Visual inspection method for defects of automotive upholstery

Abstract

The invention discloses a visual inspection method for defects of automotive upholstery, and relates to the technical field of visual inspection.The visual inspection method comprises a visual inspection module, a light interference correction module and a brightness analysis module, and the visual inspection module is used for scanning and shooting the inner contour surface of the whole starry sky roof; the light interference correction module is used for correcting interference of light between adjacent LED lamps on a brightness defect detection result, the brightness analysis module is used for analyzing obtained brightness data of the LED lamps, judging whether defects exist or not and improving the defects, and the visual detection module comprises an image acquisition unit, an image processing module and a position recognition module. The image acquisition unit is electrically connected with the image processing module, the image processing module is electrically connected with the position identification module, the image acquisition unit uses a camera to capture an inner contour image of the starry sky roof, and the image processing module is used for processing the acquired image.

Description

Technical Field

[0001] The invention relates to the technical field of visual inspection, and in particular to a method for visual inspection of defects of automobile interior decoration parts. Background Art

[0002] The starry sky ceiling is a special car interior design that usually uses LED lights or fiber optic technology to simulate the effect of the starry sky on the roof. This design is often used in luxury models to enhance the atmosphere and aesthetics of the car. During the actual use of the starry sky ceiling lighting defect test, in order to verify the lighting effect, the brightness of each LED light of the starry sky ceiling will be analyzed using the image scanning method to determine whether there is a brightness defect.

[0003] In order to simulate the natural state of the starry sky more realistically, the brightness and darkness of LED lights are usually random, and the position distribution of LED lights will be adjusted according to the personalized needs of customers. In the existing lighting test, a small part of the LED light will shine on the adjacent LED lights, making the brightness test results of the adjacent LED lights higher. The degree of deviation is related to the number and distance of the surrounding lights, and the test results are inaccurate. Therefore, it is necessary to design an accurate visual inspection method for automotive interior defects. Summary of the invention

[0004] The object of the present invention is to provide a method for visually inspecting defects of automobile interior decoration parts to solve the problems raised in the above-mentioned background technology.

[0005] In order to solve the above technical problems, the present invention provides the following technical solutions: a method for visual detection of defects in automotive interior parts, which method adopts a detection system to work, and the detection system includes a visual detection module, a light interference correction module, and a brightness analysis module. The visual detection module is used to scan and photograph the inner contour surface of the entire starry sky top, the light interference correction module is used to correct the interference of light between adjacent LED lights on the brightness defect detection results, and the brightness analysis module is used to analyze the obtained LED light brightness data to determine whether there are defects and make improvements.

[0006] According to the above technical solution, the visual detection module includes an image acquisition unit, an image processing module, and a position recognition module. The image acquisition unit is electrically connected to the image processing module, and the image processing module is electrically connected to the position recognition module. The image acquisition unit uses a camera to capture the inner contour image of the starry sky top. The image processing module is used to process the collected image, including image denoising and identifying LED lights. The position recognition module is used to mark the position of each LED light on a plane rectangular coordinate system;

[0007] The light interference correction module includes an interference calculation module, a correction algorithm module, and a feedback mechanism module. The interference calculation module is electrically connected to the image processing module and the position recognition module. The correction algorithm module is electrically connected to the interference calculation module and the feedback mechanism module. The interference calculation module is used to calculate the interference degree between each LED according to the brightness and position of adjacent LED lights to achieve modeling of interference factors. The correction algorithm module is used to correct the appropriate brightness of each LED light according to the interference calculation result. The feedback mechanism module is used to adjust the brightness by controlling the current of the LED light and provide real-time feedback of the adjustment result.

[0008] The brightness analysis module includes a data acquisition module, a statistical analysis module, and an abnormal marking module. The data acquisition module is electrically connected to the image processing module, the data acquisition module is electrically connected to the statistical analysis module, the statistical analysis module is electrically connected to the abnormal marking module, and the abnormal marking module is electrically connected to the correction algorithm module. The data acquisition module is used to collect the brightness and position data of each LED lamp to form a database. The statistical analysis module is used to perform statistical analysis on the collected data and calculate the uniformity of the brightness of all LED lamps. The abnormal marking module is used to set a brightness threshold and mark LED lamps with potential defects.

