Typical application of machine vision inspection technology

The machine vision industrial inspection system is divided into two categories, quantitative and qualitative, in terms of its detection properties and application range. Each class is divided into different sub-categories. Machine vision is very active in various applications in industrial online inspection, such as: visual inspection of printed circuit boards, automatic flaw detection of steel sheet surfaces, parallelism and perpendicularity measurement of large workpieces, container volume or impurity detection, automatic identification and classification of mechanical parts. Geometric dimension measurement, etc. In addition, machine vision systems can be effectively implemented where many other methods are difficult to detect. The application of machine vision is increasingly replacing people to do a lot of work, which undoubtedly greatly improves the level of production automation and the intelligence level of the detection system.

Machine vision systems are widely used in various aspects of quality inspection, such as large workpiece parallelism and perpendicularity measuring instruments using laser scanning and CCD detection systems. They use a stable collimated laser beam as the measurement baseline, with back The rotating shaft system rotates the pentagonal prism to sweep out the parallel or vertical reference planes and compare them with the faces of the large workpiece to be tested. When processing or installing large workpieces, the discriminator can be used to measure the parallelism and perpendicularity between the faces.

The stroboscopic flash is used as the illumination source, and the area array and linear array CCD are used as the detector parts of the contour shape of the rebar to realize the dynamic detection system for the on-line measurement of the geometric parameters of hot-rolled rebar.

Visual technology monitors bearing load and temperature changes in real time, eliminating the risk of overload and overheating. Passive measurements that traditionally measure machining quality and safe operation by measuring the ball surface are turned into active monitoring.

Using microwave as the signal source, according to the square wave of the microwave generator emitting different wave rates, the crack on the metal surface is measured. The higher the frequency of the microwave wave, the narrower the measurable crack.

In short, there are many similar practical systems, which are not outlined here. Below we describe three practical machine vision systems in more detail.

Machine vision based dashboard assembly intelligent integration test system

EQ140-II automobile instrument panel assembly is a meter product produced by an automobile company in China. The instrument panel is equipped with speed odometer, water temperature meter, fuel gauge, ammeter, signal warning light, etc. The production batch is large and needs to be carried out once before leaving the factory. Final quality inspection. The detection items include: detecting the indication error of five meter hands such as the speedometer; detecting whether the 24 signal warning lamps and the plurality of illumination 9 lamps are damaged or missing. Generally, it is checked by manual visual inspection method, which has large error and poor reliability, and cannot meet the needs of automated production. The intelligent integrated test system based on machine vision has changed this situation, realized intelligent, automatic, high-precision and fast quality inspection of the instrument panel assembly, overcoming various errors caused by manual detection and greatly improving detection. effectiveness.

The whole system is divided into four parts: an integrated multi-channel standard signal source for analog signal source for the instrument panel, a two-coordinate CNC system with image information feedback positioning, a camera image acquisition system and a master-slave parallel processing system.

The surface quality of metal plates, such as large power transformer coil flat wire radios, has high requirements, but the original method of manual visual inspection or centrifugal plus needle control is not only susceptible to subjective factors. And it may draw a new scratch on the surface being tested. The automatic flaw detection system on the surface of the metal plate uses machine vision technology to automatically inspect metal surface defects, and performs high-speed and accurate detection during the production process. At the same time, the use of non-angle measurement makes it possible to avoid new scratches. The working principle diagram is shown in Figure 8-6. In this system, the laser is used as the light source, the stray light around the laser beam is filtered by the pinhole filter, and the beam expander and the collimating mirror turn the laser beam into parallel light. The surface of the inspected metal sheet is uniformly illuminated at an incident angle of 45 degrees. The metal plate is placed on the inspection table. The test bench can be moved in three directions: X, Y and Z. The camera adopts TCD142D type 2048 line Chen CCD, and the lens adopts ordinary camera lens. The CCD interface circuit uses a single chip system. The host PC mainly performs image pre-processing and classification of defects or depth calculation of scratches, etc., and can display the detected defects or scratch images on the display. The two-way communication between the CCD interface circuit and the PC through the RS-232 port, combined with the asynchronous A/D conversion mode, constitutes an interactive data acquisition and processing of the human-machine.

The system mainly uses the self-scanning characteristic of the linear CCD in combination with the movement of the inspected steel sheet in the X direction to obtain three-dimensional image information on the surface of the metal plate.

British ROVER car company 800 series car body contour size accuracy 100% online detection, is a typical example of machine vision system used in industrial testing, the system consists of 62 measuring units, each measuring unit includes a laser And a CCD camera to detect 288 measuring points on the body shell. The car body is placed under the measuring frame and the exact position of the body is calibrated by software.

The calibration of the measuring unit will affect the accuracy of the inspection and is therefore of particular importance. Each laser/camera unit is calibrated offline. There is also a calibration device that has been calibrated with a CMM while offline, allowing online calibration of the camera.

The inspection system detects the speed of one body every 40 seconds and detects three types of bodywork. The system compares the test results with the qualified size of the person and the CAD model, and the measurement accuracy is ±0.1 mm. ROVER quality inspection personnel use the system to determine the dimensional consistency of key parts, such as the overall shape of the body, doors, glass windows and so on. It has been proven that the system is successful and will be used for body testing of other ROVER systems.

Banknote printing quality inspection system: This system uses image processing technology to compare and analyze multiple characteristics (numbers, braille, colors, patterns, etc.) of banknotes on the banknote production line to detect the quality of banknotes instead of traditional human eyes. Methods.

Intelligent traffic management system: By placing a camera on the main road, when there is a violation of the vehicle (such as a red light), the camera takes the license plate of the vehicle and transmits it to the central management system. The system uses image processing technology to analyze the captured image. The license plate number is extracted and stored in the database, which can be retrieved by the management personnel.

Metallographic analysis: Metallographic image analysis system can accurately and objectively analyze the matrix structure, impurity content and tissue composition of metal or other materials, and provide a reliable basis for product quality.

Medical image analysis: automatic classification and counting of blood cells, chromosome analysis, cancer cell recognition, and the like.

Bottled beer production line detection system: It can detect whether the beer reaches the standard capacity and whether the beer label is complete.

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