Image Processing Sensor Threshold Setting via Background Subtraction
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Solution Overview
Problem
Existing image processing sensors face challenges in stabilizing the separation of non-defective and defective products due to the complexity of registering model and non-model images, leading to difficulties in determining accurate thresholds and user-friendly operation.
Innovation Solution
The image processing sensor allows for easy setting of thresholds by enabling two-point or three-point registration modes, where users can register non-defective, defective, and background images separately, using a user-friendly interface with adjustable display magnification and matching degree thresholds, reducing the influence of background elements and improving defect detection accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If only model image registration is performed, then the setting operation is simple, but the threshold cannot be stably determined to separate non-defective and defective products
Solution Approach 1:
The patent segments the teaching process into multiple independent registration modes (one-point, two-point, three-point teaching) that can be selected based on specific needs. Each mode registers different combinations of images (model image, non-model image, background image) to calculate thresholds, allowing users to choose the appropriate level of complexity for their application while ensuring accurate defect detection.
2Measurement precision
If both model image and non-model image are registered, then the threshold determination improves, but the operation and registration procedure becomes complicated
Solution Approach 1:
The patent implements dynamic operation modes that automatically adjust the registration procedure based on the selected teaching mode. The system dynamically determines which images to register and how to calculate thresholds, adapting the complexity of the procedure to match the user's needs while maintaining accurate defect detection capabilities.
3Ease of operation
If background elements are included in the model image, then the registration is simpler, but the defect detection accuracy deteriorates due to background influence
Solution Approach 1:
The patent extracts background elements from the imaging target through dedicated background image registration in two-point and three-point teaching modes. By separately registering the background image and subtracting it from the model image, the system removes background interference while maintaining registration simplicity, thereby improving defect detection accuracy without significantly increasing operational complexity.
Data Source
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AI summary
An image processing sensor includes an image registering unit configured to register a non-defective product image, a defective product image, and a background image, a differential-image generating unit configured to generate a first differential image from the non-defective product image and the background image and generate a second differential image from the defective product image and the background image; a matching-degree calculating unit configured to calculate a matching degree indicating a degree of feature matching of the second differential image with respect to a model image corresponding to the first differential image, and a threshold calculating unit configured to calculate, on the basis of the matching degree, a threshold used in an operation mode.