Membrane material defect detection system

Abstract

The embodiment of the utility model provides a membrane material defect detection system. According to the system, a black-and-white image detection channel and an infrared image detection channel are respectively controlled by a light source controller to carry out membrane material defect detection. Wherein a visible light source in the black-and-white image detection channel emits white light to irradiate the membrane material, and a black-and-white camera collects a black-and-white image of the membrane material; an infrared light source in the infrared image detection channel emits infrared light to irradiate the membrane material, and an infrared camera collects an infrared image of the membrane material. And the collected image is sent to the image processing module for independent image recognition, so that membrane material defect recognition is carried out. According to the embodiment of the utility model, the problem of poor image effect caused by the fact that a common light source cannot penetrate through a thicker film material and a deeper film material and cannot accurately detect defects such as foreign matters, bubbles and the like under the film is solved through infrared image detection, and the detection efficiency and the detection accuracy are improved by utilizing different types of images for respective detection.

Description

TECHNICAL FIELD

[0001] The embodiment of the utility model relates to membrane material detection technology, especially a kind of membrane material defect detection system. BACKGROUND

[0002] The diaphragm is the microporous film that is used to separate positive and negative in lithium ion battery, prevent two poles from contacting short circuit, and allow lithium ion to pass through.

[0003] Lithium battery cell is commonly coated with blue film, and blue film detection is crucial to ensure product performance, the prior art generally uses black and white line scanning camera to detect blue film surface, two symmetrical distributed line light sources alternately irradiate the blue film target position scanned by black and white line scanning camera during detection, and the camera is perpendicular to the placement of blue film sample.

[0004] In the prior art, when the thickness of lithium battery blue film is thicker and the color is deeper, the defects under the film cannot be effectively detected, and there are edge overexposure regions in the edge of blue film detection image, and defects such as foreign matter and bubbles in the edge overexposure region cannot be found in time. UTILITY MODEL CONTENT

[0005] The utility model provides a kind of membrane material defect detection system, to solve the problem that ordinary light source cannot penetrate thicker membrane material, deeper membrane material, cannot accurately detect defect under film, improve detection efficiency and detection accuracy.

[0006] In the first aspect, the utility model embodiment provides a kind of membrane material defect detection system, including light source controller, black and white image detection channel, infrared image detection channel and image processing module;

[0007] The light source controller includes a black and white image control end and an infrared image control end, the black and white image detection channel is electrically connected with the black and white image control end, and the infrared image detection channel is electrically connected with the infrared image control end;

[0008] The black and white image detection channel includes a black and white image output end, the infrared image detection channel includes an infrared image output end, and the image processing module is electrically connected with the black and white image output end and the infrared image output end respectively;

[0009] The light source controller sends black and white image acquisition instruction to the black and white image detection channel through the black and white image control end;The black and white image detection channel linearly scans the membrane material to be detected in the conveying process, collects black and white image, and sends the black and white image to the image processing module;

[0010] The light source controller sends infrared image acquisition instruction to the infrared image detection channel through the infrared image control end;The infrared image detection channel linearly scans the membrane material to be detected in the conveying process, collects infrared image, and sends the infrared image to the image processing module;

[0011] The image processing module respectively performs defect recognition on the black-and-white image and the infrared image.

[0012] Optionally, the black-and-white image detection channel comprises a visible light source and a black-and-white camera; the black-and-white image control end comprises a visible light source control end and a black-and-white camera control end; the visible light source is electrically connected with the visible light source control end, and the black-and-white camera is electrically connected with the black-and-white camera control end.

[0013] The black-and-white image acquisition instruction comprises a visible light opening instruction and a black-and-white camera opening instruction; the light source controller sends the visible light opening instruction to the visible light source through the visible light source control end and sends the black-and-white camera opening instruction to the black-and-white camera through the black-and-white camera control end, so that the black-and-white camera acquires the black-and-white image.

[0014] Optionally, the visible light source comprises a first visible light source and a second visible light source; the visible light source control end comprises a first visible light source control end and a second visible light source control end; the first visible light source is electrically connected with the first visible light source control end, and the second visible light source is electrically connected with the second visible light source control end.

[0015] The visible light opening instruction comprises a first visible light opening instruction and a second visible light opening instruction, and the black-and-white camera opening instruction comprises a first black-and-white camera opening instruction and a second black-and-white camera opening instruction.

[0016] The light source controller sends the first visible light opening instruction to the first visible light source through the first visible light source control end and sends the first black-and-white camera opening instruction to the black-and-white camera through the black-and-white camera control end, so that the black-and-white camera acquires the first black-and-white image.

[0017] The light source controller also sends the second visible light opening instruction to the second visible light source through the second visible light source control end and sends the second black-and-white camera opening instruction to the black-and-white camera through the black-and-white camera control end, so that the black-and-white camera acquires the second black-and-white image.

[0018] The first black-and-white image and the second black-and-white image are images of the same region on the film material to be tested and have different brightness.

[0019] Optionally, the black-and-white image detection channel further comprises an image acquisition card, the image acquisition card is electrically connected with the black-and-white camera, and the image acquisition card performs image fusion on the first black-and-white image and the second black-and-white image provided by the black-and-white camera.

