李伟
404 lines
16 KiB
C#
404 lines
16 KiB
C#
// ============================================================================
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// Copyright © 2026 Hexagon Technology Center GmbH. All Rights Reserved.
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// 文件名: BgaVoidRateProcessor.cs
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// 描述: BGA 空洞率检测算子（两步自动检测法）
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//
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// 处理流程:
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// 第一步 — 焊球定位: 高斯模糊 → Otsu反向二值化 → 闭运算 → 轮廓检测 → 圆度过滤 → 椭圆拟合
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// 第二步 — 气泡检测: 焊球轮廓掩码 → 双阈值分割 → 轮廓检测 → 面积过滤 → 气泡率计算
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//
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// 支持多边形ROI限定检测区域，支持IPC-7095标准PASS/FAIL判定
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// 正片模式：焊球=暗区域，气泡=亮区域
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//
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// 作者: 李伟 wei.lw.li@hexagon.com
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// ============================================================================
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using Emgu.CV;
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using Emgu.CV.CvEnum;
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using Emgu.CV.Structure;
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using Emgu.CV.Util;
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using XP.ImageProcessing.Core;
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using Serilog;
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using System.Drawing;
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namespace XP.ImageProcessing.Processors;
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public class BgaVoidRateProcessor : ImageProcessorBase
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{
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private static readonly ILogger _logger = Log.ForContext<BgaVoidRateProcessor>();
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public BgaVoidRateProcessor()
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{
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Name = LocalizationHelper.GetString("BgaVoidRateProcessor_Name");
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Description = LocalizationHelper.GetString("BgaVoidRateProcessor_Description");
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}
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protected override void InitializeParameters()
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{
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// ── ROI限定区域 ──
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Parameters.Add("RoiMode", new ProcessorParameter(
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"RoiMode",
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LocalizationHelper.GetString("BgaVoidRateProcessor_RoiMode"),
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typeof(string), "None", null, null,
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LocalizationHelper.GetString("BgaVoidRateProcessor_RoiMode_Desc"),
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new string[] { "None", "Polygon" }));
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// 多边形ROI点数和坐标（由UI注入，不可见，最多支持32个点）
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Parameters.Add("PolyCount", new ProcessorParameter("PolyCount", "PolyCount", typeof(int), 0, null, null, "") { IsVisible = false });
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for (int i = 0; i < 32; i++)
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{
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Parameters.Add($"PolyX{i}", new ProcessorParameter($"PolyX{i}", $"PolyX{i}", typeof(int), 0, null, null, "") { IsVisible = false });
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Parameters.Add($"PolyY{i}", new ProcessorParameter($"PolyY{i}", $"PolyY{i}", typeof(int), 0, null, null, "") { IsVisible = false });
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}
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// ── 第一步：BGA定位参数 ──
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Parameters.Add("BgaMinArea", new ProcessorParameter(
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"BgaMinArea",
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LocalizationHelper.GetString("BgaVoidRateProcessor_BgaMinArea"),
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typeof(int), 500, 10, 1000000,
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LocalizationHelper.GetString("BgaVoidRateProcessor_BgaMinArea_Desc")));
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Parameters.Add("BgaMaxArea", new ProcessorParameter(
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"BgaMaxArea",
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LocalizationHelper.GetString("BgaVoidRateProcessor_BgaMaxArea"),
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typeof(int), 500000, 100, 10000000,
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LocalizationHelper.GetString("BgaVoidRateProcessor_BgaMaxArea_Desc")));
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Parameters.Add("BgaBlurSize", new ProcessorParameter(
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"BgaBlurSize",
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LocalizationHelper.GetString("BgaVoidRateProcessor_BgaBlurSize"),
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typeof(int), 5, 1, 31,
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LocalizationHelper.GetString("BgaVoidRateProcessor_BgaBlurSize_Desc")));
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Parameters.Add("BgaCircularity", new ProcessorParameter(
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"BgaCircularity",
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LocalizationHelper.GetString("BgaVoidRateProcessor_BgaCircularity"),
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typeof(double), 0.5, 0.0, 1.0,
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LocalizationHelper.GetString("BgaVoidRateProcessor_BgaCircularity_Desc")));
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// ── 第二步：气泡检测参数 ──
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Parameters.Add("MinThreshold", new ProcessorParameter(
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"MinThreshold",
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LocalizationHelper.GetString("BgaVoidRateProcessor_MinThreshold"),
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typeof(int), 128, 0, 255,
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LocalizationHelper.GetString("BgaVoidRateProcessor_MinThreshold_Desc")));
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Parameters.Add("MaxThreshold", new ProcessorParameter(
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"MaxThreshold",
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LocalizationHelper.GetString("BgaVoidRateProcessor_MaxThreshold"),
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typeof(int), 255, 0, 255,
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LocalizationHelper.GetString("BgaVoidRateProcessor_MaxThreshold_Desc")));
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Parameters.Add("MinVoidArea", new ProcessorParameter(
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"MinVoidArea",
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LocalizationHelper.GetString("BgaVoidRateProcessor_MinVoidArea"),
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typeof(int), 10, 1, 10000,
