feat: 改进BGA焊点和气泡检测算法，提升复杂背景下的检测精度

- 焊点检测：增加开运算去噪、闭运算改为1次减少粘连、提高默认圆度阈值0.6 - 新增焊球最小中心距过滤和面积一致性过滤，去除粘连和背景误检 - 气泡检测：新增自适应阈值，基于焊球内部灰度分布自动计算阈值 - BGA检测面板增加新参数控件：自适应阈值开关、阈值百分位、中心距、面积一致性
2026-07-21 13:31:51 +08:00
parent 26a0f5bf00
commit 38471bf510
3 changed files with 142 additions and 15 deletions
@@ -82,10 +82,30 @@ public class BgaVoidRateProcessor : ImageProcessorBase<ushort>
        Parameters.Add("BgaCircularity", new ProcessorParameter(
            "BgaCircularity",
            LocalizationHelper.GetString("BgaVoidRateProcessor_BgaCircularity"),
-            typeof(double), 0.5, 0.0, 1.0,
+            typeof(double), 0.6, 0.0, 1.0,
            LocalizationHelper.GetString("BgaVoidRateProcessor_BgaCircularity_Desc")));

+        Parameters.Add("BgaMinCenterDistance", new ProcessorParameter(
+            "BgaMinCenterDistance",
+            "焊球最小中心距", typeof(int), 0, 0, 5000,
+            "焊球中心之间的最小距离(像素)，0=不启用。用于去除粘连和背景误检"));
+
+        Parameters.Add("BgaAreaConsistency", new ProcessorParameter(
+            "BgaAreaConsistency",
+            "焊球面积一致性", typeof(double), 0.5, 0.0, 1.0,
+            "焊球面积一致性系数(0-1)，去除与均值偏差过大的离群焊球。0=不启用"));
+
        // ── 第二步：气泡检测参数（阈值 0-65535）──
+        Parameters.Add("UseAdaptiveThreshold", new ProcessorParameter(
+            "UseAdaptiveThreshold",
+            "自适应阈值", typeof(bool), false, null, null,
+            "启用自适应阈值后，每个焊球的气泡阈值根据其内部灰度分布自动计算"));
+
+        Parameters.Add("VoidThresholdPercentile", new ProcessorParameter(
+            "VoidThresholdPercentile",
+            "气泡阈值百分位", typeof(double), 80.0, 0.0, 100.0,
+            "自适应阈值百分位(0-100)，例如80表示取焊球内部灰度第80百分位作为气泡阈值"));
+
        Parameters.Add("MinThreshold", new ProcessorParameter(
            "MinThreshold",
            LocalizationHelper.GetString("BgaVoidRateProcessor_MinThreshold"),
@@ -131,6 +151,10 @@ public class BgaVoidRateProcessor : ImageProcessorBase<ushort>
        double bgaCircularity = GetParameter<double>("BgaCircularity");
        int bgaThreshLow = GetParameter<int>("BgaThresholdLow");
        int bgaThreshHigh = GetParameter<int>("BgaThresholdHigh");
+        int bgaMinCenterDist = GetParameter<int>("BgaMinCenterDistance");
+        double bgaAreaConsistency = GetParameter<double>("BgaAreaConsistency");
+        bool useAdaptiveThreshold = GetParameter<bool>("UseAdaptiveThreshold");
+        double voidThresholdPercentile = GetParameter<double>("VoidThresholdPercentile");
        int minThresh = GetParameter<int>("MinThreshold");
        int maxThresh = GetParameter<int>("MaxThreshold");
        int minVoidArea = GetParameter<int>("MinVoidArea");
@@ -166,7 +190,7 @@ public class BgaVoidRateProcessor : ImageProcessorBase<ushort>
        // 第一步：BGA焊球定位（在 16 位图上做双阈值分割）
        // ================================================================
        var bgaResults = DetectBgaBalls(inputImage, bgaBlurSize, bgaMinArea, bgaMaxArea,
-            bgaCircularity, bgaThreshLow, bgaThreshHigh, roiMask);
+            bgaCircularity, bgaThreshLow, bgaThreshHigh, bgaMinCenterDist, bgaAreaConsistency, roiMask);

        _logger.Information("第一步完成: 检测到 {Count} 个BGA焊球", bgaResults.Count);