[0020] Optionally, the first visible light source and the second visible light source are both arranged towards the film material to be tested.

[0021] The emergent light rays of the first visible light source and the second visible light source are located in a first plane, the first plane is a plane perpendicular to the film to be detected and parallel to a conveying direction of the film to be detected, and the emergent light rays of the first visible light source and the second visible light source are axisymmetric in the first plane.

[0022] Optionally, the infrared image detection channel comprises an infrared light source and an infrared camera; the infrared image control end comprises an infrared light source control end and an infrared camera control end; the infrared light source is electrically connected with the infrared light source control end, and the infrared camera is electrically connected with the infrared camera control end.

[0023] The infrared image acquisition instruction comprises an infrared light opening instruction and an infrared camera opening instruction; the light source controller sends the infrared light opening instruction to the infrared light source through the infrared light source control end and sends the infrared camera opening instruction to the infrared camera through the infrared camera control end, so that the infrared camera acquires the infrared image.

[0024] Optionally, the visible light source and the infrared light source are arranged towards the film to be detected, and the emergent light rays of the visible light source and the infrared light source are parallel to each other and are staggered in the conveying direction of the film to be detected.

[0025] Optionally, the visible light source and the infrared light source are both high-brightness linear stroboscopic light sources.

[0026] Optionally, the black-and-white image control end and the infrared image control end are both differential interfaces.

[0027] Optionally, the light source controller further comprises a pulse signal interface and a frame signal interface, the pulse signal interface receives a pulse signal reflecting a conveying position of the film to be detected provided by a magnetic levitation encoder or a linear motor, and the frame signal interface receives a frame signal reflecting starting of conveying of the film to be detected provided by a programmable logic controller or a photoelectric sensor.

[0028] The film defect detection system is provided by the embodiment of the utility model, the film defect detection is carried out through the light source controller to control the black-and-white image detection channel and the infrared image detection channel respectively. The visible light source in the black-and-white image detection channel emits white light to irradiate the film, and the black-and-white camera acquires the black-and-white image of the film; the infrared light source in the infrared image detection channel emits infrared light to irradiate the film, and the infrared camera acquires the infrared image of the film. The acquired images are sent to the image processing module for image recognition, so as to identify the film defects. The embodiment of the utility model solves the problem that the ordinary light source cannot penetrate the thick film and the deep film, cannot accurately detect the defects such as foreign matter and bubbles under the film, and the image effect is poor, and the detection efficiency and the detection accuracy are improved by using different types of images for detection. BRIEF DESCRIPTION OF DRAWINGS

[0029] Figure 1A structure schematic view of a film material defect detection system provided by the embodiment of the utility model,

[0030] Figure 2 A partial structure schematic view of the film material defect detection system provided by the embodiment of the utility model,

[0031] Figure 3 A structure schematic view of a light source controller provided by the embodiment of the utility model,

[0032] Figure 4 A control logic schematic view of the film material defect detection system controlled according to the differential signal and frame signal provided by the embodiment of the utility model. DETAILED DESCRIPTION

[0033] The utility model will be further explained in detail by combining with the drawings and embodiments. It can be understood that the specific embodiments described here are only used for explaining the utility model and not limiting the utility model. In addition, it needs to be explained that in order to facilitate the description, only the parts related to the utility model are shown in the drawings and not all structures.

[0034] Figure 1 A structure schematic view of a film material defect detection system provided by the embodiment of the utility model, Figure 2 A partial structure schematic view of the film material defect detection system provided by the embodiment of the utility model, Figure 3 A structure schematic view of a light source controller provided by the embodiment of the utility model, Figure 4 A control logic schematic view of the film material defect detection system controlled according to the differential signal and frame signal provided by the embodiment of the utility model.

[0035] As Figure 1 Shown, the film material defect detection system includes light source controller 10, black and white image detection channel 20, infrared image detection channel 30 and image processing module 40.

[0036] Wherein, light source controller 10 can be understood as the device for regulating and controlling the parameters (such as brightness, color, emitting angle, flicker frequency, etc.) of light source according to actual detection demand;Black and white image detection channel 20 can be understood as the device (such as black and white line scanning camera) for scanning imaging to the detection object (such as blue film) and obtaining black and white image;Infrared image detection channel 30 can be understood as the device (such as infrared line scanning camera) for scanning imaging to the detection object (such as blue film) using infrared wave band and obtaining infrared image;Image processing module 40 can be understood as the device for obtaining the shape, size, position and other key characteristic information of film material defect according to the obtained black and white image and infrared image.

[0037] The light source controller 10 comprises a black-and-white image control end 11 and an infrared image control end 12, the black-and-white image detection channel 20 is electrically connected with the black-and-white image control end 11, and the infrared image detection channel 30 is electrically connected with the infrared image control end 12.

[0038] The black-and-white image control end 11 can be understood as a port for black-and-white image detection in the light source controller 10, and the infrared image control end 12 can be understood as a port for infrared image detection in the light source controller 10.

[0039] The black-and-white image detection channel 20 comprises a black-and-white image output end 21, and the infrared image detection channel 30 comprises an infrared image output end 31; the image processing module 40 is electrically connected with the black-and-white image output end 21 and the infrared image output end 31 respectively.

