Visual correction sensor with double cameras
By combining the dual camera structure of low-frame rate surface array and high-speed line array image chip, the problem of difficulty in tracking complex printing materials and high cost of surface array cameras is solved, real-time image display and cost reduction are achieved.
Patent Information
- Application Number
- CN202422102491.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-08-29
- Publication Date
- 2025-08-12
- Estimated Expiration
- 2034-08-29
AI Technical Summary
Existing line array cameras are difficult to track pattern color blocks when processing complex printing materials. The surface array cameras are costly and difficult to popularize on ordinary devices, and cannot meet the requirements of high frame rates and global shutters.
The optical path structure is adopted that combines a low-frame rate surface array image chip and a high-speed linear array image chip. The optical signal is divided by a filter spectrometer. The linear array camera is used for rapid identification, the surface array camera is used for real-time monitoring, and data analysis is performed with the DSP processor.
It has achieved the advantages of linear array and surface array cameras under the premise of reducing costs, can quickly identify complex materials, provide real-time image display, reduce the cost of surface array cameras, and improve the price competitiveness of equipment.
Smart Images
Figure CN223219135U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of sensors, in particular to a dual-camera visual correction sensor. Background Art
[0002] During the roll-to-roll production process, different materials are often handled. Some materials require tracking printed marks, which is beyond the capabilities of U-shaped ultrasonic or infrared edge detection sensors. Instead, visual sensors, such as line scan or area scan cameras, are required. Line scan cameras are currently the mainstream visual correction sensors on the market. They are popular among users for their low price, low pixel count, fast processing speed, and stable performance. With the continuous advancement of printing technology, printed material styles are becoming increasingly complex. Some printed materials lack obvious printed marks and require tracking pattern blocks, which are difficult or even impossible for line scan cameras to track. Leading international correction manufacturers have introduced area scan cameras as visual correction sensors, effectively solving this problem. Using an area scan image sensor, area scan cameras can generate two-dimensional images, making measurement images more intuitive, and calibration operations and displays are real-time images. Area scan cameras are composed of rows of pixels, and their algorithms can more accurately locate edges (including column-wise filtering and redundancy detection), resulting in more accurate recognition, higher precision, and greater stability. The only drawback of area array cameras is their high cost. Due to the high speed of printing presses, the frame rate requirements for the camera are very high, usually reaching more than 200 frames per second, and a global shutter is required. This leads to high costs that many customers cannot afford. It can only be used on some high-end equipment, which limits the popularity of area array vision correction sensors. Utility Model Content
[0003] To this end, the technical problem to be solved by the present invention is to overcome the shortcomings of the existing technology and provide a dual-camera visual correction sensor. It adopts a low-frame-rate area array image chip and a high-speed linear array image chip to combine to form a complementary detection optical path structure to upgrade the existing linear array camera. The sensor has the advantages of both linear array and area array cameras and can adapt to more complex materials.
[0004] In order to solve the above technical problems, the present invention provides a dual-camera visual correction sensor, comprising: a housing, wherein a light outlet is provided on the housing; and wherein:
[0005] A light source assembly, comprising a light source and a filter spectroscope, wherein the light source and the filter spectroscope are fixed in the housing via a mounting and fixing shell, and the filter spectroscope is used to reflect the light signal emitted by the light source to the object to be measured, and to transmit the light signal reflected back from the object to be measured;
[0006] A circuit board is mounted on the inner side of the housing through a metal structural member, and the metal structural member is attached to the surface of the mounting and fixing shell;
[0007] An area array camera is used to collect a first path of light signal reflected by the object to be tested to the filter spectroscope and transmitted through the filter spectroscope for imaging; the area array camera is arranged on the metal structure and is electrically connected to the circuit board via a cable;
[0008] A linear array camera, comprising a first optical lens and a linear array image chip, wherein the first optical lens is embedded in the metal structure and is used to receive a second optical signal reflected by the object to be measured and transmitted to the filter spectroscope through the filter spectroscope, and the linear array image chip is disposed on the circuit board and is used to collect the optical signal transmitted by the first optical lens for imaging;
[0009] The processor is arranged on the circuit board and connected to the line array camera and the area array camera, and is used for analyzing and processing the data collected by the line array image camera and the area array camera.
[0010] In one embodiment of the present invention, the light source is an LED multi-color array light source.
[0011] In one embodiment of the present invention, the LED multi-color array light source is composed of three groups of LED lamp beads connected in parallel, namely red, green and blue, and each group of LED lamp beads is connected to a PWM dimmer.
[0012] In one embodiment of the present invention, the filtering spectroscope forms an angle of 45° with the direction of the light path emitted by the light source.
[0013] In one embodiment of the present invention, the center extension lines of the area array camera and the linear array image chip intersect at the intersection point of the optical axes of the object to be measured.
[0014] In one embodiment of the present invention, the area array camera includes a second optical lens and an area array image chip, and the area array image chip is used to receive the light signal transmitted by the second optical lens.
[0015] In one embodiment of the present invention, the angle formed between the main optical axis of the second optical lens and the main optical axis of the first optical lens is 15°.