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LocalizationHelper.GetString("BgaVoidRateProcessor_MinVoidArea_Desc")));
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Parameters.Add("VoidLimit", new ProcessorParameter(
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"VoidLimit",
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LocalizationHelper.GetString("BgaVoidRateProcessor_VoidLimit"),
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typeof(double), 25.0, 0.0, 100.0,
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LocalizationHelper.GetString("BgaVoidRateProcessor_VoidLimit_Desc")));
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Parameters.Add("Thickness", new ProcessorParameter(
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"Thickness",
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LocalizationHelper.GetString("BgaVoidRateProcessor_Thickness"),
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typeof(int), 2, 1, 10,
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LocalizationHelper.GetString("BgaVoidRateProcessor_Thickness_Desc")));
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}
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public override Image<Gray, byte> Process(Image<Gray, byte> inputImage)
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{
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string roiMode = GetParameter<string>("RoiMode");
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int bgaMinArea = GetParameter<int>("BgaMinArea");
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int bgaMaxArea = GetParameter<int>("BgaMaxArea");
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int bgaBlurSize = GetParameter<int>("BgaBlurSize");
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double bgaCircularity = GetParameter<double>("BgaCircularity");
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int minThresh = GetParameter<int>("MinThreshold");
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int maxThresh = GetParameter<int>("MaxThreshold");
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int minVoidArea = GetParameter<int>("MinVoidArea");
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double voidLimit = GetParameter<double>("VoidLimit");
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int thickness = GetParameter<int>("Thickness");
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// 确保模糊核为奇数
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if (bgaBlurSize % 2 == 0) bgaBlurSize++;
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OutputData.Clear();
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int w = inputImage.Width, h = inputImage.Height;
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// 构建ROI掩码（限定检测区域）
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Image<Gray, byte>? roiMask = null;
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if (roiMode == "Polygon")
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{
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int polyCount = GetParameter<int>("PolyCount");
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if (polyCount >= 3)
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{
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var pts = new Point[polyCount];
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for (int i = 0; i < polyCount; i++)
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pts[i] = new Point(GetParameter<int>($"PolyX{i}"), GetParameter<int>($"PolyY{i}"));
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roiMask = new Image<Gray, byte>(w, h);
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using var vop = new VectorOfPoint(pts);
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using var vvop = new VectorOfVectorOfPoint(vop);
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CvInvoke.DrawContours(roiMask, vvop, 0, new MCvScalar(255), -1);
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_logger.Debug("ROI Polygon: {Count} points", polyCount);
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}
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}
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OutputData["RoiMode"] = roiMode;
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OutputData["RoiMask"] = roiMask;
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_logger.Debug("BgaVoidRate 两步法: BgaArea=[{Min},{Max}], Blur={Blur}, Circ={Circ}, Thresh=[{TMin},{TMax}]",
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bgaMinArea, bgaMaxArea, bgaBlurSize, bgaCircularity, minThresh, maxThresh);
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// ================================================================
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// 第一步：自动检测BGA焊球位置
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// ================================================================
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var bgaResults = DetectBgaBalls(inputImage, bgaBlurSize, bgaMinArea, bgaMaxArea, bgaCircularity, roiMask);
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_logger.Information("第一步完成: 检测到 {Count} 个BGA焊球", bgaResults.Count);
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if (bgaResults.Count == 0)
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{
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OutputData["BgaVoidResult"] = true;
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OutputData["BgaCount"] = 0;
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OutputData["BgaBalls"] = bgaResults;
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OutputData["VoidRate"] = 0.0;
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OutputData["Classification"] = "N/A";
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OutputData["ResultText"] = "No BGA detected";
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OutputData["Thickness"] = thickness;
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OutputData["VoidLimit"] = voidLimit;
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OutputData["TotalBgaArea"] = 0;
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OutputData["TotalVoidArea"] = 0;
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OutputData["TotalVoidCount"] = 0;
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roiMask?.Dispose();
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return inputImage.Clone();
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}
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// ================================================================
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// 第二步：在每个焊球区域内检测气泡
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// ================================================================
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int totalBgaArea = 0;
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int totalVoidArea = 0;
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int totalVoidCount = 0;
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foreach (var bga in bgaResults)
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{
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DetectVoidsInBga(inputImage, bga, minThresh, maxThresh, minVoidArea);
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totalBgaArea += bga.BgaArea;
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totalVoidArea += bga.VoidPixels;
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totalVoidCount += bga.Voids.Count;
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}
