基于远程调控的烟包外观视觉检测系统的研发

Research and Development of Visual Inspection System of Cigarette Packet Based on Remote Control

目的小盒烟包在包裹过程中易出现烟包内框纸破损、脱落、丢失,以及铝箔纸破损、刮烂等缺陷,为解决在完全包裹好小盒商标纸之前,GD包装机未对这些缺陷进行相关检测和剔除而带来的质量风险问题。方法通过对视觉技术的研究、全方位可旋转支架的设计制作、PLC控制程序的设计与IPC系统融合等,设计一种新型烟包外观视觉检测装置;通过多次实验调整可旋转支架的角度确定检测的最佳安装位置及角度;采用高斯核滤波、卷积等方法对图像进行预处理,采用相对熵对颜色相近的铝箔纸与内框纸进行图像处理分析;利用In-Sight资源管理器,并结合远程控制设计,实现对烟包内框纸、铝箔纸与商标纸同时检测的远程调试与监测。结果该新型外观视觉检测装置安装后,实现在完全包裹好小盒商标纸之前对烟包铝箔纸、内框纸与商标纸的精确检测,缺陷烟包的产品检测剔除率≥99.99%,误检率≤0.01%。结论所设计的新型小盒烟包外观检测装置能在完全包裹好小盒商标纸之前远程调试与监测烟包内框纸、铝箔纸与商标纸,并对缺陷烟包进行准确剔除,降低有缺陷烟包进入下道工序的风险,可推广应用于烟草行业内所有包装设备上。

The work aims to solve the quality risk problem caused by failure of GD packaging machine to detect and reject defects before completely wrapping small cigarette packets,because small cigarette packets are prone to breakage,shedding and loss of inner frame paper and breakage and scratching of aluminum foil paper.A new type of visual inspection device for cigarette packet appearance was designed through the study on visual technology,design and fabrication of all-round rotating bracket,integration of PLC control program and IPC system,etc.The angle of rotating bracket was adjusted through many experiments to determine the best installation position and angle for detection.Gaussian kernel filtering,convolution and other methods were used to preprocess the images,and relative entropy was used to analyze the images of aluminum foil paper and inner frame paper with similar colors.In-Sight Explore was combined with remote control design to realize the remote debugging and monitoring of cigarette packet inner frame paper,aluminum foil paper and trademark paper.After the installation of the new visual inspection device,accurate detection of cigarette packet aluminum foil paper,inner frame paper and trademark paper was realized before the trademark paper of small packet was completely wrapped.The detection rejection rate of defective cigarette packets was≥99.99%,and the error detection rate was≤0.01%.The designed visual inspection device for small packet can remotely debug and monitor the inner frame paper,aluminum foil paper and trademark paper before the small cigarette packet is completely wrapped,and accurately remove the defective cigarette packets,thus reducing the risk of defective cigarette packets entering the next process and can be popularized and applied to all packaging equipment in the tobacco industry.