或者组合某些部件,或者不同的部件布置。Those skilled in the art will appreciate that the device structure shown in FIG. 5 does not constitute a limitation on the control device of the visual inspection system, and may include more or fewer components than shown in the figure, or a combination of certain components, or a different arrangement of components.
实现上述实施例中应用于视觉检测系统的控制装置的控制方法所需的非暂态软件程序以及指令存储在存储器中,当被控制处理器执行时,执行上述实施例中应用于控制装置的控制方法。The non-transient software program and instructions required to implement the control method of the control device applied to the visual inspection system in the above embodiment are stored in the memory, and when executed by the control processor, the control method applied to the control device in the above embodiment is executed.
此外,本发明的一个实施例还提供了一种计算机可读存储介质,该计算机可读存储介质存储有计算机可执行指令,该计算机可执行指令被一个或多个控制处理器执行,可使得上述一个或多个控制处理器执行上述方法实施例中的控制方法。In addition, an embodiment of the present invention further provides a computer-readable storage medium, which stores computer-executable instructions. The computer-executable instructions are executed by one or more control processors, so that the one or more control processors can execute the control method in the above method embodiment.
本领域普通技术人员可以理解,上文中所公开方法中的全部或某些步骤、系统可以被实施为软件、固件、硬件及其适当的组合。某些物理组件或所有物理组件可以被实施为由处理器,如中央处理器、数字信号处理器或微处理器执行的软件,或者被实施为硬件,或者被实施为集成电路,如专用集成电路。这样的软件可以分布在计算机可读介质上,计算机可读介质可以包括计算机存储介质(或非暂时性介质)和通信介质(或暂时性介质)。如本领域普通技术人员公知的,术语计算机存储介质包括在用于存储信息(诸如计算机可读指令、数据结构、程序模块或其他数据)的任何方法或技术中实施的易失性和非易失性、可移除和不可移除介质。计算机存储介质包括但不限于RAM、ROM、EEPROM、闪存或其他存储器技术、CD-ROM、数字多功能盘(DVD)或其他光盘存储、磁盒、磁带、磁盘存储或其他磁存储装置、或者可以用于存储期望的信息并且可以被计算机访问的任何其他的介质。此外,本领域普通技术人员公知的是,通信介质通常包含计算机可读指令、数据结构、程序模块或者诸如载波或其他传输机制之类的调制数据信号中的其他数据,并且可包括任何信息递送介质。It will be appreciated by those skilled in the art that all or some of the steps and systems in the disclosed method above may be implemented as software, firmware, hardware and appropriate combinations thereof. Some physical components or all physical components may be implemented as software executed by a processor, such as a central processing unit, a digital signal processor or a microprocessor, or may be implemented as hardware, or may be implemented as an integrated circuit, such as an application specific integrated circuit. Such software may be distributed on a computer-readable medium, which may include a computer storage medium (or a non-transitory medium) and a communication medium (or a temporary medium). As known to those skilled in the art, the term computer storage medium includes volatile and non-volatile, removable and non-removable media implemented in any method or technology for storing information (such as computer-readable instructions, data structures, program modules or other data). Computer storage media include, but are not limited to, RAM, ROM, EEPROM, flash memory or other memory technologies, CD-ROM, digital versatile disks (DVD) or other optical disk storage, magnetic cassettes, magnetic tapes, disk storage or other magnetic storage devices, or any other medium that may be used to store desired information and may be accessed by a computer. Furthermore, it is well known to those skilled in the art that communication media typically embodies computer readable instructions, data structures, program modules, or other data in a modulated data signal such as a carrier wave or other transport mechanism, and may include any information delivery media.
上面结合附图对本发明实施例作了详细说明,但是本发明不限于上述实施例,在所属技术领域普通技术人员所具备的知识范围内,还可以在不脱离本发明宗旨的前提下作出各种变化。The embodiments of the present invention are described in detail above in conjunction with the accompanying drawings, but the present invention is not limited to the above embodiments, and various changes can be made within the knowledge scope of ordinary technicians in the relevant technical field without departing from the purpose of the present invention.
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