[0009] According to the above technical solution, the working method of the system is:

[0010] S1, using the camera in the image acquisition unit to capture the inner contour image of the starry sky top, generating raw image data, and preparing for subsequent processing;

[0011] S2, denoising the collected images and identifying the LED lights in the image processing module, and extracting clear LED light features through image processing algorithms;

[0012] S3. Based on the processed image, mark the positions of all LED lights on a plane rectangular coordinate system to form light position information, and calculate the brightness of each LED light;

[0013] S4, collecting the brightness and position information of each LED lamp, calculating the interference degree between adjacent LED lamps, and constructing an interference factor model;

[0014] S5. Calculate the brightness uniformity of all LED lamps and mark defective LED lamps;

[0015] S6. According to the interference calculation results and the defective LED lamps, the appropriate brightness of each LED lamp is determined, and the current of the LED lamp is adjusted in real time through the feedback mechanism module to achieve the preset brightness.

[0016] According to the above technical solution, in S3, the specific method of forming the light position information is: mark the position of each LED light with coordinates to form a position coordinate set {(x1, y1), (x2, y2), ..., (x n ,y n )}, where x is the horizontal coordinate of the LED light, y is the vertical coordinate of the LED light, and n is the number of LED lights;

[0017] The specific method for calculating the brightness of each LED lamp is as follows: continuously collect several images of the inner contour of the starry sky with a certain LED lamp on, and average the color values ​​of the images. The brightness l is divided according to the average color value of a certain LED in the collected image. The brighter the image color value, the greater the l is proportional to form a brightness set {l1, l2, ..., l n}.

[0018] According to the above technical solution, in S4, the specific method of constructing the interference factor model is:

[0019] S4-1. In the image captured when a certain LED light is on, determine the influence range of the LED light according to the brightness of the LED light. The greater the brightness of the LED light, the greater the influence range. The specific influence range is αl i , where α is the influence range coefficient of brightness, and i is the serial number of a certain LED lamp;

[0020] S4-2, calculate the straight-line distance H of the position coordinates of each LED light, where the straight-line distance between two LED lights with serial numbers i and k is

[0021] S4-3. When calculating the interference degree of a certain LED light, it is only necessary to consider the situation where the position coordinates of this LED light are within the influence range of other LED lights. If the position coordinates of this LED light are beyond the influence range of other LED lights, there is no need to consider the interference. That is, only when H ik <αl i Only when the LED lights with serial numbers i and k are connected, the degree of interference between them needs to be considered;

[0022] S4-4, the brightness l of a LED lamp with serial number i i Correction: Since the brightness of light usually follows the inverse square as the distance increases, correct the brightness Where β is the attenuation coefficient of distance with brightness, is the brightness of the LED light with serial number k i The impact of m is the number of LED lamps that affect the LED lamp with serial number i.

[0023] According to the above technical solution, in S5, the specific method of marking the defective LED lamp is: let the appropriate light brightness range be [lmin ~l max ], in [l min ~l max ] other than a corrected brightness l it The LED lights with defects will be marked as defective, while the brightness of others is normal. Only the brightness of the LED lights marked as defective needs to be adjusted.

[0024] According to the above technical solution, in S6, the method for determining the appropriate brightness of each LED lamp is: when the corrected brightness l it >l max When the LED light with serial number i is turned down to [l min ~l max ], specifically adjust the brightness When the corrected brightness l it <l min When the brightness is adjusted up

[0025] According to the above technical solution, in S6, the specific method of adjusting the current of the LED lamp in real time through the feedback mechanism module is: by changing the current I of the LED lamp with sequence number i i To adjust the brightness, the current changes by ΔI i =I i ±μΔl i , where μ is the conversion factor between current and brightness, which is positive when the brightness is adjusted up and negative when the brightness is adjusted down;

[0026] After adjustment, check the brightness of each LED again. min ~l max ], no adjustment is required. If the brightness change is too large, change the brightness from the adjusted brightness to the original brightness. Adjust according to the binary method, that is, change the brightness again. It is positive when the brightness is adjusted up, and negative when the brightness is adjusted down.