[0040] The black-and-white image output end 21 can be understood as a port for outputting black-and-white image data collected and processed (such as camera imaging and preliminary image optimization) by the black-and-white camera 23 to the image processing module 40 in the black-and-white image detection channel 20, and the infrared image output end 31 can be understood as a port for outputting infrared image data collected and processed (such as camera imaging and temperature compensation processing) by the infrared camera 33 to the image processing module 40 in the infrared image detection channel 30.

[0041] Specifically, as shown in the figure, Figure 2 The black-and-white image detection channel 20 and the infrared image detection channel 30 are perpendicular to the film sample, and the light source controller 10 irradiates the scanning area of the black-and-white image detection channel 20 and the infrared image detection channel 30 at a certain angle according to the actual detection requirement. The black-and-white image control end 11 and the infrared image control end 12 acquire the film detection requirement, control the brightness of the light source in the black-and-white image detection channel 20, adjust the intensity of the visible light source 22 and the infrared light source 32, and avoid image oversaturation or excessive stray light interference imaging caused by excessively high light intensity on the premise of ensuring sufficient penetration of the blue film.

[0042] Exemplarily, the black-and-white image detection channel 20 comprises a black-and-white line scanning camera, and the infrared image detection channel 30 comprises an infrared line scanning camera, and the working distance is determined according to the lens focal length of the black-and-white line scanning camera and the infrared line scanning camera, and the lens focal length is between 200mm-400mm.

[0043] The light source controller 10 sends a black-and-white image collection instruction to the black-and-white image detection channel 20 through the black-and-white image control end 11; the black-and-white image detection channel 20 linearly scans the film material to be tested in the transmission process, collects black-and-white images, and sends the black-and-white images to the image processing module 40;

[0044] The black-and-white image acquisition instruction can be understood as an electrical signal for controlling the black-and-white image detection channel 20 to perform image acquisition, and the electrical signal includes various parameter information required for image acquisition, such as exposure time, gain value, image resolution, etc. The film material to be measured can be understood as a film material that needs to be detected in the detection system to determine whether there are defects on the surface and under the film, and to evaluate whether the quality meets the relevant standards or requirements. For example, the film material to be measured can be a polyethylene terephthalate (PET) blue film used in lithium battery cells. The image processing module 40 can be understood as a functional unit responsible for receiving, processing, analyzing, and finally outputting the detection results of the image data output by the black-and-white image detection channel 20 and the infrared image detection channel 30 in the detection system.

[0045] Specifically, the light source controller 10 generates a black-and-white image acquisition instruction based on the film material to be measured and the film material detection requirements (such as image resolution, detection accuracy, etc.). The acquisition instruction includes the exposure time, gain value, image resolution, etc. of the black-and-white image detection channel 20 (such as a black-and-white line scanning camera), as well as parameters related to the light source such as illumination intensity, illumination time, etc. Subsequently, the light source controller 10 transmits the black-and-white image acquisition instruction to the camera and related control circuit in the black-and-white image detection channel 20 through the black-and-white image control end 11. The film material to be measured is driven by the conveying device (such as a conveyor belt or roller mechanism) to pass through the scanning imaging area of the black-and-white image detection channel 20 at a constant speed, and the linear sensor of the black-and-white image detection channel 20 scans the surface of the film material row by row. For example, assuming that the sensor has 1024 pixels per row and the scanning frequency is 100 rows per second, the sensor can completely scan 100 rows of pixels in 1 second, and these 100 rows of data form a black-and-white image containing partial area information of the film material surface.

[0046] The light source controller 10 sends an infrared image acquisition instruction to the infrared image detection channel 30 through the infrared image control end 12. The infrared image detection channel 30 performs linear scanning on the film material to be measured during the conveying process, acquires infrared images, and sends the infrared images to the image processing module 40.

[0047] Specifically, the light source controller 10 generates an infrared image acquisition instruction according to the to-be-tested film material and the film material detection requirements (such as image resolution, detection accuracy, etc.), and the acquisition instruction includes the exposure time, gain value, image resolution, and the like of the infrared image detection channel 30 (such as an infrared line scan camera), and the parameters related to the light source such as the illumination intensity and illumination time. Subsequently, the light source controller 10 transmits the infrared image acquisition instruction to the camera and the related control circuit in the infrared image detection channel 30 through the infrared image control end 12. The to-be-tested film material is driven by the conveying device (such as a conveying belt or a roller mechanism) to pass through the scanning imaging area of the infrared image detection channel 30 at a constant speed, and the linear sensor of the infrared image detection channel 30 scans the surface of the film material row by row.

[0048] The image processing module 40 performs defect identification on the black-and-white image and the infrared image respectively.

[0049] Specifically, after receiving the images of the to-be-tested film material (such as a PET blue film) collected by the black-and-white image detection channel 20 and the infrared image detection channel 30, the image processing module 40 distinguishes and marks the defects existing in the images. The defects include whether there are scratches, damages, foreign matters, bubbles, wrinkles, buckling, pits, pockmarks, and the like on the surface of the film material and under the film.

[0050] For example, the bubble defects, foreign matters, and dirt defects in the film material all exhibit white characteristics under the irradiation of the visible light source 22. Under the irradiation of the infrared light source 32, the bubbles still exhibit white characteristics, the foreign matters exhibit pure black characteristics or black characteristics with a white ring, and the types of the defects can be further distinguished by combining the black-and-white image and the infrared image.