@@ -196,7 +220,8 @@ public class BgaVoidRateProcessor : ImageProcessorBase<ushort>

        foreach (var bga in bgaResults)
        {
-            DetectVoidsInBga(inputImage, bga, minThresh, maxThresh, minVoidArea);
+            DetectVoidsInBga(inputImage, bga, minThresh, maxThresh, minVoidArea,
+                useAdaptiveThreshold, voidThresholdPercentile);
            totalBgaArea += bga.BgaArea;
            totalVoidArea += bga.VoidPixels;
            totalVoidCount += bga.Voids.Count;
@@ -229,12 +254,14 @@ public class BgaVoidRateProcessor : ImageProcessorBase<ushort>
    }

    /// <summary>
-    /// 第一步：BGA焊球定位（16 位双阈值分割 → 8 位二值图 → FindContours）
+    /// 第一步：BGA焊球定位（16 位双阈值分割 → 8 位二值图 → 形态学 → FindContours → 过滤）
+    /// 改进：增加开运算去噪、闭运算1次防粘连、距离过滤、面积一致性过滤
    /// </summary>
    private List<BgaBallInfo> DetectBgaBalls(
        Image<Gray, ushort> input, int blurSize,
        int minArea, int maxArea, double minCircularity,
-        int threshLow, int threshHigh, Image<Gray, byte>? roiMask)
+        int threshLow, int threshHigh, int minCenterDist, double areaConsistency,
+        Image<Gray, byte>? roiMask)
    {
        var results = new List<BgaBallInfo>();
        int w = input.Width, h = input.Height;
@@ -258,9 +285,13 @@ public class BgaVoidRateProcessor : ImageProcessorBase<ushort>
        if (roiMask != null)
            CvInvoke.BitwiseAnd(binary, roiMask, binary);

-        // 形态学闭运算
        using var kernel = CvInvoke.GetStructuringElement(ElementShape.Ellipse, new Size(5, 5), new Point(-1, -1));
-        CvInvoke.MorphologyEx(binary, binary, MorphOp.Close, kernel, new Point(-1, -1), 2, BorderType.Default, new MCvScalar(0));
+
+        // 开运算去除小噪点（先腐蚀后膨胀）
+        CvInvoke.MorphologyEx(binary, binary, MorphOp.Open, kernel, new Point(-1, -1), 1, BorderType.Default, new MCvScalar(0));
+
+        // 闭运算填补焊球内部小孔（迭代1次，减少粘连）
+        CvInvoke.MorphologyEx(binary, binary, MorphOp.Close, kernel, new Point(-1, -1), 1, BorderType.Default, new MCvScalar(0));

        // 轮廓检测
        using var contours = new VectorOfVectorOfPoint();
@@ -297,6 +328,39 @@ public class BgaVoidRateProcessor : ImageProcessorBase<ushort>
            });
        }

+        // ── 距离过滤：去除中心距过近的粘连轮廓 ──
+        if (minCenterDist > 0 && results.Count > 1)
+        {
+            var filtered = new List<BgaBallInfo>();
+            foreach (var bga in results)
+            {
+                bool tooClose = false;
+                foreach (var other in filtered)
+                {
+                    double dx = bga.CenterX - other.CenterX;
+                    double dy = bga.CenterY - other.CenterY;
+                    double dist = Math.Sqrt(dx * dx + dy * dy);
+                    if (dist < minCenterDist)
+                    {
+                        tooClose = true;
+                        break;
+                    }
+                }
+                if (!tooClose)
+                    filtered.Add(bga);
+            }
+            results = filtered;
+        }
+
+        // ── 面积一致性过滤：去除与均值偏差过大的离群焊球 ──
+        if (areaConsistency > 0 && results.Count > 2)
+        {
+            double avgArea = results.Average(r => r.BgaArea);
+            double minAllowed = avgArea * (1.0 - areaConsistency);
+            double maxAllowed = avgArea * (1.0 + areaConsistency);
+            results = results.Where(r => r.BgaArea >= minAllowed && r.BgaArea <= maxAllowed).ToList();
+        }
+
        results.Sort((a, b) => b.BgaArea.CompareTo(a.BgaArea));
        for (int i = 0; i < results.Count; i++) results[i].Index = i + 1;

@@ -308,8 +372,9 @@ public class BgaVoidRateProcessor : ImageProcessorBase<ushort>

    /// <summary>
    /// 第二步：在焊球区域内检测气泡（16 位双阈值分割 → 8 位二值图 → FindContours）
+    /// 改进：支持自适应阈值，基于焊球内部灰度分布自动计算气泡阈值
    /// </summary>
-    private void DetectVoidsInBga(Image<Gray, ushort> input, BgaBallInfo bga, int minThresh, int maxThresh, int minVoidArea)
+    private void DetectVoidsInBga(Image<Gray, ushort> input, BgaBallInfo bga, int minThresh, int maxThresh, int minVoidArea, bool useAdaptiveThreshold, double thresholdPercentile)
    {
        int w = input.Width, h = input.Height;

