Design and Application of Image Processing Technology in Surface Damage Detection of Parts

Proposal for surface damage detection

Accurate and rapid detection of surface defects of parts is directly related to product quality. If the unqualified products are not removed in time, there will be quality hazards. However, in the automobile, motorcycle, internal combustion engine and other industries characterized by mass production, the surface defects of key parts of important parts have been identified and detected so far. Due to the complexity involved in the process execution process (especially after the use of advanced split-size connecting rod breaking processes), it is also necessary to propose a specification. For example, there may be specific damage to the joint of the connecting rod size head: the breaking area is less than 3 mm2; the linear length of any direction of the breaking is less than 2.5 mm. As long as one of the conditions is met, it will be rejected as judged as unqualified.

According to the characteristics of the part, the area where the break may appear is on the outside of the joint surface (line), and its range is "eight" shape. Under this circumstance, relying on manual visual observation and estimation, not only is the efficiency low, the labor intensity is large, and the provisions in the above standards cannot be accurately implemented. On the other hand, even if other conventional measurement methods are employed, it is difficult to achieve the above object.

The principle of image processing technology for surface defect detection

Image processing technology, also known as "machine vision", is to use the image of the object under test as a carrier of information, and extract useful information from it to achieve the purpose of measurement. It has the advantages of non-contact, high speed, large measuring range and rich information. Different detection requirements can be realized by a combination of a CCD (Charge Coupled Device) camera and an optical system and a processing system. For the identification of the above surface defects of the workpiece, the reflection mode shown in Fig. 1 can be adopted.

As shown in the figure, the system illuminates the area to be detected through a square LED diffuse light source. After the light hits the surface of the object, it is reflected into the photocoupled CCD component in the camera and converted into a corresponding power signal. The CCD component can be understood as a dot matrix composed of photosensitive pixels. Each pixel of the CCD corresponds to the two-dimensional image feature of the measured object one by one, that is, the analysis of the "pixel point imaging result" can indirectly analyze the object. Image features, such as by calculating the number of imaging pixels in the binarized image, can obtain the length and area values ​​of the corresponding object. The image processing system binarizes the obtained image based on the power signal, and performs further calculation and analysis on the binary image as an object.

In the actual use of the image processing system, the binarization threshold of the gradation and the setting of the light source are implemented by a comparison method. Specific method of comparison: using a known sample as a reference for calibration (alignment), the known reference value of the reference is divided by the pixel value corresponding to the reference object to obtain the correspondence between the pixel and the actual value. Proportional value. By adjusting the brightness of the light source and the binarization threshold of the system, the binarization threshold of the gray level is optimized to ensure that the system has a relatively high resolution on the object boundary, that is, the optimized binarization threshold and the light source can make the boundary The change produces as large a change in pixel value as possible.

As a novel and practical sensing technology, the image detection unit has been commercialized in recent years. Some well-known manufacturers, such as Panasonic Corporation of Japan and Siemens of Germany, have launched a series of products with complete specifications, including light sources. , camera, image processor, etc., which has created favorable conditions for the promotion and application of image detection technology. At the same time, the relevant corporate standards promulgated not only regulate production, but also provide a basis for users to select suitable detection units in different situations and to design systems faster and better.

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