[0027] Compared with the prior art, the beneficial effect achieved by the present invention is that during the lighting defect test of the starry sky ceiling, the position coordinates and preset brightness of each LED lamp are entered, and the degree of light interference between adjacent LED lamps is calculated, thereby making targeted corrections to the actual test results and ensuring accurate detection. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The accompanying drawings are used to provide a further understanding of the present invention and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation of the present invention. In the accompanying drawings:

[0029] Figure 1It is a schematic diagram of the overall module structure of the present invention. DETAILED DESCRIPTION

[0030] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0031] See also Figure 1 The present invention provides a technical solution: a method for visually detecting defects of automobile interior decoration parts, the method adopts a detection system to work, the detection system includes a visual detection module, a light interference correction module, and a brightness analysis module, the visual detection module is used to scan and shoot the inner contour surface of the entire starry sky top, the light interference correction module is used to correct the interference of lights between adjacent LED lights on the brightness defect detection results, and the brightness analysis module is used to analyze the obtained LED light brightness data to determine whether there are defects and make improvements;

[0032] The visual detection module includes an image acquisition unit, an image processing module, and a position recognition module. The image acquisition unit is electrically connected to the image processing module, and the image processing module is electrically connected to the position recognition module. The image acquisition unit uses a camera to capture the inner contour image of the starry sky top. The image processing module is used to process the acquired image, including image denoising and identifying LED lights. The position recognition module is used to mark the position of each LED light on a plane rectangular coordinate system.

[0033] The light interference correction module includes an interference calculation module, a correction algorithm module, and a feedback mechanism module. The interference calculation module is electrically connected to the image processing module and the position recognition module. The correction algorithm module is electrically connected to the interference calculation module and the feedback mechanism module. The interference calculation module is used to calculate the interference degree between each LED according to the brightness and position of adjacent LED lights to achieve modeling of interference factors. The correction algorithm module is used to correct the appropriate brightness of each LED light according to the interference calculation result. The feedback mechanism module is used to adjust the brightness by controlling the current of the LED light and provide real-time feedback of the adjustment result.

[0034] The brightness analysis module includes a data acquisition module, a statistical analysis module, and an abnormal marking module. The data acquisition module is electrically connected to the image processing module, the data acquisition module is electrically connected to the statistical analysis module, the statistical analysis module is electrically connected to the abnormal marking module, and the abnormal marking module is electrically connected to the correction algorithm module. The data acquisition module is used to collect the brightness and position data of each LED lamp to form a database. The statistical analysis module is used to perform statistical analysis on the collected data and calculate the uniformity of the brightness of all LED lamps. The abnormal marking module is used to set a brightness threshold and mark LED lamps with potential defects;

[0035] The system works as follows:

[0036] S1, using the camera in the image acquisition unit to capture the inner contour image of the starry sky top, generating raw image data, and preparing for subsequent processing;

[0037] S2, denoising the collected images and identifying the LED lights in the image processing module, and extracting clear LED light features through image processing algorithms;

[0038] S3. Based on the processed image, mark the positions of all LED lights on a plane rectangular coordinate system to form light position information, and calculate the brightness of each LED light;

[0039] S4, collecting the brightness and position information of each LED lamp, calculating the interference degree between adjacent LED lamps, and constructing an interference factor model;

[0040] S5. Calculate the brightness uniformity of all LED lamps and mark defective LED lamps;

[0041] S6. Determine the appropriate brightness of each LED lamp according to the result of the interference calculation and the defective LED lamp, and adjust the current of the LED lamp in real time through the feedback mechanism module to achieve the preset brightness;

[0042] In S3, the specific method of forming the light position information is: mark the position of each LED light with coordinates to form a position coordinate set {(x1, y1), (x2, y2), ..., (x n ,y n )}, where x is the horizontal coordinate of the LED light, y is the vertical coordinate of the LED light, and n is the number of LED lights;

[0043] The specific method for calculating the brightness of each LED lamp is as follows: continuously collect several images of the inner contour of the starry sky with a certain LED lamp on, and average the color values ​​of the images. The brightness l is divided according to the average color value of a certain LED in the collected image. The brighter the image color value, the greater the l is proportional to form a brightness set {l1, l2, ..., l n};

[0044] In S4, the specific method for constructing the interference factor model is:

[0045] S4-1. In the image captured when a certain LED light is on, determine the influence range of the LED light according to the brightness of the LED light. The greater the brightness of the LED light, the greater the influence range. The specific influence range is αl i , where α is the influence range coefficient of brightness, and i is the serial number of a certain LED lamp;

