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纸膜双层缺陷检测的视觉成像光场设计

蒋仕飞 张兆国 王法安 解开婷 王成琳 李治

蒋仕飞, 张兆国, 王法安, 解开婷, 王成琳, 李治. 纸膜双层缺陷检测的视觉成像光场设计[J]. 中国光学(中英文), 2024, 17(2): 354-365. doi: 10.37188/CO.2023-0134
引用本文: 蒋仕飞, 张兆国, 王法安, 解开婷, 王成琳, 李治. 纸膜双层缺陷检测的视觉成像光场设计[J]. 中国光学(中英文), 2024, 17(2): 354-365. doi: 10.37188/CO.2023-0134
JIANG Shi-fei, ZHANG Zhao-guo, WANG Fa-an, XIE Kai-ting, WANG Cheng-lin, LI Zhi. Design of optical field of vision imaging for defect detection of paper and transparent film[J]. Chinese Optics, 2024, 17(2): 354-365. doi: 10.37188/CO.2023-0134
Citation: JIANG Shi-fei, ZHANG Zhao-guo, WANG Fa-an, XIE Kai-ting, WANG Cheng-lin, LI Zhi. Design of optical field of vision imaging for defect detection of paper and transparent film[J]. Chinese Optics, 2024, 17(2): 354-365. doi: 10.37188/CO.2023-0134

纸膜双层缺陷检测的视觉成像光场设计

doi: 10.37188/CO.2023-0134
基金项目: 国家重点研发计划项目(No. 2022YFD2002004);云南省院士(专家)工作站项目(No. 202105AF150030);云南中烟重点项目(No. 2022ZK05)
详细信息
    作者简介:

    蒋仕飞(1987—),男,云南昭通人,博士研究生,工程师,2014年于昆明理工大学获得硕士学位,主要从事机器视觉及自动检测方面的研究。E-mail:20211103008@stu.kust.edu.cn

    王法安(1990—),男,河南信阳人,博士,硕士生导师,2014年于安阳工学院获得学士学位,2017年于昆明理工大学获得硕士学位,2022年于东南大学获得博士学位,主要从事智能机械装备设计制造研究等方面的研究。E-mail:wfa@kust.edu.cn

  • 中图分类号: TB811;TB858.2

Design of optical field of vision imaging for defect detection of paper and transparent film

Funds: Supported by National Key R & D Program of China (No. 2022YFD2002004); Yunnan Province Academician (Expert) Workstation Project (No. 202105AF150030); Key Project of China Tobacco Industry in Yunnan (No. 2022ZK05)
More Information
  • 摘要:

    为实现包装盒纸质基底层和透明膜层缺陷的同步检测,开展了对纸和膜缺陷的同步成像研究。首先,分别建立了标准球面积分光场、椭球面积分光场和弧面积分光场模型,并利用COMSOL Multiphysics 5.6对3类光场进行射线仿真,对比分析了球面积分光场下射线角度均匀性及辐照均匀性,通过正交仿真优化椭球面积分光场参数;其次,在椭球面积分光场环境、亮场前打光环境、暗场前打光环境下对包装盒成像。与此同时,对包装盒的油污、抵触、开口、泡皱、破损5项常见缺陷依次进行物理检测和机器视觉检测,验证缺陷成像的有效性。试验结果表明,在椭球面积分光场下成像,图像对纸质基底层缺陷特征、透明膜层缺陷特征均有较好的呈现效果,图像上油污、抵触、开口、泡皱、破损的物理检出率分别为96.2%、92.5%、100%、95%、92%,异常检出率分别为98.6%、97.5%、100%、100%、98.4%,缺陷类别检出率分别为97.6%、96%、100%、97%、96%。研究结果表明,椭球面积分光场光路角度和辐照强度均匀,覆透明膜包装盒的缺陷特征呈现清晰,满足工业生产的检测要求。

     

  • 图 1  亮场前打光方式对纸质基底层的成像

    Figure 1.  Imaging of paper in bright field forward lighting

    图 2  暗场前打光方式对透明膜的成像

    Figure 2.  Imaging of transparent film in dark field forward lighting

    图 3  曲面反射光路图

    Figure 3.  Optical path diagram of curved surface reflection

    图 4  标准球面积分光场模型

    Figure 4.  Spherical integral light field model

    图 5  椭球面内球面积分光场模型

    Figure 5.  Ellipsoidal integral light field model

    图 6  弧面积分光场模型

    Figure 6.  Arc-area integral light field model

    图 7  射线以(a)30°、(b)45°、(c)60°向上释放的球面光场光路

    Figure 7.  Optical paths of a spherical light field with rays emitted upward at (a) 30°, (b) 45°, (c) 60°

    图 8  在长半轴端射线以(a)30°、(b)45°、(c)60°向上释放的椭球面光场光路

    Figure 8.  Optical paths of an ellipsoidal light field with rays emitted upward at the end of semi-major axis at (a) 30°, (b) 45°, (c) 60°