[0051] In the embodiment of the utility model, the light source controller adjusts the parameters such as brightness, color, light-emitting angle, and flicker frequency according to the characteristics and detection requirements of the to-be-tested film material (such as a PET blue film), so as to ensure the imaging effect of the blue film with different thicknesses and colors. The black-and-white image detection channel and the infrared image detection channel both use the linear scanning mode to respectively acquire the black-and-white line scan image and the infrared line scan image. The black-and-white image mainly acquires the surface characteristics of the film material, and the infrared image focuses on the detection of the defects under the film. The image processing module realizes the omnidirectional detection of the film material from the surface to the inside by combining the black-and-white image and the infrared image, effectively solves the problems such as the difficulty in detecting the defects under the film, the poor imaging effect, and the overexposure of the edges, improves the accuracy and reliability of the detection, reduces the false detection rate and the missed detection rate, and improves the production efficiency.

[0052] Optionally, the black-and-white image detection channel 20 includes a visible light source 22 and a black-and-white camera 23; the black-and-white image control end 11 includes a visible light source control end 111 and a black-and-white camera control end 112; the visible light source 22 is electrically connected with the visible light source control end 111, and the black-and-white camera 23 is electrically connected with the black-and-white camera control end 112;

[0053] The black-and-white image acquisition instruction comprises a visible light opening instruction and a black-and-white camera opening instruction; the light source controller 10 sends the visible light opening instruction to the visible light source 22 through the visible light source control end 111 and sends the black-and-white camera opening instruction to the black-and-white camera 23 through the black-and-white camera control end 112, so that the black-and-white camera 23 acquires the black-and-white image.

[0054] The visible light source 22 can be understood as a light source for providing illumination, the light wavelength of which is in the visible light band (about 380nm-780nm) and can meet the receiving and imaging requirements of the black-and-white camera 23; the black-and-white camera 23 can be understood as a camera for acquiring a black-and-white film layer image; the visible light source control end 111 can be understood as a port of the visible light source 22 for receiving a control signal (such as the visible light opening instruction); the black-and-white camera control end 112 can be understood as a port of the black-and-white camera 23 for receiving a control signal (such as the black-and-white camera opening instruction); the visible light opening instruction can be understood as an electrical signal form of instruction sent by the visible light source control end 111 of the light source controller 10 to the visible light source 22, which comprises controlling the visible light source 22 to be turned on at a specific time and providing illumination according to preset parameters; the black-and-white camera opening instruction can be understood as an electrical signal instruction sent by the black-and-white camera control end 112 of the light source controller 10 to the black-and-white camera 23 for starting the camera to acquire a black-and-white image, which comprises various parameter information required for the black-and-white camera 23 to acquire an image.

[0055] Specifically, before starting to acquire a black-and-white image, an operator needs to set the parameters of the light source controller 10 and the black-and-white camera 23 according to the characteristics (such as thickness, color, surface roughness, etc.) of the film material to be measured and the detection requirements (such as detection accuracy, detection speed, etc.). The light source controller 10 generates the black-and-white image acquisition instruction and the visible light opening instruction according to the above parameters. During the conveying of the film material to be measured, the visible light source 22 is turned on according to the visible light opening instruction, and the black-and-white camera 23 acquires black-and-white image data according to the black-and-white image acquisition instruction and transmits the data to the image processing module 40.

[0056] The embodiment of the utility model improves the efficiency of image acquisition and avoids repeated acquisition or acquisition failure caused by uncoordinated operation of the light source and the camera.

[0057] As Figure 2As shown, in an optional embodiment, the visible light source 22 includes a first visible light source 221 and a second visible light source 222; the visible light source control end 111 includes a first visible light source control end 1111 and a second visible light source control end 1112; the first visible light source 221 is electrically connected to the first visible light source control end 1111, and the second visible light source 222 is electrically connected to the second visible light source control end 1112.

[0058] The visible light-on instruction includes a first visible light-on instruction and a second visible light-on instruction, and the black-and-white camera-on instruction includes a first black-and-white camera-on instruction and a second black-and-white camera-on instruction.

[0059] The first visible light source 221 and the second visible light source 222 can be understood as visible light sources with the same or different brightness. The first visible light source 221 is controlled individually by the first visible light-on instruction sent by the corresponding first visible light source control end 1111. The second visible light source 222 is controlled individually by the second visible light-on instruction sent by the corresponding second visible light source control end 1112. The first black-and-white camera-on instruction and the second black-and-white camera-on instruction can be understood as electrical signal instructions sent by the black-and-white camera control end 112 of the light source controller 10 to the black-and-white camera 23, for controlling the black-and-white camera 23 to collect the first black-and-white image and the second black-and-white image under certain conditions.

[0060] The light source controller 10 sends the first visible light-on instruction to the first visible light source 221 through the first visible light source control end 1111, and sends the first black-and-white camera-on instruction to the black-and-white camera 23 through the black-and-white camera control end 112, so that the black-and-white camera 23 collects the first black-and-white image.