[0046] S4-2, calculate the straight-line distance H of the position coordinates of each LED light, where the straight-line distance between two LED lights with serial numbers i and k is

[0047] S4-3. When calculating the interference degree of a certain LED light, it is only necessary to consider the situation where the position coordinates of this LED light are within the influence range of other LED lights. If the position coordinates of this LED light are beyond the influence range of other LED lights, there is no need to consider the interference. That is, only when H ik <αl i Only when the LED lights with serial numbers i and k are connected, the degree of interference between them needs to be considered;

[0048] S4-4, the brightness l of a LED lamp with serial number i i Correction: Since the brightness of light usually follows the inverse square as the distance increases, correct the brightness Where β is the attenuation coefficient of distance with brightness, is the brightness of the LED light with serial number k i The impact of, m is the number of LED lamps that affect the LED lamp with serial number i;

[0049] In S5, the specific method of marking the defective LED lamp is: let the appropriate light brightness range be [l min ~l max ], in [l min ~l max ] other than a corrected brightness l it The LED lights with defects will be marked as defective, while the brightness of others is normal. Only the brightness of the LED lights with defects needs to be adjusted.

[0050] In S6, the method for determining the appropriate brightness of each LED lamp is: when the corrected brightness l it >l max When the LED light with serial number i is turned down to [l min ~l max ], specifically adjust the brightness When the corrected brightness l it <l min When the brightness is adjusted up

[0051] In S6, the specific method of adjusting the current of the LED lamp in real time through the feedback mechanism module is: by changing the current I of the LED lamp with sequence number i i To adjust the brightness, the current changes by ΔI i =I i ±μΔl i , where μ is the conversion factor between current and brightness, which is positive when the brightness is adjusted up and negative when the brightness is adjusted down;

[0052] After adjustment, check the brightness of each LED again. min ~l max ], no adjustment is required. If the brightness change is too large, change the brightness from the adjusted brightness to the original brightness. Adjust according to the binary method, that is, change the brightness again. It is positive when the brightness is adjusted up, and negative when the brightness is adjusted down.

[0053] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.

[0054] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art can still modify the technical solutions described in the aforementioned embodiments or replace some of the technical features therein by equivalents. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A method for visually inspecting defects of automobile interior parts, characterized in that: The method adopts a detection system to work, which includes a visual detection module, a light interference correction module, and a brightness analysis module. The visual detection module is used to scan and photograph the inner contour surface of the entire starry sky top, the light interference correction module is used to correct the interference of light between adjacent LED lights on the brightness defect detection results, and the brightness analysis module is used to analyze the obtained LED light brightness data to determine whether there are defects and make improvements.

2. The method for visually inspecting defects of automotive interior parts according to claim 1, characterized in that: The visual detection module includes an image acquisition unit, an image processing module, and a position recognition module. The image acquisition unit is electrically connected to the image processing module, and the image processing module is electrically connected to the position recognition module. The image acquisition unit uses a camera to capture the inner contour image of the starry sky top. The image processing module is used to process the acquired image, including image denoising and identifying LED lights. The position recognition module is used to mark the position of each LED light on a plane rectangular coordinate system; The light interference correction module includes an interference calculation module, a correction algorithm module, and a feedback mechanism module. The interference calculation module is electrically connected to the image processing module and the position recognition module. The correction algorithm module is electrically connected to the interference calculation module and the feedback mechanism module. The interference calculation module is used to calculate the interference degree between each LED according to the brightness and position of adjacent LED lights to achieve modeling of interference factors. The correction algorithm module is used to correct the appropriate brightness of each LED light according to the interference calculation result. The feedback mechanism module is used to adjust the brightness by controlling the current of the LED light and provide real-time feedback of the adjustment result. The brightness analysis module includes a data acquisition module, a statistical analysis module, and an abnormal marking module. The data acquisition module is electrically connected to the image processing module, the data acquisition module is electrically connected to the statistical analysis module, the statistical analysis module is electrically connected to the abnormal marking module, and the abnormal marking module is electrically connected to the correction algorithm module. The data acquisition module is used to collect the brightness and position data of each LED lamp to form a database. The statistical analysis module is used to perform statistical analysis on the collected data and calculate the uniformity of the brightness of all LED lamps. The abnormal marking module is used to set a brightness threshold and mark LED lamps with potential defects.

