修复：Notch测量坐标异常导致崩溃的问题，增强日志输出。 - 在 Notch_Process_Calculate 函数中，增加对坐标有效性的检查，避...

mrDarker

2025-07-10 479a65f7e29c06766a426756e1f5b9b7de498fa1

修复：Notch测量坐标异常导致崩溃的问题，增强日志输出。
- 在 Notch_Process_Calculate 函数中，增加对坐标有效性的检查，避免非法坐标（如 -1, -1）导致 OpenCV 函数异常崩溃；
- 当发现坐标异常时，记录错误日志，并跳过该测量点，防止程序崩溃；
- 增加超大测量值的日志记录（Dimension 或 Chamfer 大于 2000 um），进一步提高程序的稳定性；

 EdgeInspector_App/Process/InspectCamera.cpp

@@ -3720,13 +3720,6 @@

BOOL CInspectCamera::Notch_Process(int iThread,DimensionDir emDim, stFrameIndex stFrame)
{
    //CTime tCurrentTime = CTime::GetCurrentTime();
    //CTime tLimitTime = CTime(2023,3,31,11,59,59);
    //CTimeSpan tSpanTime = tLimitTime - tCurrentTime;

    //if(tSpanTime.GetTotalSeconds() < 0)
    //    return FALSE;

    if(m_pGlassData == NULL)
        return FALSE;

@@ -3782,24 +3775,20 @@
        pEdgeImage = cvCloneImage(pOriginImage);
        pBinImage = cvCloneImage(pOriginImage);

        g_pLog->DisplayMessage(_T("1. Notch_Process %s : %d, idx %d"),g_SideName[(int) emDim], stFrame.nFrameIdx,i);

        // 1. Image PreProcess..
        g_pLog->DisplayMessage(_T("1. Notch_Process %s : %d, idx %d"), g_SideName[(int)emDim], stFrame.nFrameIdx, i);
        Notch_Process_PreProcess(emDim, stFrame, i, pOriginImage, pEdgeImage, pBinImage, rtRotateArea);
        // Notch_Process_PreProcess_2(emDim, stFrame, i, pOriginImage, pEdgeImage, pBinImage, rtRotateArea);

        g_pLog->DisplayMessage(_T("2. Notch_Process %s : %d, idx %d"),g_SideName[(int) emDim], stFrame.nFrameIdx,i);

        // 2. Notch Dimension/Chamfer Find..
        g_pLog->DisplayMessage(_T("2. Notch_Process %s : %d, idx %d"), g_SideName[(int)emDim], stFrame.nFrameIdx, i);
        Notch_Process_Measure(emDim, stFrame, i, pOriginImage, pEdgeImage, pBinImage, rtRotateArea);

        g_pLog->DisplayMessage(_T("3. Notch_Process %s : %d, idx %d"),g_SideName[(int) emDim], stFrame.nFrameIdx,i);

        // 3. Notch Dimension/Chamfer Calculate Result..
        g_pLog->DisplayMessage(_T("3. Notch_Process %s : %d, idx %d"), g_SideName[(int)emDim], stFrame.nFrameIdx, i);
        bool bResult = Notch_Process_Calculate(emDim, stFrame, i, pOriginImage, pEdgeImage, pBinImage, rtRotateArea);

        g_pLog->DisplayMessage(_T("4. Notch_Process %s : %d, idx %d"),g_SideName[(int) emDim], stFrame.nFrameIdx,i);
        // 4. Notch Dimension/Chamfer Judge
        g_pLog->DisplayMessage(_T("4. Notch_Process %s : %d, idx %d"), g_SideName[(int)emDim], stFrame.nFrameIdx, i);
        Notch_Process_Judge(emDim, stFrame, i, pOriginImage, pEdgeImage, pBinImage, rtRotateArea);

        if (!bResult)
@@ -3822,21 +3811,19 @@

            pSideData->m_bNotchInspection_Complete = TRUE;