[0061] The light source controller 10 also sends the second visible light-on instruction to the second visible light source 222 through the second visible light source control end 1112, and sends the second black-and-white camera-on instruction to the black-and-white camera 23 through the black-and-white camera control end 112, so that the black-and-white camera 23 collects the second black-and-white image; wherein the first black-and-white image and the second black-and-white image are images with different brightness of the same area on the film to be tested.

[0062] Specifically, before starting the detection of the film material to be detected (such as PET blue film), the operator needs to set parameters in the light source controller 10 according to the known characteristics of the film material (such as thickness, color, surface roughness, etc.) and the detection requirements (such as the type of defects expected to be detected, detection accuracy, detection speed, etc.). According to different inspection requirements or different film materials, multiple different visible light sources 22 can be set, and different visible light on instructions, camera on instructions, and different images can be collected. For example, assume that the first visible light source 221 is a high-brightness light source. The first visible light source 221 provides high-brightness illumination, which is suitable for specific types of defects (such as deep scratches, large foreign matter, etc.). Adaptively, under the high-brightness light source, the exposure time of the first black-and-white camera 23 is relatively short to prevent overexposure of the image, and the exposure instruction in the first black-and-white camera on instruction is a short exposure instruction. Based on the high-brightness light source, the first black-and-white camera 23 generates a high- gray image (such as 220DN, where DN is the gray value unit, white is 255DN, and black is 0DN). Assume that the second visible light source 222 is a low-brightness light source, which is suitable for specific types of defects (such as fine stains, slight wrinkles). Adaptively, under the low-brightness light source, the exposure time of the second black-and-white camera 23 is relatively long to prevent insufficient exposure of the image, and the exposure instruction in the second black-and-white camera on instruction is a long exposure instruction. Based on the low-brightness light source, the second black-and-white camera 23 generates a high- gray image (such as 150DN).

[0063] As shown in Figure 2 In an optional embodiment, the first visible light source 221 and the second visible light source 222 are both arranged towards the film material to be detected; the light rays of the first visible light source 221 and the second visible light source 222 are located in the first plane, which is a plane perpendicular to the film material to be detected and parallel to the conveying direction of the film material to be detected; the light rays of the first visible light source 221 and the second visible light source 222 are axially symmetric in the first plane.

[0064] Among them, the first plane can be understood as a reference plane (such as Figure 2 The plane where the black-and-white image detection channel 20 is located), which is used to determine the directions of the light rays of the first visible light source 221 and the second visible light source 222 and their spatial positional relationship with the film material to be detected.

[0065] Specifically, the angle between each light source (including the first visible light source 221, the second visible light source 222, and / or the infrared light source 32) and the plane of the image detection channel is between 20° and 70°, and the working distance (the distance from the light source to the surface of the film material) of the first visible light source 221 and the second visible light source 222 is between 50mm and 200mm. A larger angle (such as 70°) can cause defects with a certain height or depth (such as protruding foreign matter, concave pits, etc.) to form a longer shadow, enhancing the contrast between the defect and the background, and facilitating detection and identification by the black-and-white camera 23. A smaller angle (such as 20°) makes the light more perpendicular to the film material, and the reflected light is stronger, which is beneficial for obtaining overall brightness information of the film material surface.

[0066] The embodiments of the utility model enhance the contrast between the defect and the background by setting the symmetrical first visible light source and the second visible light source. By comparing the grayscale difference of the images on both sides of the defect, the position, shape, and size of the defect can be more accurately determined, and the precision of defect detection is improved.

[0067] As shown in Figure 2 The infrared image detection channel 30 includes an infrared light source 32 and an infrared camera 33, the infrared image control end 12 includes an infrared light source control end 121 and an infrared camera control end 122, the infrared light source 32 is electrically connected with the infrared light source control end 121, and the infrared camera 33 is electrically connected with the infrared camera control end 122.

[0068] The infrared image acquisition instruction includes an infrared light opening instruction and an infrared camera opening instruction; the light source controller 10 sends the infrared light opening instruction to the infrared light source 32 through the infrared light source control end 121 and sends the infrared camera opening instruction to the infrared camera 33 through the infrared camera control end 122, so that the infrared camera 33 acquires the infrared image.

[0069] The infrared light opening instruction can be understood as an instruction in the form of an electrical signal sent by the infrared light source control end 121 of the light source controller 10 to the infrared light source 32, which includes controlling the infrared light source 32 to be turned on at a specific time and providing illumination according to the preset parameters; the infrared camera opening instruction can be understood as an electrical signal instruction sent by the infrared camera control end 122 of the light source controller 10 to the infrared camera 33 for starting the camera to acquire the infrared image, which includes various parameter information required for the infrared camera 33 to acquire the image.

[0070] Specifically, for dark color and thick film layer, the infrared light source 32 and the infrared camera 33 are difficult to effectively penetrate the film material. Before starting to collect the infrared image, the operator needs to set the light source controller 10, the infrared camera 33 parameters according to the characteristics (such as thickness, color, surface roughness, etc.) of the film material to be measured and the detection requirements (such as detection accuracy, detection speed, etc.). The light source controller 10 generates infrared image acquisition instructions and infrared light opening instructions according to the above parameters. During the transmission of the film material to be measured, the infrared light source 32 opens the light source according to the infrared light opening instruction, and the infrared camera 33 collects the infrared image data according to the infrared image acquisition instruction and transmits it to the image processing module 40.

