Digital Image Processing CCD Camera Visual Inspection Machine For Aluminium Plate

Digital Image Processing CCD Camera Visual Inspection Machine For Aluminium Plate

With the rapid development of aluminum processing technology, high value-added anodizing materials, CTP board bases, aluminum for pop-top cans, and automotive sheets have become the main products of various aluminum sheet and strip processing plants. However, the inspection method that relies on the human eye for surface quality has long been unable to meet the needs of new forms of real-time monitoring, online early warning, defect analysis, and finished product classification for high-speed production. To this end, a machine vision system must be introduced for real-time and accurate monitoring of surface quality to ensure the quality inspection capability of high-precision aluminum strips. The aluminum (plate, strip, foil) surface defect detection system is divided into two parts: hardware structure and software system.

Inspection methods

The CCD signal transmitted synchronously by the encoder is first preprocessed by the accelerator card to further enhance the signal, and then continuously form an image. The preprocessing includes: using Fourier analysis, denoising the signal, adjusting the brightness and contrast of the image, edge sharpening and smoothing filtering. The adjustment of intensity and contrast enhances the characteristic value of the image and is easy to identify. Edge sharpening will make the image boundary clear from blur, and it is easy to define the size and shape of the defect. The smoothing filter adopts the median filter method, which can well suppress the interference pulse and point-like noise, and at the same time can better preserve the edge information.

After the grayscale analysis is completed, the signal will be handed over to the automatic identification system. The automatic identification system is equipped with a range of expected characteristic values ​​for each type of hexidine defect based on common defects on the surface of the aluminum sheet. During inspection, the identification system compares how well the signal features match the defined defect types and, once confirmed, triggers the display. If defects are found, synchronous marking can be performed, and the surface quality of the whole roll of aluminum sheet can be graded to obtain complete data of the surface quality of the whole roll of aluminum sheet.

Equipment overview

-Online high speed detection, improve detection efficiency and accuracy, reduce human cost.

- High-pixel industrial camera accurate identification, the number of cameras is designed, accurate 0.1mm, speed can be customized according to the detection requirements.

- Compatible with multiple specifications, cost savings.

-Perform online detection and exclude for disabled fork defects:black spots, color difference, impurities, gaps, residues of material, overlaps, bubbles, air cavities, deformation, thickness, sizes, etc.

Hardware&software

1)The hardware structure includes providing high-intensity illumination light source, CCD camera, image acquisition and processing system, data interface system, system server, data server and disk array.

• High-intensity illumination light source is an important part of the entire surface inspection system. The intensity of the light source solves the difficulty of signal acquisition for the CCD camera caused by the harsh environment and the diffuse emission caused by the surface roughness of the aluminum plate. A halogen light source with strong penetrating power should be used on the hot rolling mill, and an LED light source with evenly scattered light should be used on the finishing machine.
• The camera adopts Canada dalsa high-speed CCD line scan camera. The camera uses line scanning technology to continuously scan the surface of the aluminum strip, and can complete signal tracking of up to 20,000 lines per second.

2)The software system is composed of a series of software with powerful image functions under the windows framework. It includes system operation monitoring module, quality defect acquisition module, image quality secondary processing module, system real-time display module, report and grading module.

After-sale service

The company has a complete technical service team and rapid response mechanism, and has dedicated service specialists for each customer, who can receive technical consultation and fault reports from customers at any time. And to ensure rapid response to customer emergencies, to ensure that customers receive satisfactory service.During the epidemic or due to special reasons, when after-sales engineers are unable to reach the site, the service center can remotely adjust customer equipment for troubleshooting and technical consultation.

After the equipment arrives at the customer site, the after-sales engineer arrives in time to carry out equipment installation, commissioning, and operation training. The product quality of the whole machine is traceable, and the quality warranty period is 1 year from the date of acceptance. In the event of non-human faults during the warranty period, after-sales engineers will quickly arrive at the site or provide remote guidance for free maintenance.