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double overallVoidRate = totalBgaArea > 0 ? (double)totalVoidArea / totalBgaArea * 100.0 : 0;
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string classification = overallVoidRate <= voidLimit ? "PASS" : "FAIL";
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// 检查每个焊球是否单独超标
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foreach (var bga in bgaResults)
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{
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bga.Classification = bga.VoidRate <= voidLimit ? "PASS" : "FAIL";
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}
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_logger.Information("第二步完成: 总气泡率={VoidRate:F1}%, 气泡数={Count}, 判定={Class}",
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overallVoidRate, totalVoidCount, classification);
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// 输出数据
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OutputData["BgaVoidResult"] = true;
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OutputData["BgaCount"] = bgaResults.Count;
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OutputData["BgaBalls"] = bgaResults;
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OutputData["VoidRate"] = overallVoidRate;
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OutputData["FillRate"] = 100.0 - overallVoidRate;
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OutputData["TotalBgaArea"] = totalBgaArea;
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OutputData["TotalVoidArea"] = totalVoidArea;
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OutputData["TotalVoidCount"] = totalVoidCount;
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OutputData["VoidLimit"] = voidLimit;
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OutputData["Classification"] = classification;
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OutputData["Thickness"] = thickness;
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OutputData["ResultText"] = $"Void: {overallVoidRate:F1}% | {classification} | BGA×{bgaResults.Count}";
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roiMask?.Dispose();
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return inputImage.Clone();
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}
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/// <summary>
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/// 第一步：自动检测BGA焊球位置
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/// 使用Otsu二值化 + 轮廓检测 + 圆度过滤 + 椭圆拟合
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/// </summary>
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private List<BgaBallInfo> DetectBgaBalls(Image<Gray, byte> input, int blurSize, int minArea, int maxArea, double minCircularity, Image<Gray, byte>? roiMask)
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{
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var results = new List<BgaBallInfo>();
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int w = input.Width, h = input.Height;
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// 高斯模糊降噪
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var blurred = new Image<Gray, byte>(w, h);
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CvInvoke.GaussianBlur(input, blurred, new Size(blurSize, blurSize), 0);
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// Otsu自动二值化（X-Ray正片：焊球=暗区域）
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var binary = new Image<Gray, byte>(w, h);
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CvInvoke.Threshold(blurred, binary, 0, 255, ThresholdType.Otsu | ThresholdType.BinaryInv);
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// 如果有ROI掩码，只保留ROI区域内的二值化结果
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if (roiMask != null)
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{
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CvInvoke.BitwiseAnd(binary, roiMask, binary);
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}
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// 形态学闭运算填充小孔洞
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var kernel = CvInvoke.GetStructuringElement(ElementShape.Ellipse, new Size(5, 5), new Point(-1, -1));
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CvInvoke.MorphologyEx(binary, binary, MorphOp.Close, kernel, new Point(-1, -1), 2, BorderType.Default, new MCvScalar(0));
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// 查找轮廓
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using var contours = new VectorOfVectorOfPoint();
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using var hierarchy = new Mat();
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CvInvoke.FindContours(binary, contours, hierarchy, RetrType.External, ChainApproxMethod.ChainApproxSimple);
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int bgaIndex = 0;
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for (int i = 0; i < contours.Size; i++)
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{
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double area = CvInvoke.ContourArea(contours[i]);
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if (area < minArea || area > maxArea) continue;
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// 圆度过滤: circularity = 4π × area / perimeter²
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double perimeter = CvInvoke.ArcLength(contours[i], true);
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if (perimeter < 1) continue;
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double circularity = 4.0 * Math.PI * area / (perimeter * perimeter);
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if (circularity < minCircularity) continue;
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// 需要至少5个点才能拟合椭圆
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if (contours[i].Size < 5) continue;
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var ellipse = CvInvoke.FitEllipse(contours[i]);
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var moments = CvInvoke.Moments(contours[i]);
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if (moments.M00 < 1) continue;
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bgaIndex++;
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results.Add(new BgaBallInfo
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{
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Index = bgaIndex,
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CenterX = moments.M10 / moments.M00,
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CenterY = moments.M01 / moments.M00,
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FittedEllipse = ellipse,
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ContourPoints = contours[i].ToArray(),
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BgaArea = (int)area,
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Circularity = circularity
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});
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}
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// 按面积从大到小排序
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results.Sort((a, b) => b.BgaArea.CompareTo(a.BgaArea));
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for (int i = 0; i < results.Count; i++) results[i].Index = i + 1;
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blurred.Dispose();
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binary.Dispose();
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kernel.Dispose();
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return results;
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}
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/// <summary>