[0071] The embodiment of the utility model discloses through infrared image acquisition instruction and infrared light opening instruction cooperative control, ensure that the system when gathering infrared image infrared light source provides suitable illumination. The efficiency of image acquisition has been improved, and the problems such as repeated collection or collection failure caused by the incoordination of light source and camera operation are avoided.

[0072] As Figure 2 As shown in an optional embodiment, the visible light source 22 and the infrared light source 32 are arranged towards the film material to be measured, and the outgoing light rays of the visible light source 22 and the infrared light source 32 are parallel to each other and staggered in the conveying direction of the film material to be measured.

[0073] Specifically, the visible light source 22 and the infrared light source 32 are arranged in parallel, the visible light source 22 irradiates the scanning position of the black-and-white camera 23 on the film material, the infrared light source 32 irradiates the scanning position of the infrared camera 33 on the film material, and the outgoing light rays of the two light sources are parallel to each other and staggered in the conveying direction of the film material to be measured, which avoids the reflection, scattering and interference of light caused by the simultaneous irradiation of the two light sources on the film material, improves the image quality and the accuracy of defect detection. The visible light source 22 and the black-and-white camera 23 are used to obtain the surface information of the region, and the infrared light source 32 irradiates the adjacent region to detect the defects under the film. By the distance difference between the black-and-white camera 23 and the infrared camera 33, the information of the surface of the film material and the different regions under the film at the same position is obtained at different times, the detection efficiency is improved, and the occurrence of misjudgment and omission is reduced.

[0074] Optionally, the visible light source 22 and the infrared light source 32 are arranged towards the film material to be measured, and the outgoing light rays of the visible light source 22 and the infrared light source 32 are parallel to each other and staggered in the conveying direction of the film material to be measured.

[0075] Specifically, the visible light source 22 and the infrared light source 32 are arranged in parallel, the visible light source 22 irradiates the scanning position of the black-and-white camera 23 on the film material, and the infrared light source 32 irradiates the scanning position of the infrared camera 33 on the film material. The light rays of the two light sources are parallel to each other and are arranged in a staggered manner in the conveying direction of the film material to be detected, avoiding the reflection, scattering and interference of light rays caused by the simultaneous irradiation of the film material by the two light sources, thereby improving the image quality and the accuracy of defect detection. The visible light source 22 and the black-and-white camera 23 are used to obtain the surface information of the region, while the infrared light irradiates the adjacent region to detect the defects under the film. By means of the distance difference between the black-and-white camera 23 and the infrared camera 33, the information of the surface of the film material and the different regions under the film at the same position is obtained at different times, thereby improving the detection efficiency and reducing the occurrence of misjudgment and omission.

[0076] Optionally, the visible light source 22 and the infrared light source 32 are both high-brightness linear stroboscopic light sources.

[0077] The high-brightness linear stroboscopic light source can be understood as a light source with high brightness, linear light distribution and stroboscopic function, which is used to cooperate with the camera to collect images at a high speed for a short time.

[0078] Specifically, when the visible light source 22 and the infrared light source 32 are both high-brightness linear stroboscopic light sources, the stroboscopic light source can illuminate the film material multiple times in a very short time, and the black-and-white camera 23 / infrared camera 33 collects images at the moment when the light source is turned on. The black-and-white line scanning camera collects the first black-and-white image and the second black-and-white image through the stroboscopic of the multiple light sources (the first visible light source 221 and the second visible light source 222), and the infrared camera 33 collects the infrared image through the stroboscopic of the infrared light source 32.

[0079] For example, in the film defect detection system as shown in FIG. 2, four stroboscopes are used, and the first visible light source 221 and the second visible light source 222 are used to stroboscopically collect images at the same time and position in high and low exposure poses, respectively. Figure 2 By using the stroboscopic imaging at different times, the surface and defect detection under the film are realized, and the problem of difficulty in penetrating the blue film due to excessive thickness is solved.

[0080] Optionally, the black-and-white image detection channel 20 further comprises an image acquisition card 24, the image acquisition card 24 is electrically connected with the black-and-white camera 23, and the image acquisition card 24 performs image fusion on the first black-and-white image and the second black-and-white image provided by the black-and-white camera 23.

[0081] The image acquisition card 24 can be understood as a device for receiving image data (first black-and-white image and second black-and-white image data transmitted by the black-and-white camera 23) and performing subsequent image processing.

[0082] Specifically, the image acquisition card 24 in the black and white image detection channel 20 receives the first black and white image and the second black and white image data transmitted by the black and white camera 23, and performs image fusion. The fused image, the first black and white image and the second black and white image data are transmitted to the image processing module 40 for defect recognition.

[0083] The first visible light source and the second visible light source are provided in the embodiment of the utility model, to form high and low dynamic imaging, and the size, shape and gray scale information of defects in high dynamic images and low dynamic images are combined, and the edge missing problem caused by edge overexposure can be solved through image fusion.