[0016] In one embodiment of the present invention, the center of the linear array image chip is located on the extension line of the main optical axis of the first optical lens.
[0017] In one embodiment of the present invention, the light irradiated by the light source assembly onto the object to be measured is diffusely reflected or specularly reflected.
[0018] In one embodiment of the present invention, a cable socket is further included, and the cable socket is arranged on the side wall of the shell.
[0019] The above technical solution of the utility model has the following beneficial effects compared with the prior art:
[0020] The utility model describes a dual-camera visual correction sensor, in which the line array camera and the area array camera cooperate with each other to adapt to more complex materials; the line array camera has fewer pixels, is easy to process, has a simple algorithm, is stable and reliable, and has a fast speed; the area array camera can monitor and track the target in real time, and display the real-time image on the touch screen, which is more intuitive and convenient for users to observe, and has the characteristics of a high-speed area array camera, solving the problem that the line array camera can only display virtual images but cannot present real-time images; the line array camera is used as the main camera, which reduces the parameters of the area array camera, so the area array camera does not need to choose an expensive high-frame rate global shutter camera, which can greatly reduce the material cost, make the product more price-competitive, and is conducive to product promotion. BRIEF DESCRIPTION OF THE DRAWINGS
[0021] In order to make the content of the present invention more clearly understood, the present invention is further described in detail below based on specific embodiments of the present invention in conjunction with the accompanying drawings.
[0022] Figure 1 This is a schematic diagram of the internal structure of the visual correction sensor of the dual camera in the preferred embodiment of the present utility model;
[0023] Figure 2 This is a schematic structural diagram of the housing of the present utility model;
[0024] Figure 3 This is a circuit diagram for controlling the color of the light source of the present invention;
[0025] Description of the drawings: 1. Light source; 2. Filter spectrometer; 3. Mounting and fixing housing; 4. Circuit board; 5. Metal structural parts; 6. Area array camera; 7. Cable arrangement; 8. First optical lens; 9. Linear array image chip; 100. Object to be measured; 101. Intersection of optical axes. DETAILED DESCRIPTION
[0026] The present invention will be further described below with reference to the accompanying drawings and specific embodiments so that those skilled in the art can better understand the present invention and implement it. However, the embodiments are not intended to limit the present invention.
[0027] Reference Figure 1 and 2As shown, the present invention describes a dual-camera visual correction sensor, comprising: a housing, the housing being provided with a light outlet; a light source assembly being provided in the housing, the light source assembly comprising a light source 1 and a filter spectroscope 2, the light source 1 and the filter spectroscope 2 being fixed in the housing by a mounting and fixing shell 3, the filter spectroscope 2 being used to reflect the light signal emitted by the light source 1 onto the object to be measured 100, and to transmit the light signal reflected back from the object to be measured 100; the light irradiated by the light source 1 onto the surface of the object to be measured 10 and the light reflected by the object to be measured 100 both pass through the light outlet;
[0028] A circuit board 4 is mounted on the inner side of the housing via a metal structure 5, and the metal structure 5 is attached to the surface of the mounting and fixing shell 3;
[0029] An area array camera 6 is configured to collect a first optical signal reflected by the object to be measured and transmitted through the optical filter spectrometer 2. The area array camera 6 is disposed on the metal structure 5 to receive the first optical signal for imaging and is electrically connected to the circuit board 4 via a flat cable 7.
[0030] The linear array camera includes a first optical lens 8 and a linear array image chip 9. The first optical lens 8 is embedded in the metal structure 5 and is used to receive the second light signal reflected by the object to be measured 100 to the filter spectrometer 2 and transmitted through the filter spectrometer 2. The linear array image chip 9 is arranged on the circuit board 4 to receive the light signal transmitted by the first optical lens 8 for imaging; in this embodiment, the linear array image chip 9 is directly soldered to the circuit board 4.
[0031] The processor is provided on the circuit board 4 and is used for analyzing and processing the data collected by the line array camera and the area array camera 6 .
[0032] In this embodiment, the filter spectrometer 2 forms an angle of 45° with the direction of the light path emitted by the light source 1 .
[0033] In addition, the center extension lines of the area array camera 6 and the line array image chip 9 intersect at the optical axis intersection point 101 of the object to be measured 100 .
[0034] Furthermore, the area array camera 6 includes a second optical lens and an area array image chip, and the area array image chip is used to receive the light signal transmitted by the second optical lens to perform imaging.
[0035] Preferably, the angle formed between the main optical axis of the second optical lens and the main optical axis of the first optical lens 8 is 15°.
[0036] Furthermore, it also includes a cable socket, which is arranged on the side wall of the shell.
[0037] In this embodiment, the center of the linear array image chip 9 is located on the extension line of the main optical axis of the first optical lens 8 .
[0038] The light irradiated by the light source assembly onto the object to be measured 100 is diffusely reflected or specularly reflected.