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/// 第二步：在单个BGA焊球区域内检测气泡
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/// 使用焊球轮廓作为掩码，双阈值分割气泡区域
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/// </summary>
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private void DetectVoidsInBga(Image<Gray, byte> input, BgaBallInfo bga, int minThresh, int maxThresh, int minVoidArea)
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{
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int w = input.Width, h = input.Height;
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// 创建该焊球的掩码
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var mask = new Image<Gray, byte>(w, h);
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using (var vop = new VectorOfPoint(bga.ContourPoints))
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using (var vvop = new VectorOfVectorOfPoint(vop))
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{
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CvInvoke.DrawContours(mask, vvop, 0, new MCvScalar(255), -1);
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}
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int bgaPixels = CvInvoke.CountNonZero(mask);
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bga.BgaArea = bgaPixels;
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// 双阈值分割（正片模式：气泡=亮，灰度在[minThresh, maxThresh]范围内判为气泡）
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var voidImg = new Image<Gray, byte>(w, h);
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byte[,,] srcData = input.Data;
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byte[,,] dstData = voidImg.Data;
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byte[,,] maskData = mask.Data;
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for (int y = 0; y < h; y++)
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{
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for (int x = 0; x < w; x++)
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{
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if (maskData[y, x, 0] > 0)
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{
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byte val = srcData[y, x, 0];
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dstData[y, x, 0] = (val >= minThresh && val <= maxThresh) ? (byte)255 : (byte)0;
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}
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}
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}
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int voidPixels = CvInvoke.CountNonZero(voidImg);
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bga.VoidPixels = voidPixels;
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bga.VoidRate = bgaPixels > 0 ? (double)voidPixels / bgaPixels * 100.0 : 0;
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// 检测每个气泡的轮廓
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using var contours = new VectorOfVectorOfPoint();
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using var hierarchy = new Mat();
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CvInvoke.FindContours(voidImg, contours, hierarchy, RetrType.External, ChainApproxMethod.ChainApproxSimple);
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for (int i = 0; i < contours.Size; i++)
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{
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double area = CvInvoke.ContourArea(contours[i]);
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if (area < minVoidArea) continue;
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var moments = CvInvoke.Moments(contours[i]);
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if (moments.M00 < 1) continue;
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bga.Voids.Add(new VoidInfo
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{
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Index = bga.Voids.Count + 1,
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CenterX = moments.M10 / moments.M00,
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CenterY = moments.M01 / moments.M00,
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Area = area,
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AreaPercent = bgaPixels > 0 ? area / bgaPixels * 100.0 : 0,
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BoundingBox = CvInvoke.BoundingRectangle(contours[i]),
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ContourPoints = contours[i].ToArray()
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});
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}
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// 按面积从大到小排序
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bga.Voids.Sort((a, b) => b.Area.CompareTo(a.Area));
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for (int i = 0; i < bga.Voids.Count; i++) bga.Voids[i].Index = i + 1;
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mask.Dispose();
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voidImg.Dispose();
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}
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}
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/// <summary>
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/// 单个BGA焊球信息
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/// </summary>
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public class BgaBallInfo
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{
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public int Index { get; set; }
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public double CenterX { get; set; }
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public double CenterY { get; set; }
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public RotatedRect FittedEllipse { get; set; }
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public Point[] ContourPoints { get; set; } = Array.Empty<Point>();
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public int BgaArea { get; set; }
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public double Circularity { get; set; }
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public int VoidPixels { get; set; }
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public double VoidRate { get; set; }
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public string Classification { get; set; } = "N/A";
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public List<VoidInfo> Voids { get; set; } = new();
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}
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/// <summary>
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/// 单个气泡信息
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/// </summary>
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public class VoidInfo
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{
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public int Index { get; set; }
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public double CenterX { get; set; }
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public double CenterY { get; set; }
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public double Area { get; set; }
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public double AreaPercent { get; set; }
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public Rectangle BoundingBox { get; set; }
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public Point[] ContourPoints { get; set; } = Array.Empty<Point>();
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}
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