			

            return FALSE;
        }

        g_pLog->DisplayMessage(_T("5. Notch_Process %s : %d, idx %d"),g_SideName[(int) emDim], stFrame.nFrameIdx,i);
        // 5. Notch Defect Inspect (Chip/Crack)
        g_pLog->DisplayMessage(_T("5. Notch_Process %s : %d, idx %d"), g_SideName[(int)emDim], stFrame.nFrameIdx, i);
        Notch_Process_Defect(emDim, stFrame, i, pOriginImage, pEdgeImage, pBinImage, rtRotateArea);

        g_pLog->DisplayMessage(_T("6. Notch_Process %s : %d, idx %d"),g_SideName[(int) emDim], stFrame.nFrameIdx,i);
        // 6. Notch Find Circle
        g_pLog->DisplayMessage(_T("6. Notch_Process %s : %d, idx %d"), g_SideName[(int)emDim], stFrame.nFrameIdx, i);
        Notch_Process_FindCircle(emDim, stFrame, i);

        // 7. Notch Process End
        g_pLog->DisplayMessage(_T("7. Notch_Process %s : %d, idx %d"),g_SideName[(int) emDim], stFrame.nFrameIdx,i);

        cvReleaseImageHeader(&pOriginImage);
        cvReleaseImage(&pEdgeImage);
        cvReleaseImage(&pBinImage);
@@ -3844,79 +3831,47 @@

    pSideData->m_bNotchInspection_Complete = TRUE;

    g_pLog->DisplayMessage(_T("7. Notch_Process End %s : %d"),g_SideName[(int) emDim], stFrame.nFrameIdx);

    return TRUE;
}

void CInspectCamera::Notch_Process_PreProcess(DimensionDir emDim, stFrameIndex stFrame, int nNotchIdx, IplImage* scr, IplImage* img_Edge, IplImage* img_Bin, CRect rtROI)
{
    if(m_pRecipe == NULL)
    if (m_pRecipe == nullptr) {
        return;
    }

    if(nNotchIdx < 0 || MAX_SIDE_NOTCH_COUNT <= nNotchIdx)
    if (nNotchIdx < 0 || nNotchIdx >= MAX_SIDE_NOTCH_COUNT) {
        return;
    }

    CString strTemp;
    // 中值滤波器大小，用于去噪，必须为奇数（若偶数会自动减1）
    const int nSmoothFilter = m_pRecipe->m_SideParam[(int)emDim].m_NotchPrm[nNotchIdx].m_nSmooth_Filter;

    int sigma1 = m_pRecipe->m_SideParam[(int) emDim].m_NotchPrm[nNotchIdx].m_nSmooth_Filter;
    int sigma2 = 7;
    // 磨边区域阈值，控制反二值化阈值，主要用于提取 Notch 边缘特征
    const int nGrindThreshold = m_pRecipe->m_SideParam[(int)emDim].m_NotchPrm[nNotchIdx].m_nGrind_Threshold;

    if(sigma1 % 2 == 0)
        sigma1 = sigma1 - 1;
    // 玻璃区域阈值，控制正二值化阈值，用于提取玻璃主体区域
    const int nGlassThreshold = m_pRecipe->m_SideParam[(int)emDim].m_NotchPrm[nNotchIdx].m_nGlass_Threshold;

    if(1 < sigma1)
        cvSmooth(scr,img_Bin,CV_MEDIAN,sigma1);
    // 确保奇数滤波器大小
    int nFilterSize = (nSmoothFilter % 2 == 0) ? (nSmoothFilter - 1) : nSmoothFilter;

//     double th1 = (double) m_pRecipe->m_SideParam[(int) emDim].m_NotchPrm[nNotchIdx].m_nGrind_Threshold * 10;
//     double th2 = 40.0;
//     int sigma=5;
// 
//     cvCanny(img_Bin,img_Edge,th1,th2,sigma);
    if (nFilterSize > 1) {
        // 中值滤波降噪
        cvSmooth(scr, img_Bin, CV_MEDIAN, nFilterSize);
    }

    double th1 = (double) m_pRecipe->m_SideParam[(int) emDim].m_NotchPrm[nNotchIdx].m_nGrind_Threshold;
    // Edge图：反二值化阈值处理
    cvThreshold(scr, img_Edge, nGrindThreshold, 255, CV_THRESH_BINARY_INV);
    CString strEdgeFileName;
    strEdgeFileName.Format(_T("Notch\\Notch_%d_Edge.jpg"), nNotchIdx);
    SaveDebugImage(emDim, stFrame, img_Edge, strEdgeFileName);

