换向器如图所示
针对图示的八种换向器表面缺陷，依托德国MVtec公司的Halcon软件平台来设计实施有效的缺陷检测算法与程序。
八种缺陷说明
槽边毛刺：在槽的加工过程产生的紧靠槽边的毛刺，如图(所示。
槽边毛刺
槽打伤，尾端槽口打伤，外圆打伤：相应部位因撞击产生的凹坑，分别如图所示。
(b)槽打伤
(g)尾端槽口打伤
(h)尾端槽口毛刺
槽内卡铜丝：切削换向片表面产生的铜丝进入槽内部，如图所示。
槽内毛刺：在槽的加工过程产生的位于槽内部的毛刺，如图所示。
外圆不圆：换向器侧表面部分区域曲率半径与整体相差过大而未能接触到刀具，表现为切削前的状态，颜色泛绿是由于铜锈的缘故所示。
外圆打伤：在右侧端面加工过程中产生的毛刺, 如图所示。
检测方案
线圈缺陷检测的目的是基于Halcon检测分析线圈的槽边毛刺、槽打伤、槽内卡铜丝、槽内毛刺、外圆不圆、外圆打伤、尾端槽口打伤、尾端槽口毛刺8种常见缺陷。首先分析各种缺陷的特征，然后根据缺陷特征类型确定各种缺陷的检测方法，最终采用不同的阈值分割、颜色检测等常用图像检测方法检测出线圈的缺陷类型以及位置。
1. 缺陷特征分析
1.1槽边毛刺
槽边毛刺缺陷特征在图像上表现为：开槽口小面积的灰度值变化，开槽形状凸起。
1.2槽打伤
槽打伤缺陷特征在图像上表现为：开槽的形状发生严重畸变。
1.3槽内卡铜丝
槽内卡铜丝缺陷特征在图像上表现为：槽内有大块异物。
1.4槽内毛刺
槽内毛刺缺陷特征在图像上表现为：开槽矩形小面积凹陷。
1.5外圆不圆
槽内毛刺缺陷特征在图像上表现为：由于光线反射导致线圈圆柱身部分颜色发生突变。
1.6外圆打伤
外圆打伤缺陷特征在图像上表现为：圆柱身部分灰度值变暗。
1.7尾端槽口打伤
尾端槽口打伤缺陷特征在图像上表现为：开槽尾端的形状发生严重畸变。
1.8槽边毛刺
槽边毛刺缺陷特征在图像上表现为：槽边的形状发生严重畸变。
2. 缺陷特征分类以及检测方案
根据线圈八种缺陷的特征进行分类，以此为基础确定检测方案。
2.1槽边毛刺、槽打伤、槽内毛刺、尾端槽口
槽边毛刺、槽打伤、槽内毛刺、尾端槽口打伤4中缺陷均为开槽形状发生变化的开槽口缺陷，因此这4种缺陷可通过检测线圈开槽的形状进行检测，其中槽边毛刺和槽内毛刺开槽形状均发生小面积突变，对于开槽形状而言槽边毛刺为凸起区域、槽内为凹陷区域。槽打伤和尾端槽口打伤开槽形状发生大面积畸变，其中尾端槽口打伤发生在开槽尾端区域。
2.2槽内卡铜丝
定位开槽区域后对开槽内的灰度值进行检测，如果存在大面积灰度值变化区域则认为开口槽内存在异物。
2.3外圆打伤
对线圈圆柱部分的灰度值进行检测分析，根据圆度部分灰度变化梯度可检测圆柱部分缺陷。
2.4外圆不圆
由于线圈外圆形状发生突变的时候外圆颜色发生了变化，为了排除反光效果的干扰，需要将图像有RGB（红、绿、蓝）空间转化至HSV（色调、饱和度、亮度）空间对其色调进行分析检测，从而检测出圆柱变化区域来判断是否有外圆不圆的缺陷。
2.5槽边毛刺
将图像转化至灰度图，定位槽边并分析其形状，根据形状突变情况确定槽边是否存在缺陷。
最终总的检测流程如下：
检测源码如图所示：
read_image (Image01, 'G:/机器视觉/20180118毕业设计/尾端槽口毛刺02.bmp')**1.将读入图像分别转化为灰度图以供后续检测，将图像由RGB空间转化到HSV空间以便根据颜色检测外圆不圆rgb1_to_gray (Image01, GrayImage)decompose3 (Image01, ImageR, ImageG, ImageB)trans_from_rgb (ImageR, ImageG, ImageB, ImageH, ImageS, ImageV, 'hsv')**2.定位开槽、外圆部分、尾边等ROI区域***1）.定位开槽区域threshold (GrayImage, Region, 50, 255)connection (Region, ConnectedRegions)select_shape (ConnectedRegions, SelectedRegions, 'area', 'and', 100000, 9999999)union1 (SelectedRegions, RegionUnion)closing_rectangle1 (RegionUnion, RegionClosing, 2, 100)difference (RegionClosing, RegionUnion, RegionDifference)connection (RegionDifference, ConnectedRegions1)select_shape (ConnectedRegions1, SelectedRegions1, 'area', 'and', 3999, 99999)union1 (SelectedRegions1, RegionUnion1)***2）.初步检测槽内毛刺（开槽内陷）opening_circle (RegionUnion1, RegionOpening2, 3.5)closing_rectangle1 (RegionOpening2, RegionClosing5, 20, 2)difference (RegionClosing5, RegionOpening2, RegionDifference8)connection (RegionDifference8, ConnectedRegions8)select_shape (ConnectedRegions8, CaoneiMaoci, 'area', 'and', 50, 99999)***3）.初步检测铜带（开槽中间有异物）opening_rectangle1 (RegionOpening2, RegionOpening5, 100, 2)closing_rectangle1 (RegionOpening5, RegionClosing4, 150, 2)difference (RegionClosing4, RegionOpening5, RegionDifference7)connection (RegionDifference7, ConnectedRegions7)select_shape (ConnectedRegions7, Tongdai, 'area', 'and', 1000, 99999)dilation_circle (Tongdai, Tongdai, 5)***4）.