@@ -324,19 +389,45 @@ public class BgaVoidRateProcessor : ImageProcessorBase<ushort>
        int bgaPixels = CvInvoke.CountNonZero(mask);
        bga.BgaArea = bgaPixels;

+        // 确定气泡阈值
+        int effectiveMinThresh = minThresh;
+        int effectiveMaxThresh = maxThresh;
+
+        if (useAdaptiveThreshold && bgaPixels > 0)
+        {
+            // 收集焊球内部所有像素灰度值
+            var grayValues = new List<ushort>();
+            var srcData = input.Data;
+            var maskData = mask.Data;
+
+            for (int y = 0; y < h; y++)
+                for (int x = 0; x < w; x++)
+                    if (maskData[y, x, 0] > 0)
+                        grayValues.Add(srcData[y, x, 0]);
+
+            if (grayValues.Count > 0)
+            {
+                grayValues.Sort();
+                int percentileIndex = (int)(grayValues.Count * thresholdPercentile / 100.0);
+                percentileIndex = Math.Min(percentileIndex, grayValues.Count - 1);
+                effectiveMinThresh = grayValues[percentileIndex];
+                effectiveMaxThresh = 65535;
+            }
+        }
+
        // 在 16 位图上做双阈值分割，输出 8 位二值图
        var voidImg = new Image<Gray, byte>(w, h);
-        var srcData = input.Data;
+        var srcData2 = input.Data;
        var dstData = voidImg.Data;
-        var maskData = mask.Data;
+        var maskData2 = mask.Data;

        for (int y = 0; y < h; y++)
            for (int x = 0; x < w; x++)
            {
-                if (maskData[y, x, 0] > 0)
+                if (maskData2[y, x, 0] > 0)
                {
-                    ushort val = srcData[y, x, 0];
-                    dstData[y, x, 0] = (val >= minThresh && val <= maxThresh) ? (byte)255 : (byte)0;
+                    ushort val = srcData2[y, x, 0];
+                    dstData[y, x, 0] = (val >= effectiveMinThresh && val <= effectiveMaxThresh) ? (byte)255 : (byte)0;
                }
            }

@@ -79,9 +79,15 @@ namespace XplorePlane.ViewModels.ImageProcessing
        private int _blurSize = 5;
        public int BlurSize { get => _blurSize; set => SetProperty(ref _blurSize, value); }

-        private double _circularity = 0.5;
+        private double _circularity = 0.6;
        public double Circularity { get => _circularity; set => SetProperty(ref _circularity, value); }

+        private int _bgaMinCenterDistance = 0;
+        public int BgaMinCenterDistance { get => _bgaMinCenterDistance; set => SetProperty(ref _bgaMinCenterDistance, value); }
+
+        private double _bgaAreaConsistency = 0.5;
+        public double BgaAreaConsistency { get => _bgaAreaConsistency; set => SetProperty(ref _bgaAreaConsistency, value); }
+
        // BGA定位阈值参数
        private int _bgaThresholdLow = 0;
        public int BgaThresholdLow { get => _bgaThresholdLow; set => SetProperty(ref _bgaThresholdLow, value); }
@@ -96,6 +102,12 @@ namespace XplorePlane.ViewModels.ImageProcessing
        private int _maxThreshold = 65535;
        public int MaxThreshold { get => _maxThreshold; set => SetProperty(ref _maxThreshold, value); }

+        private bool _useAdaptiveThreshold = false;
+        public bool UseAdaptiveThreshold { get => _useAdaptiveThreshold; set => SetProperty(ref _useAdaptiveThreshold, value); }
+
+        private double _voidThresholdPercentile = 80.0;
+        public double VoidThresholdPercentile { get => _voidThresholdPercentile; set => SetProperty(ref _voidThresholdPercentile, value); }
+
        private int _minVoidArea = 10;
        public int MinVoidArea { get => _minVoidArea; set => SetProperty(ref _minVoidArea, value); }