    图 9  在短半球端射线以(a)30°、(b)45°、(c)60°向上释放的椭球面光场光路

    Figure 9.  Optical paths of an ellipsoidal light field with rays emitted upward at the end of short haff-shaft at (a) 30°, (b) 45°, (c) 60°

    图 10  弧面积分光场仿真结果

    Figure 10.  Simulation results of arc-area integral light field

    图 11  半径比与投射口距离对辐照比的响应曲面

    Figure 11.  Response surface plotted by three coefficients, ie., radius radio, projection port distance, and irradiation ratio

    图 12  半径比与辐照面距离对辐照比的响应曲面

    Figure 12.  Response surface plotted by three coefficients, i.e., radius ratio, irradiation surface distance, and irradiation ratio

    图 13  成像系统结构设计图

    Figure 13.  Structural design graph of imaging system

    图 14  试验设备

    Figure 14.  Experiment equipment

    图 15  前打光环境成像装置

    Figure 15.  Imaging device of forward lighting field

    图 16  包装盒缺陷图像

    Figure 16.  Defect images of packaging box

    图 17  不同光环境下成像缺陷比例

    Figure 17.  Presentation rates of imaging defects under different light fields

    图 18  PaDiM异常检测的patch 嵌入向量与定位分割

    Figure 18.  Patch embedding vector and location segmentation of PaDiM abnormal detection

    图 19  缺陷的异常检测和类别检测结果

    Figure 19.  Abnormal detection and classification detection results of defects

    图 20  缺陷检出率雷达图

    Figure 20.  Radar map of defects detection rate

    表  1  3种光场主要参数

    Table  1.   Main parameters of the three types of integrated light fields

    光场类型光罩尺寸A
    ×B×H/mm
    半径RR1×R2×R3/mm投射口距
    S/mm
    辐照面
    距离C/mm
    标准球面积分光场180×180×130853520
    椭球面积
    分光场1
    180×180×11085×65×653520
    椭球面积
    分光场2
    180×180×11065×85×653520
    弧面积
    分光场
    180×130×130853520
    下载: 导出CSV

    表  2  因素水平表

    Table  2.   Coding table of experimental factors and levels

    水平因素
    半径比(R1/R2投射口距离S/(mm)辐照面距离C/( mm)
    11.1305
    01.33517.5
    -11.54030
    下载: 导出CSV

    表  3  试验方案与结果

    Table  3.   Experimental scheme and results

    序号因素辐照比Q/%
    R1/R2S/(mm)C/( mm)
    11.3403080
    21.135576
    31.535574
    41.33517.592
    51.13017.576
    61.3303082
    71.5353070
    81.33517.590
    91.33517.590
    101.54017.570
    111.330586
    121.340584
    131.33517.592
    141.33517.592
    151.14017.574
    161.1353072
    171.53017.572
    下载: 导出CSV

    表  4  方差分析

    Table  4.   Variance analysis

    变异来源 平方和 自由度 均方 F P
    模型 1104.73 9 122.75 126.36 < 0.0001***
    R1:R2 18.00 1 18.00 18.53 0.0035***
    S 8.00 1 8.00 8.24 0.0240**
    C 32.00 1 32.00 32.94 0.0007***
    残差 6.80 7 0.9714
    失拟 2.00 3 0.6667 0.5556 0.6716
    误差 4.80 4 1.20
    总和 1111.53 16
    注:**表示影响显著(P<0.05),***表示影响极显著(P<0.01)
    下载: 导出CSV

    表  5  缺陷检出数量统计

    Table  5.   Statistics on detected defects

    缺陷类别缺陷数量椭球面积分光场环境亮场前打光环境暗场前打光环境
    缺陷检出数量缺陷检出率/%缺陷检出数量缺陷检出率/%缺陷检出数量缺陷检出率/%
    油污21320596.220696.713864.8
    抵触807492.576955467.5
    开口5050100501003876
    泡皱98939564659395
    破损12511592745911692.8
    下载: 导出CSV

    表  6  图像缺陷的机器视觉检测结果

    Table  6.   Machine Vision detection results of image defects

    缺陷
    类别
    缺陷
    数量
    椭球面积分光场环境亮场前打光环境暗场前打光环境
    异常检
    出数量
    异常检
    出率/%
    类别检出
    数量
    类别
    检出率/%
    异常检
    出数量
    异常检
    出率/%
    类别检出
    数量
    类别
    检出率/%
    异常检
    出数量
    异常检
    出率/%
    类别检出
    数量
    类别
    检出率/%
    油污21321098.620897.621098.621098.614065.714065.7
    抵触807897.575967998.77897.560756277.5
    开口505010050100501005010038764080
    泡皱989810095977071.4676895979597
    破损12512398.4120968265.580641209612297.6
    下载: 导出CSV
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  • 收稿日期:  2023-08-09
  • 修回日期:  2023-09-12
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