根据开槽区域定位整体需要检测的区域area_center (RegionOpening5, Area, Row, Column)gen_rectangle1 (Rectangle, 0, 0, Row-250, 1280)gen_rectangle1 (Rectangle1, Row+250, 0, 960, 1280)union2 (Rectangle, Rectangle1, RegionUnion2)threshold (GrayImage, Region2, 0, 40)difference (Region2, RegionUnion2, RegionDifference2)fill_up (RegionDifference2, RegionFillUp)closing_circle (RegionFillUp, RegionClosing2, 3.5)opening_circle (RegionClosing2, RegionOpening3, 30)connection (RegionOpening3, ConnectedRegions2)select_shape_std (ConnectedRegions2, SelectedRegions2, 'max_area', 70)dilation_circle (SelectedRegions2, RegionDilation, 60)smallest_rectangle1 (RegionDilation, Row1, Column1, Row2, Column2)gen_rectangle1 (Rectangle2, Row1-100, Column1, Row2+100, Column2)difference (RegionUnion2, Rectangle2, RegionDifference3)union2 (RegionUnion2, Rectangle2, RegionUnion3)complement (RegionUnion3, RegionComplement)***5）.定位尾边检测区域，检测槽口毛刺reduce_domain (GrayImage, RegionComplement, ImageReduced)threshold (ImageReduced, Region3, 250, 255)connection (Region3, ConnectedRegions3)select_shape (ConnectedRegions3, SelectedRegions3, 'area', 'and', 1500, 99999)select_shape (SelectedRegions3, SelectedRegions4, 'height', 'and', 200, 99999)union1 (SelectedRegions4, RegionUnion4)fill_up (RegionUnion4, RegionFillUp1)closing_rectangle1 (RegionFillUp1, RegionClosing3, 10, 50)opening_rectangle1 (RegionClosing3, RegionOpening7, 2, 20)difference (RegionClosing3, RegionOpening7, RegionDifference11)connection (RegionDifference11, ConnectedRegions11)select_shape (ConnectedRegions11, CaokouMaoci, 'area', 'and', 50, 99999)***6）.初步检测槽边毛刺difference (RegionOpening2, RegionClosing3, RegionDifference4)difference (RegionDifference4, RegionUnion3, RegionDifference5)connection (RegionDifference5, ConnectedRegions4)select_shape (ConnectedRegions4, SelectedRegions5, 'area', 'and', 3999, 99999)dilation_circle (SelectedRegions5, RegionDilation1, 20)intersection (RegionDilation1, RegionComplement, RegionIntersection)reduce_domain (GrayImage, RegionIntersection, ImageReduced1)threshold (ImageReduced1, Region4, 0, 60)connection (Region4, ConnectedRegions5)select_shape (ConnectedRegions5, SelectedRegions6, 'area', 'and', 4000, 99999)opening_rectangle1 (SelectedRegions6, RegionOpening4, 150, 2)difference (SelectedRegions6, RegionOpening4, RegionDifference6)opening_circle (RegionDifference6, RegionOpening6, 1.5)connection (RegionOpening6, ConnectedRegions6)select_shape (ConnectedRegions6, CaobianMaoci1, 'area', 'and', 50, 99999)select_shape (CaobianMaoci1, CaobianMaoci, 'width', 'and', 0, 20)select_shape (CaobianMaoci, CaobianMaoci, 'height', 'and', 10, 999999)union1 (CaobianMaoci1, RegionUnion6)closing_rectangle1 (RegionUnion6, RegionClosing6, 2, 150)connection (RegionClosing6, ConnectedRegions12)select_shape (ConnectedRegions12, Caokoudashang, 'height', 'and', 45, 99999)union1 (Caokoudashang, Caokoudashang)dilation_circle (Caokoudashang, RegionDilation3, 100)difference (CaobianMaoci, RegionDilation3, CaobianMaoci)***7）.根据颜色检测外圆不圆mean_image (ImageH, ImageMean, 12, 12)median_image (ImageH, ImageMedian, 'circle', 5, 'mirrored')threshold (ImageMedian, Region1, 45, 255)closing_rectangle1 (Region1, RegionClosing1, 10, 200)opening_rectangle1 (RegionClosing1, RegionOpening, 10, 800)difference (RegionClosing1, RegionOpening, RegionDifference1)opening_circle (RegionDifference1, WaiYuanBuyuan, 30)***8）.