基于机器视觉的金工实训圆形零件评分系统设计

Design of Scoring System for Round Parts in Metalworking Training based on Machine Vision

  • 摘要: 金工实训作为装备制造专业的核心实践课程,在培养学生金属切削加工能力中具有重要作用。传统车削实训采用人工游标卡尺检测方式,存在效率低、误差大、评价标准不统一等问题。为此,本文开发了基于机器视觉的圆形零件智能评分系统,显著提升了检测效率和精度。系统硬件由大恒工业相机、环形光源及工作机架构成,软件基于Halcon算法库开发,结合Qt Creator构建交互界面。检测流程分为四个核心环节:通过工业相机完成高精度图像采集,经相机校准和畸变校正确保图像质量;采用灰度化、滤波去噪和图像分割技术消除表面划痕干扰;运用Canny算子进行边缘检测,结合最小二乘法拟合轮廓,精确提取零件几何特征;最后通过双重判据实现自动评分,先以圆形度(Cr<0.75)筛选形状缺陷件,再通过标定转换将亚像素尺寸转换为实际尺寸进行公差检测。经400套零件实测验证,系统尺寸检测误差小于0.06 mm,单件检测耗时降低至传统方法的1/5。检测结果通过交互界面实时显示,并自动生成Excel格式的合格率统计与评级报告。该系统不仅解决了人工检测的主观性问题,检测效率提升83%,同时建立了标准化的评价体系。为智能制造教育与实践提供更全面的技术支持。

     

    Abstract: As a core practical course for equipment manufacturing majors, metalworking training plays a vital role in cultivating students' metal cutting capabilities. Traditional lathe operation training relies on manual vernier caliper measurements, which suffer from low efficiency, significant errors, and inconsistent evaluation criteria. To address these issues, this paper develops a machine vision-based intelligent scoring system for circular components, significantly enhancing detection efficiency and accuracy. The system hardware comprises a Daheng industrial camera, ring light source, and workstation frame, while the software leverages Halcon algorithm library with a Qt Creator-built interactive interface. The detection process involves four key stages: 1) High-precision image acquisition via industrial camera, ensuring image quality through camera calibration and distortion correction; 2) Image preprocessing using grayscale conversion, filtering, and noise reduction to eliminate surface scratch interference; 3) Precise geometric feature extraction through Canny operator edge detection combined with least squares contour fitting; 4) Dual-criteria automatic scoring: initial shape defect screening via circularity (Cr<0.75), followed by tolerance detection through subpixel-to-actual dimension conversion. Verified with 400 component tests, the system achieves dimensional errors below 0.06mm and reduces detection time to 1/5 of conventional methods. Real-time results display through the interface, with automatic Excel report generation for qualification rate statistics and grading. This system not only resolves subjective manual evaluation issues but also improves detection efficiency by 83% while establishing standardized assessment protocols. Future enhancements may incorporate multi-angle imaging for 3D detection accuracy and extend to complex features like threads and curved surfaces, providing comprehensive technical support for intelligent manufacturing education.

     

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