[0084] In an optional embodiment, the black and white image control end and the infrared image control end are differential interfaces. As shown in Figure 3 The black and white image control end and the infrared image control end in the light source controller are differential interfaces, and the differential signals are output to the black and white image detection channel and the infrared image detection channel through 1+, 1-, 2+, 2- and the like. As shown in Figure 4 The infrared camera and the infrared light source in the infrared image detection channel periodically acquire exposed / unexposed infrared images according to the built-in trigger logic (configured by the light source controller before detection starts) upon receiving the external trigger signal (differential signal) sent by the light source controller. The black and white camera and the visible light source in the black and white image detection channel periodically acquire exposed / unexposed black and white images according to the built-in trigger logic (configured by the light source controller before detection starts) upon receiving the external trigger signal (differential signal) sent by the light source controller. In addition, the image acquisition card in the black and white image detection channel is also correspondingly provided with a switching parameter, which is used to switch and start different black and white cameras and corresponding visible light sources according to the differential signal when the black and white camera and the visible light source are multiple. For example, the exposed image and the unexposed image corresponding to the visible light source with high brightness, and the exposed image and the unexposed image corresponding to the visible light source with low brightness are sequentially photographed through the differential signal.

[0085] As shown in Figure 3 In an optional embodiment, the black and white image control end 11 and the infrared image control end 12 are differential interfaces.

[0086] Specifically, the black and white image control end 11 and the infrared image control end 12 in the light source controller 10 are differential interfaces, and the differential signals are output to the black and white image detection channel 20 and the infrared image detection channel 30 through 1+, 1-, 2+, 2- and the like. As shown in Figure 4As shown, the infrared camera 33 and the infrared light source 32 in the infrared image detection channel 30 periodically acquire exposed / unexposed infrared images according to the built-in trigger logic (configured by the light source controller 10 before the detection is started) upon receiving the external trigger signal (differential signal) sent by the light source controller 10. The black-and-white camera 23 and the visible light source 22 in the black-and-white image detection channel 20 periodically acquire exposed / unexposed black-and-white images according to the built-in trigger logic (configured by the light source controller 10 before the detection is started) upon receiving the external trigger signal (differential signal) sent by the light source controller 10. In addition, the image acquisition card 24 in the black-and-white image detection channel 20 is also correspondingly provided with a switching parameter, which is used to switch different black-and-white cameras 23 and corresponding visible light sources 22 according to the differential signal when the black-and-white camera 23 and the visible light source 22 are multiple. For example, the exposed image and the unexposed image corresponding to the visible light source 22 with high brightness are sequentially shot through the differential signal, and the exposed image and the unexposed image corresponding to the visible light source 22 with low brightness are sequentially shot through the differential signal.

[0087] The embodiment of the utility model realizes the orderly collaborative work of the black-and-white image detection channel and the infrared image detection channel by alternately triggering different image detection channels through the differential signal. In the conveying process of the to-be-detected film material, the acquisition of the black-and-white image and the infrared image can be completed in time and efficiently, and the detection efficiency of the whole film material defect detection system is improved.

[0088] As shown in the figure, Figure 3 In an optional embodiment, the light source controller 10 further comprises a pulse signal interface 13 and a frame signal interface 14. The pulse signal interface 13 receives the pulse signal reflecting the conveying position of the to-be-detected film material provided by the magnetic suspension encoder or the linear motor, and the frame signal interface 14 receives the frame signal reflecting the starting of the conveying of the to-be-detected film material provided by the programmable logic controller or the photoelectric sensor.

[0089] The pulse signal reflecting the conveying position of the to-be-detected film material provided by the magnetic suspension encoder or the linear motor can be understood as a signal representing the conveying speed of the film material conveying driving device. The signal reflects the speed in the form of a frequency signal. The higher the frequency, the faster the conveying speed. The frame signal provided by the programmable logic controller or the photoelectric sensor can be understood as a time-varying judgment signal. When the photoelectric sensor or the programmable logic controller obtains the film material on the conveying device through other forms, the corresponding frame signal is sent.

[0090] Specifically, when the conveying device starts, the light source controller 10 obtains the pulse signal sent by the conveying device of the conveying film structure through the pulse signal interface 13 (A+, A-, B+ and B-), and the speed of the conveying device is determined by the frequency of the pulse signal in a fixed period. For example, 0~320 pulses per minute correspond to a conveying belt speed of 0~80 meters per second. When the film is detected on the conveying belt, the light source controller 10 obtains the frame signal through the frame signal interface 14 (F+ and F-), and the light source controller 10 sends the detection signal to the black and white image detection channel 20 and the infrared image detection channel 30 through the differential signal output port (1+, 1-, 2+ and 2-), and starts the black and white camera 23 and the infrared camera 33. The black and white camera 23 linearly scans the film to be tested in the conveying process, collects black and white images, and sends the black and white images to the image processing module 40; the infrared camera 33 linearly scans the film to be tested in the conveying process, collects infrared images, and sends the infrared images to the image processing module 40.

[0091] The utility model embodiment sets pulse signal interface and frame signal interface, obtains actual conveying condition (speed, position etc.) of film, only when film is detected on the conveying belt, start camera to collect image, obtain black and white image and infrared image, improve accuracy and reliability of film defect detection result, reduce the possibility of misjudgment, missed judgment and the like.