    cvThreshold(scr,img_Edge,th1,255,CV_THRESH_BINARY_INV);
	                                               
    strTemp.Format(_T("Notch\\Notch_%d_Edge.jpg"), nNotchIdx);    
    SaveDebugImage(emDim, stFrame, img_Edge, strTemp);

    th1 = m_pRecipe->m_SideParam[(int) emDim].m_NotchPrm[nNotchIdx].m_nGlass_Threshold;

    cvThreshold(scr,img_Bin,th1,255,CV_THRESH_BINARY);

    strTemp.Format(_T("Notch\\Notch_%d_Bin.jpg"), nNotchIdx);
    SaveDebugImage(emDim, stFrame, img_Bin, strTemp);
}

void CInspectCamera::Notch_Process_PreProcess_2(DimensionDir emDim, stFrameIndex stFrame, int nNotchIdx, IplImage* scr, IplImage* img_Edge, IplImage* img_Bin, CRect rtROI)
{
    if(m_pRecipe == NULL)
        return;

    if(nNotchIdx < 0 || MAX_SIDE_NOTCH_COUNT <= nNotchIdx)
        return;

    int sigma1 = m_pRecipe->m_SideParam[(int) emDim].m_NotchPrm[nNotchIdx].m_nSmooth_Filter;

    CString strTemp;
    cvThreshold(scr,img_Edge,sigma1,255,CV_THRESH_BINARY_INV);

    double th1 = (double) m_pRecipe->m_SideParam[(int) emDim].m_NotchPrm[nNotchIdx].m_nGrind_Threshold;
    double th2 = 40.0;
    int sigma=5;

    cvCanny(img_Edge, img_Edge,th1,th2,sigma);

    strTemp.Format(_T("Notch\\Notch_%d_Edge.jpg"), nNotchIdx);
    SaveDebugImage(emDim, stFrame, img_Edge, strTemp);

    th1 = m_pRecipe->m_SideParam[(int) emDim].m_NotchPrm[nNotchIdx].m_nGlass_Threshold;

    cvThreshold(scr,img_Bin,th1,255,CV_THRESH_BINARY);

    strTemp.Format(_T("Notch\\Notch_%d_Bin.jpg"), nNotchIdx);
    SaveDebugImage(emDim, stFrame, img_Bin, strTemp);
    // Bin图：正常二值化
    cvThreshold(scr, img_Bin, nGlassThreshold, 255, CV_THRESH_BINARY);
    CString strBinFileName;
    strBinFileName.Format(_T("Notch\\Notch_%d_Bin.jpg"), nNotchIdx);
    SaveDebugImage(emDim, stFrame, img_Bin, strBinFileName);
}

void CInspectCamera::Notch_Process_Measure(DimensionDir emDim, stFrameIndex stFrame, int nNotchIdx, IplImage* scr,IplImage* img_Edge,IplImage* img_Bin, CRect rtROI)
@@ -4088,7 +4043,6 @@
                        break;
            }


            if(bEdgeCheck == FALSE && (bEdgeFind == TRUE || bBinEdgeFind == TRUE))
            {
                if(bFindEdge == FALSE && bEdgeFind == TRUE)
@@ -4156,6 +4110,21 @@
        CPoint ptDim_pxl = m_pGlassData->GetSideData(emDim)->m_ptNotch_Dimension_Edge[nNotchIdx][nMeasureIdx];
        CPoint ptChamfer_pxl = m_pGlassData->GetSideData(emDim)->m_ptNotch_Chamfer_Edge[nNotchIdx][nMeasureIdx];

        if (ptRef_pxl.x < 0 || ptRef_pxl.y < 0) {
            g_pLog->DisplayMessage(_T("[ERROR] Invalid Ref Point at Notch_Process_Calculate, NotchIdx: %d, MeasureIdx: %d, Point: (%d, %d)"), nNotchIdx, nMeasureIdx, ptRef_pxl.x, ptRef_pxl.y);
            continue;
        }
		