3. The method for visually inspecting defects of automotive interior parts according to claim 2, characterized in that: The system works as follows: S1, using the camera in the image acquisition unit to capture the inner contour image of the starry sky top, generating raw image data, and preparing for subsequent processing; S2, denoising the collected images and identifying the LED lights in the image processing module, and extracting clear LED light features through image processing algorithms; S3. Based on the processed image, mark the positions of all LED lights on a plane rectangular coordinate system to form light position information, and calculate the brightness of each LED light; S4, collecting the brightness and position information of each LED lamp, calculating the interference degree between adjacent LED lamps, and constructing an interference factor model; S5. Calculate the brightness uniformity of all LED lamps and mark defective LED lamps; S6. According to the interference calculation results and the defective LED lamps, the appropriate brightness of each LED lamp is determined, and the current of the LED lamp is adjusted in real time through the feedback mechanism module to achieve the preset brightness.

4. The method for visually inspecting defects of automotive interior parts according to claim 3, characterized in that: In S3, the specific method of forming the light position information is: marking the position of each LED light with coordinates to form a position coordinate set {(x1, y1), (x2, y2), ..., (x n ,y n )}, where x is the horizontal coordinate of the LED light, y is the vertical coordinate of the LED light, and n is the number of LED lights; The specific method for calculating the brightness of each LED lamp is as follows: continuously collect several images of the inner contour of the starry sky with a certain LED lamp on, and average the color values ​​of the images. The brightness l is divided according to the average color value of a certain LED in the collected image. The brighter the image color value, the greater the l is proportional to form a brightness set {l1, l2, ..., l n }.

5. The method for visually inspecting defects of automobile interior parts according to claim 4, characterized in that: In S4, the specific method of constructing the interference factor model is: S4-1. In the image captured when a certain LED light is on, determine the influence range of the LED light according to the brightness of the LED light. The greater the brightness of the LED light, the greater the influence range. The specific influence range is αl i , where α is the influence range coefficient of brightness, and i is the serial number of a certain LED lamp; S4-2, calculate the straight-line distance H of the position coordinates of each LED light, where the straight-line distance between two LED lights with serial numbers i and k is S4-3. When calculating the interference degree of a certain LED light, it is only necessary to consider the situation where the position coordinates of this LED light are within the influence range of other LED lights. If the position coordinates of this LED light are beyond the influence range of other LED lights, there is no need to consider the interference. That is, only when H ik <αl i Only when the LED lights with serial numbers i and k are connected, the degree of interference between them needs to be considered; S4-4, the brightness l of a LED lamp with serial number i i Correction: Since the brightness of light usually follows the inverse square as the distance increases, correct the brightness Where β is the attenuation coefficient of distance with brightness, is the brightness of the LED light with serial number k i The impact of m is the number of LED lamps that affect the LED lamp with serial number i.

6. The method for visually inspecting defects of automobile interior parts according to claim 5, characterized in that: In S5, the specific method of marking the defective LED lamp is: let the appropriate light brightness range be [l min ~l max ], in [l mi n~l max ] other than a corrected brightness l it The LED lights with defects will be marked as defective, while the brightness of others is normal. Only the brightness of the LED lights marked as defective needs to be adjusted.

7. The method for visually inspecting defects of automobile interior parts according to claim 6, characterized in that: In S6, the method for determining the appropriate brightness of each LED lamp is: when the corrected brightness is l it >l max When the LED light with serial number i is turned down to [l min ~l max ], specifically lower the brightness by Δ When the corrected brightness l it <l min When the brightness is adjusted up 8. The method for visually inspecting defects of automobile interior parts according to claim 7, characterized in that: In S6, the specific method of adjusting the current of the LED lamp in real time through the feedback mechanism module is: by changing the current I of the LED lamp with sequence number i i To adjust the brightness, the current changes by ΔI i =I i ±μΔl i , where μ is the conversion factor between current and brightness, which is positive when the brightness is adjusted up and negative when the brightness is adjusted down; After adjustment, check the brightness of each LED again. min ~l max ], no adjustment is required. If the brightness change is too large, change the brightness from the adjusted brightness to the original brightness. Adjust according to the binary method, that is, change the brightness again. It is positive when the brightness is adjusted up, and negative when the brightness is adjusted down.

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