[0039] The light source 1 in this embodiment is a multi-color LED array light source. The multi-color LED array light source is composed of three groups of LED lamp beads connected in parallel, namely red, green and blue, and each group of LED lamp beads is connected to a PWM dimmer. Figure 3 As shown, by changing the PWM duty cycle, the brightness of light source 1 can be adjusted, achieving 10-100% stepless dimming. The PWM dimmer uses MOSFET switches as control switches to select the color of light source 1. When all three switches are turned on simultaneously, light source 1 emits white light.
[0040] The specific working process of the dual-camera visual correction sensor based on the above structure is as follows:
[0041] Filtering spectroscope 2 reflects light from light source 1, which then strikes object 100. Whether the light is diffusely reflected or specularly reflected from the surface of object 100 depends on the material's properties. A first path of diffusely or specularly reflected light is projected through filtering spectroscope 2 onto area array camera 6. A second path of light passes through first optical lens 8 and is imaged onto linear array image chip 9.
[0042] Under the control of the processor on the circuit board 4, the area array camera 6 and the line array image chip 9 periodically capture real-time images. The area array camera 6 uses a low-cost integrated camera with a typical frame rate of 30-50 frames per second and a rolling shutter exposure method, which is low in cost. The line array image chip 9 uses a CCD line array chip, such as the Toshiba image sensor TCD1304DG, with a frame rate of up to 2000 frames per second.
[0043] The processor on circuit board 4 uses a TI DSP processor, with an acquisition cycle of 1 millisecond for the linear image chip 9 and 20 milliseconds for the area camera 6. Of the two sets of image data collected, the linear image data is prioritized because it is smaller and easier to process. When the image is complex and the linear image data cannot effectively identify the tracked target, the area image data is analyzed. Simultaneously, the linear and area image data are compared with the calibrated and stored template image data of the object under test 100 to determine the matching degree of their characteristic values. If the characteristic value matching degree exceeds a preset threshold, the target is considered correctly identified, and the DSP processor transmits the recognition result to the control system via the data line to complete the correction action.
[0044] Obviously, the above embodiments are merely examples for clarity of explanation and are not intended to limit the implementation methods. Those skilled in the art will readily appreciate that other variations or modifications based on the above descriptions are possible. It is not necessary and impossible to enumerate all implementation methods here. Obvious variations or modifications arising therefrom remain within the scope of protection of the present invention.
Claims
1. A dual-camera visual correction sensor, characterized by: include: A housing, wherein the housing is provided with a light outlet; and the housing is provided with: A light source assembly, comprising a light source and a filter spectroscope, wherein the light source and the filter spectroscope are fixed in the housing via a mounting and fixing shell, and the filter spectroscope is used to reflect the light signal emitted by the light source to the object to be measured, and to transmit the light signal reflected back from the object to be measured; A circuit board is mounted on the inner side of the housing through a metal structural member, and the metal structural member is attached to the surface of the mounting and fixing shell; An area array camera is used to collect a first path of light signal reflected by the object to be tested to the filter spectroscope and transmitted through the filter spectroscope for imaging; the area array camera is arranged on the metal structure and is electrically connected to the circuit board via a cable; A linear array camera, comprising a first optical lens and a linear array image chip, wherein the first optical lens is embedded in the metal structure and is used to receive a second optical signal reflected by the object to be measured and transmitted to the filter spectroscope through the filter spectroscope, and the linear array image chip is disposed on the circuit board and is used to collect the optical signal transmitted by the first optical lens for imaging; The processor is arranged on the circuit board and is used for analyzing and processing the data collected by the line array image camera and the area array camera.
2. The dual-camera visual correction sensor according to claim 1, characterized in that: The light source is an LED multi-color array light source.
3. The dual-camera visual correction sensor according to claim 2, characterized in that: The LED multi-color array light source is composed of three groups of LED lamp beads connected in parallel, namely red, green and blue, and each group of LED lamp beads is connected to a PWM dimmer.
4. The dual-camera visual correction sensor according to claim 1, characterized in that: The filtering spectroscope forms an angle of 45° with the direction of the light path emitted by the light source.
5. The dual-camera visual correction sensor according to claim 1, characterized in that: The center extension lines of the area array camera and the linear array image chip intersect at the intersection point of the optical axes of the object to be measured.
6. The dual-camera visual correction sensor according to claim 1, characterized in that: The area array camera includes a second optical lens and an area array image chip, and the area array image chip is used to receive the light signal transmitted by the second optical lens to perform imaging.
7. The dual-camera visual correction sensor according to claim 6, characterized in that: The angle formed between the principal optical axis of the second optical lens and the principal optical axis of the first optical lens is 15°.
8. The dual-camera visual correction sensor according to claim 7, characterized in that: The center of the linear array image chip is located on the extension line of the main optical axis of the first optical lens.
9. The dual-camera visual correction sensor according to claim 1, characterized in that: The light irradiated by the light source assembly onto the object to be measured is diffusely reflected or specularly reflected.
10. The dual-camera visual correction sensor according to claim 1, characterized in that: A cable socket is also included, and the cable socket is arranged on the side wall of the shell.