        if (ptDim_pxl.x < 0 || ptDim_pxl.y < 0) {
            g_pLog->DisplayMessage(_T("[ERROR] Invalid Dim Point at Notch_Process_Calculate, NotchIdx: %d, MeasureIdx: %d, Point: (%d, %d)"), nNotchIdx, nMeasureIdx, ptDim_pxl.x, ptDim_pxl.y);
            continue;
        }
		
        if (ptChamfer_pxl.x < 0 || ptChamfer_pxl.y < 0) {
            g_pLog->DisplayMessage(_T("[ERROR] Invalid Chamfer Point at Notch_Process_Calculate, NotchIdx: %d, MeasureIdx: %d, Point: (%d, %d)"), nNotchIdx, nMeasureIdx, ptChamfer_pxl.x, ptChamfer_pxl.y);
            continue;
        }

        // Dimension
        double dX_dim_um = (double)(ptRef_pxl.x - ptDim_pxl.x) * m_dPixelSizeX;
        double dY_dim_um = (double)(ptRef_pxl.y - ptDim_pxl.y) * m_dPixelSizeY;
@@ -4169,9 +4138,9 @@

        m_pGlassData->GetSideData(emDim)->m_dNotch_Chamfer_Edge_Result_um[nNotchIdx][nMeasureIdx] = dChamfer;

        if (dDimension > 2000 && dChamfer > 2000)
        {
            return FALSE;
        if (dDimension > 2000.0 && dChamfer > 2000.0) {
            g_pLog->DisplayMessage(_T("[ERROR] Abnormal Dimension & Chamfer too large at Notch_Process_Calculate, NotchIdx: %d, MeasureIdx: %d, Dimension: %.2f, Chamfer: %.2f"), nNotchIdx, nMeasureIdx, dDimension, dChamfer);
            continue;
        }
    }

@@ -4242,8 +4211,7 @@
            //选取测量研磨尺寸最大值
            if (m_nChamferOffset_um < dChamfer_um)
            {
                    m_nChamferOffset_um = dChamfer_um;
				
                m_nChamferOffset_um = dChamfer_um;
            }
            m_pGlassData->GetSideData(emDim)->m_dNotch_Chamfer_Edge_Result_Diff_um[nNotchIdx][nMeasureIdx] = dChamfer_std_um - dChamfer_um;
            m_pGlassData->GetSideData(emDim)->m_dNotch_Chamfer_Edge_Judge_Std_um[nNotchIdx][nMeasureIdx] = dChamfer_std_um;
@@ -4308,7 +4276,6 @@
    
    CString strTemp;
        
		
    int nSide = (int) emDim;
    int nThreshold = pNotchParam->m_nNotch_Inspect_Defect_Threshold;
    int nOffset = pNotchParam->m_nNotch_Inspect_Defect_Offset;
@@ -4353,8 +4320,7 @@
        vecDefectCandidateList.push_back(defectInfo);
    }
    m_pDefectControl->ExtractDefect_Notch(emDim, m_iCamera, stFrame.nScanIdx, nNotchIdx, &vecDefectCandidateList);
#else
	
#else	
    nOffset = m_nChamferOffset_um / m_pGlassData->GetSideData(emDim)->m_dPixelSizeX;
    nOffset += pNotchParam->m_nNotch_Inspect_Defect_Offset;
    m_nChamferOffset_um = 0;
@@ -4518,27 +4484,21 @@
        CRect rtSet_Area = pNotchParam->m_rtNotch_Circle_Area_pxl[nCircleIdx];

        CRect rtRotateArea;

        if(GetAlignRotate(emDim, ptSet_TopMark, ptSet_BotMark, rtSet_Area, rtRotateArea) == FALSE)
        if (GetAlignRotate(emDim, ptSet_TopMark, ptSet_BotMark, rtSet_Area, rtRotateArea) == FALSE) {
            g_pLog->DisplayMessage(_T("Notch Circle %d Rotate Area Error"), nCircleIdx);
            continue;
        }

        CRect rtROI = rtRotateArea;
        if (rtROI.Width() <= 0 || rtROI.Height() <= 0) {
            g_pLog->DisplayMessage(_T("Invalid ROI size: %d x %d"), rtROI.Width(), rtROI.Height());
            continue;
        }
        pSideData->m_rtNotchCircleArea_pxl[nNotchIdx][nCircleIdx] = rtROI;