@@ -315,6 +327,10 @@ namespace XplorePlane.ViewModels.ImageProcessing
                processor.SetParameter("BgaCircularity", Circularity);
                processor.SetParameter("BgaThresholdLow", BgaThresholdLow);
                processor.SetParameter("BgaThresholdHigh", BgaThresholdHigh);
+                processor.SetParameter("BgaMinCenterDistance", BgaMinCenterDistance);
+                processor.SetParameter("BgaAreaConsistency", BgaAreaConsistency);
+                processor.SetParameter("UseAdaptiveThreshold", UseAdaptiveThreshold);
+                processor.SetParameter("VoidThresholdPercentile", VoidThresholdPercentile);
                processor.SetParameter("MinThreshold", MinThreshold);
                processor.SetParameter("MaxThreshold", MaxThreshold);
                processor.SetParameter("MinVoidArea", MinVoidArea);
@@ -471,6 +487,10 @@ namespace XplorePlane.ViewModels.ImageProcessing
            parameters["BgaCircularity"] = Circularity;
            parameters["BgaThresholdLow"] = BgaThresholdLow;
            parameters["BgaThresholdHigh"] = BgaThresholdHigh;
+            parameters["BgaMinCenterDistance"] = BgaMinCenterDistance;
+            parameters["BgaAreaConsistency"] = BgaAreaConsistency;
+            parameters["UseAdaptiveThreshold"] = UseAdaptiveThreshold;
+            parameters["VoidThresholdPercentile"] = VoidThresholdPercentile;
            parameters["MinThreshold"] = MinThreshold;
            parameters["MaxThreshold"] = MaxThreshold;
            parameters["MinVoidArea"] = MinVoidArea;
@@ -114,10 +114,20 @@
                            <Slider Minimum="1" Maximum="31" Value="{Binding BlurSize}" VerticalAlignment="Center" />
                        </DockPanel>
                        <TextBlock Text="圆度阈值" Style="{StaticResource ParamLabel}" />
-                        <DockPanel>
+                        <DockPanel Margin="0,0,0,6">
                            <TextBox DockPanel.Dock="Right" Width="55" Text="{Binding Circularity, StringFormat=F2, UpdateSourceTrigger=PropertyChanged}" VerticalContentAlignment="Center" Margin="6,0,0,0" />
                            <Slider Minimum="0" Maximum="1" Value="{Binding Circularity}" SmallChange="0.01" LargeChange="0.1" VerticalAlignment="Center" />
                        </DockPanel>
+                        <TextBlock Text="焊球最小中心距" Style="{StaticResource ParamLabel}" />
+                        <DockPanel Margin="0,0,0,6">
+                            <TextBox DockPanel.Dock="Right" Width="55" Text="{Binding BgaMinCenterDistance, UpdateSourceTrigger=PropertyChanged}" VerticalContentAlignment="Center" Margin="6,0,0,0" />
+                            <Slider Minimum="0" Maximum="500" Value="{Binding BgaMinCenterDistance}" VerticalAlignment="Center" />
+                        </DockPanel>
+                        <TextBlock Text="焊球面积一致性" Style="{StaticResource ParamLabel}" />
+                        <DockPanel>
+                            <TextBox DockPanel.Dock="Right" Width="55" Text="{Binding BgaAreaConsistency, StringFormat=F2, UpdateSourceTrigger=PropertyChanged}" VerticalContentAlignment="Center" Margin="6,0,0,0" />
+                            <Slider Minimum="0" Maximum="1" Value="{Binding BgaAreaConsistency}" SmallChange="0.01" LargeChange="0.1" VerticalAlignment="Center" />
+                        </DockPanel>
                    </StackPanel>
                </Border>

@@ -125,6 +135,12 @@
                <Border Style="{StaticResource CardStyle}">
                    <StackPanel>
                        <TextBlock Text="气泡检测参数" FontWeight="SemiBold" FontSize="12" Margin="0,0,0,8" />
+                        <CheckBox IsChecked="{Binding UseAdaptiveThreshold}" Content="使用自适应阈值" FontSize="11" Margin="0,0,0,6" Foreground="#555" />
+                        <TextBlock Text="气泡阈值百分位" Style="{StaticResource ParamLabel}" />
+                        <DockPanel Margin="0,0,0,6">
+                            <TextBox DockPanel.Dock="Right" Width="55" Text="{Binding VoidThresholdPercentile, StringFormat=F1, UpdateSourceTrigger=PropertyChanged}" VerticalContentAlignment="Center" Margin="6,0,0,0" />
+                            <Slider Minimum="0" Maximum="100" Value="{Binding VoidThresholdPercentile}" VerticalAlignment="Center" />
+                        </DockPanel>
                        <TextBlock Text="最小灰度阈值" Style="{StaticResource ParamLabel}" />
                        <DockPanel Margin="0,0,0,6">
                            <TextBox DockPanel.Dock="Right" Width="55" Text="{Binding MinThreshold, UpdateSourceTrigger=PropertyChanged}" VerticalContentAlignment="Center" Margin="6,0,0,0" />