[0092] It should be noted that the above is only the preferred embodiment of the utility model and the applied technical principle. Those skilled in the art will understand that the utility model is not limited to the specific embodiments here, and those skilled in the art can make various obvious changes, re-adjustment, mutual combination and replacement without departing from the protection scope of the utility model. Therefore, although the utility model has been described in more detail through the above embodiments, the utility model is not limited to the above embodiments, and can include more other equivalent embodiments without departing from the utility model concept, and the scope of the utility model is determined by the appended claims.

Claims

1. A film material defect detection system characterized by, The system comprises a light source controller, a black-and-white image detection channel, an infrared image detection channel and an image processing module. The light source controller comprises a black-and-white image control end and an infrared image control end, the black-and-white image detection channel is electrically connected with the black-and-white image control end, and the infrared image detection channel is electrically connected with the infrared image control end. The black-and-white image detection channel comprises a black-and-white image output end, the infrared image detection channel comprises an infrared image output end, and the image processing module is electrically connected with the black-and-white image output end and the infrared image output end respectively. The light source controller sends a black-and-white image acquisition instruction to the black-and-white image detection channel through the black-and-white image control end, the black-and-white image detection channel performs linear scanning on the film material to be tested in the conveying process, acquires a black-and-white image, and sends the black-and-white image to the image processing module. The light source controller sends an infrared image acquisition instruction to the infrared image detection channel through the infrared image control end, the infrared image detection channel performs linear scanning on the film material to be tested in the conveying process, acquires an infrared image, and sends the infrared image to the image processing module. The image processing module performs defect identification on the black-and-white image and the infrared image respectively.

2. The film defect detection system according to claim 1, wherein the black-and-white image detection channel comprises a visible light source and a black-and-white camera, the black-and-white image control end comprises a visible light source control end and a black-and-white camera control end, the visible light source is electrically connected with the visible light source control end, and the black-and-white camera is electrically connected with the black-and-white camera control end. The black-and-white image acquisition instruction comprises a visible light opening instruction and a black-and-white camera opening instruction, the light source controller sends the visible light opening instruction to the visible light source through the visible light source control end and sends the black-and-white camera opening instruction to the black-and-white camera through the black-and-white camera control end, so that the black-and-white camera acquires a black-and-white image.

3. The film defect detection system according to claim 2, wherein the visible light source comprises a first visible light source and a second visible light source, the visible light source control end comprises a first visible light source control end and a second visible light source control end, the first visible light source is electrically connected with the first visible light source control end, and the second visible light source is electrically connected with the second visible light source control end. The visible light opening instruction comprises a first visible light opening instruction and a second visible light opening instruction, and the black-and-white camera opening instruction comprises a first black-and-white camera opening instruction and a second black-and-white camera opening instruction. The light source controller sends the first visible light opening instruction to the first visible light source through the first visible light source control end and sends the first black-and-white camera opening instruction to the black-and-white camera through the black-and-white camera control end, so that the black-and-white camera acquires a first black-and-white image. ​ ​ The light source controller further sends the second visible light opening instruction to the second visible light source through the second visible light source control end and sends the second black-and-white camera opening instruction to the black-and-white camera through the black-and-white camera control end, so that the black-and-white camera collects a second black-and-white image. The first black-and-white image and the second black-and-white image are images of the same region on the film material to be tested and have different brightnesses.

4. The film defect detection system of claim 3, wherein The black-and-white image detection channel further comprises an image acquisition card, which is electrically connected to the black-and-white camera and performs image fusion on the first black-and-white image and the second black-and-white image provided by the black-and-white camera.

5. The film defect detection system of claim 3, wherein The first visible light source and the second visible light source are both arranged towards the film material to be tested. The light rays of the first visible light source and the second visible light source are located in a first plane, which is a plane perpendicular to the film material to be tested and parallel to the conveying direction of the film material to be tested; the light rays of the first visible light source and the second visible light source are axially symmetric in the first plane.

6. The film defect detection system of claim 2, wherein The infrared image detection channel comprises an infrared light source and an infrared camera; the infrared image control end comprises an infrared light source control end and an infrared camera control end; the infrared light source is electrically connected to the infrared light source control end, and the infrared camera is electrically connected to the infrared camera control end. The infrared image acquisition instruction comprises an infrared light opening instruction and an infrared camera opening instruction; the light source controller sends the infrared light opening instruction to the infrared light source through the infrared light source control end and sends the infrared camera opening instruction to the infrared camera through the infrared camera control end, so that the infrared camera collects an infrared image.

7. The film defect detection system of claim 6, wherein The visible light source and the infrared light source are arranged towards the film material to be tested, and the light rays of the visible light source and the infrared light source are parallel to each other and are offset in the conveying direction of the film material to be tested.

8. The film defect detection system of claim 6, wherein The visible light source and the infrared light source are both high-brightness linear stroboscopic light sources.

9. The film defect detection system of claim 6, wherein, The black-and-white image control end and the infrared image control end are both differential interfaces.

10. The film defect detection system of claim 1, wherein The light source controller further comprises a pulse signal interface and a frame signal interface; the pulse signal interface receives a pulse signal reflecting the conveying position of the film material to be tested provided by a magnetic levitation encoder or a linear motor; and the frame signal interface receives a frame signal reflecting the start of conveying of the film material to be tested provided by a programmable logic controller or a photoelectric sensor.

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