A Robust Texture-Less Gray-Scale Surface Matching Method Applied to a Liquid Crystal Display TV Diffuser Plate Assembly System

In most liquid crystal display (LCD) backlight modules (BLMs), diffuser plates (DPs) play the essential role in blurring the backlight. A common BLM consists of multiple superimposed optical films. In a vision-based automated assembly system, to ensure sufficient accuracy, each of the multiple cameras usually shoots a local corner of the DP and jointly estimates the target pose, guiding the robot to assemble the DP on the BLM. In general, DPs are typical of texture-less objects with simple shapes. Due to the image background of superimposed multilayer optical films, the robustness of the most common detection methods must be improved to meet industrial needs. To solve the above problem, a texture-less surface matching method based on gray-scale images was proposed. An augmented and normalized gray-scale vector represents the texture-less gray-scale surface in a low-dimensional space. The cosine distance is then used to calculate the similarity between the template and matching vectors, combined with shape-based matching (SBM); the proposed method can obtain high robustness when detecting DPs. An image database from actual production lines was used in the experiment. In comparative tests with the NCC, SBM, YOLOv5s, and YOLOv5x methods, our proposed method had the best precision at all confidence thresholds. Although recall was slightly inferior to SBM, the comprehensive evaluation F1-Score reached 0.826, significantly outperforming the other methods. Regarding localizing accuracy, our algorithm also performed best, reaching 5.7 pixels. Although the time consumption of a single prediction is about 0.6 s, it can still meet industrial needs. These experimental results show that the proposed method has high robustness in detecting DPs and is especially suitable for vision-based automatic assembly tasks in BLM.