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基于改进BiSeNet的片烟加料机雾化效果实时监测系统

Real-Time Monitoring System for Atomization Effect of Tobacco Lamina Feeder Based on Improved BiSeNet

  • 摘要: 为解决片烟加料过程中喷嘴对料液的雾化效果无法实时监测的问题,设计一种基于深度学习的实时视觉监测系统。该系统集成图像采集模块、图像处理模块与在线报警模块,实时采集喷嘴雾化图像,其中图像处理模块利用形态学处理与改进轻量化语义分割模型(LightBiSeUNet)提取雾化特征。该模型以非对称的双路径并行架构(细节分支与语义分支)为基础,通过引入轻量化深度可分离卷积(LightConv Block)、 SE(Squeeze-and-Excitation)通道注意力机制以及全局上下文增强模块(GAP Enhance),有效抑制滚筒高亮背景等复杂干扰,实现对不规则雾化边缘的自适应聚焦。实验结果表明,LightBiSeUNet 模型平均交并比(MIoU)达99.57% ,参数量仅约 0.11 M,可对高速相机采集的雾化图像进行逐帧全量精准分割。与U-Net、MobileUNet 及 BiSeNet 等模型的对比进一步验证了其在分割精度与抗过拟合能力上的优越性。柳州卷烟厂工业产线应用显示,基于该视觉系统高频反馈的闭环控制使加料机具备对瞬态异常的秒级干预能力,片烟加料均匀性变异系数(CV 值)由 4.80%降至 2.24%。该方法不仅实现了雾化效果的实时精准监测,也为工业图像分割的实时化与轻量化部署提供了新的思路。

     

    Abstract: To address the issue of real-time monitoring of the atomization effect of the nozzle on the material liquid during the tobacco lamina feeding process, a real-time visual monitoring system based on deep learning is designed. This system integrates an image acquisition module, an image processing module, and an online alarm module to capture real-time images of nozzle atomization. The image processing module utilizes morphological processing and an improved lightweight semantic segmentation model (LightBiSeUNet) to extract atomization features. Based on an asymmetric dual-path parallel architecture (detail branch and semantic branch), this model effectively suppresses complex interferences such as the bright background of the roller by introducing lightweight depthwise separable convolution (LightConvBlock), Squeeze-and-Excitation (SE) channel attention mechanism, and global average pooling (GAP) enhancement module, achieving adaptive focusing on irregular atomization edges. Experimental results show that the LightBiSeUNet model achieves an average mean intersection over union (MIoU) of 99.57% with only about 0.11M parameters, enabling full and precise segmentation of atomization images captured by a high-speed camera frame by frame. Comparisons with models such as U-Net, MobileUNet, and BiSeNet further verify its superiority in segmentation accuracy and resistance to overfitting. The application in the industrial production line of Liuzhou Cigarette Factory demonstrates that the closed-loop control based on high-frequency feedback from this visual system enables the feeder to intervene in real-time for transient anomalies, reducing the coefficient of variation (CV value) of tobacco lamina feeding uniformity from 4.80% to 2.24%. This method not only achieves real-time precise monitoring of atomization effects but also provides new ideas for the real-time and lightweight deployment of industrial image segmentation.

     

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