动态阈值分割检测外圆打伤dilation_circle (RegionClosing3, RegionDilation2, 10)difference (RegionComplement, RegionDilation2, RegionDifference9)connection (RegionDifference9, ConnectedRegions9)select_shape_std (ConnectedRegions9, SelectedRegions8, 'max_area', 70)difference (SelectedRegions8, RegionDilation1, RegionDifference10)reduce_domain (GrayImage, RegionDifference10, ImageReduced2)mean_image (ImageReduced2, ImageMean1, 30, 30)dyn_threshold (ImageReduced2, ImageMean1, RegionDynThresh, 40, 'dark')opening_circle (RegionDynThresh, RegionOpening1, 1.5)connection (RegionOpening1, ConnectedRegions10)select_shape (ConnectedRegions10, WaiYuanDaShang, 'area', 'and', 200, 99999)**3.根据各缺陷位置关系进一步精确检验***铜带区域不会有槽口毛刺difference (CaokouMaoci, Tongdai, CaokouMaoci)***尾边区域不会有槽内毛刺difference (CaoneiMaoci, RegionDilation2, CaoneiMaoci)difference (CaoneiMaoci, Tongdai, CaoneiMaoci)***槽内毛刺一定在开槽区域intersection (CaoneiMaoci, RegionDilation1, CaoneiMaoci)difference (Caokoudashang, Tongdai, Caokoudashang)intersection (Caokoudashang, RegionDilation1, Caokoudashang)***外圆不圆一定在检测区域intersection (WaiYuanBuyuan, RegionComplement, WaiYuanBuyuan)difference (CaobianMaoci, Tongdai, CaobianMaoci)intersection (CaobianMaoci, SelectedRegions8, CaobianMaoci)**4.对检测结果进行显示area_center (CaobianMaoci, Area1, Row3, Column3)dev_display (Image01)dev_set_draw ('fill')tryif(Area1[0]>10)dev_set_color ('red')dev_display (CaobianMaoci)disp_message (3600, 'CaoBianMaoci', 'window', 12, 12, 'red', 'false')endifcatch (Exception)endtryarea_center (CaokouMaoci, Area2, Row4, Column4)tryif(Area2[0]>10)dev_set_color ('blue')dev_display (CaokouMaoci)disp_message (3600, 'CaoKouMaoCi', 'window', 27, 12, 'blue', 'false')endifcatch (Exception)endtryarea_center (CaoneiMaoci, Area3, Row5, Column5)tryif(Area3[0]>10)dev_set_color ('green')dev_display (CaoneiMaoci)disp_message (3600, 'CaoNeiMaoCi', 'window', 87, 12, 'green', 'false')endifcatch (Exception)endtryarea_center (Caokoudashang, Area4, Row6, Column6)try)if(Column6[0]<990)dev_set_color ('cyan')dev_display (Caokoudashang)disp_message (3600, 'CaoKouDaShang', 'window', 72, 12, 'cyan', 'false')elsedev_set_color ('slate blue')dev_display (Caokoudashang)disp_message (3600, 'WeiDuanCaoKouDaShang', 'window', 72, 12, 'slate blue', 'false')endifendifcatch (Exception)endtrydev_set_draw ('margin')area_center (WaiYuanBuyuan, Area5, Row7, Column7)tryif(Area5[0]>10)dev_set_color ('magenta')dev_display (WaiYuanBuyuan)disp_message (3600, 'WaiYuanBuyuan', 'window', 42, 12, 'magenta', 'false')endifcatch (Exception)endtryarea_center (Tongdai, Area6, Row8, Column8)tryif(Area6[0]>10)dev_set_color ('spring green')dev_display (Tongdai)disp_message (3600, 'TongDai', 'window', 57, 12, 'spring green', 'false')endifcatch (Exception)endtryarea_center (WaiYuanDaShang, Area7, Row9, Column9)tryif(Area7[0]>10)dev_set_color ('coral')dev_display (WaiYuanDaShang)disp_message (3600, 'WaiYuanDaShang', 'window', 102, 12, 'coral', 'false')endifcatch (Exception)endtry
检测效果如图所示：
更多缺陷检测算法参照本公众号以下相关文章：