        VectorDouble vectorX;
        VectorDouble vectorY;
        VectorDouble vectorR;

        /*
        for(int nMeasureIdx=0; nMeasureIdx<MAX_SIDE_NOTCH_MEASURE_COUNT; nMeasureIdx++)
        {
            if(pSideData->m_nNotch_Dimension_Edge_Judge[nMeasureIdx] ==0)
                continue;

            vectorX.push_back((double) pSideData->m_ptNotch_Dimension_Edge[nNotchIdx][nMeasureIdx].x);
            vectorY.push_back((double) pSideData->m_ptNotch_Dimension_Edge[nNotchIdx][nMeasureIdx].y);
        }
        */

        // 2. Get Edge Line
        int nThreshold = m_pRecipe->m_SideParam[(int) emDim].m_nChamferLineThreshold;
@@ -4548,22 +4508,27 @@
        IplImage* pEdgeImage = cvCreateImage(cvSize(rtROI.Width(), rtROI.Height()), 8, 1);
        IplImage* pCannyEdgeImage = cvCreateImage(cvSize(rtROI.Width(), rtROI.Height()), 8, 1);

        for(int i=0; i<rtROI.Height(); i++)
            memcpy(&pEdgeImage->imageData[(i*pEdgeImage->widthStep)], (pFrameBuffer + ((rtROI.top+i)*m_nFrameWidth) + rtROI.left), rtROI.Width());
        for (int i = 0; i < rtROI.Height(); i++) {
            memcpy(&pEdgeImage->imageData[(i * pEdgeImage->widthStep)], (pFrameBuffer + ((rtROI.top + i) * m_nFrameWidth) + rtROI.left), rtROI.Width());
        }

        int sigma1 = m_pRecipe->m_SideParam[(int) emDim].m_NotchPrm[nNotchIdx].m_nSmooth_Filter;
        int nMedianFilterSize = m_pRecipe->m_SideParam[(int)emDim].m_NotchPrm[nNotchIdx].m_nSmooth_Filter;
        nMedianFilterSize = std::max(3, std::min(nMedianFilterSize, 31));
        if (nMedianFilterSize % 2 == 0) {
            nMedianFilterSize--;
        }
        cvSmooth(pEdgeImage, pEdgeImage, CV_MEDIAN, nMedianFilterSize);

        if(sigma1 % 2 == 0)
            sigma1 = sigma1 - 1;
        double th1 = 40.0;
        double th2 = std::max(1.0, std::min((double)m_pRecipe->m_SideParam[(int)emDim].m_NotchPrm[nNotchIdx].m_nGrind_Threshold * 10, 255.0));

        if(1 < sigma1)
            cvSmooth(pEdgeImage,pEdgeImage,CV_MEDIAN,sigma1);
        if (th1 > th2) {
            std::swap(th1, th2);
        }

        double th1 = (double) m_pRecipe->m_SideParam[(int) emDim].m_NotchPrm[nNotchIdx].m_nGrind_Threshold * 10;
        double th2 = 40.0;
        int sigma=5;
        g_pLog->DisplayMessage(_T("Smooth Filter: %d, Canny th1: %.1f, th2: %.1f"), nMedianFilterSize, th1, th2);

        cvCanny(pEdgeImage,pCannyEdgeImage,th1,th2,sigma);
        cvCanny(pEdgeImage, pCannyEdgeImage, th1, th2, nMedianFilterSize);

        CString strTemp;
        strTemp.Format(_T("Notch\\Notch_%d_Circle_%d_Ori.jpg"), nNotchIdx, nCircleIdx);
@@ -4647,7 +4612,6 @@
            {
                sprintf(pSideData->m_strNotchCircle_Radius_Comment[nNotchIdx][nCircleIdx], "Rad. [OK] %.1f um / %.1f um", dRadiuse_um, dResult_um);
            }
	
        }
    }
}
@@ -5565,8 +5529,6 @@
    return TRUE;
}



BOOL CInspectCamera::Measure_TopCorner_RCut(int iThread,DimensionDir emDim, stFrameIndex stFrame)
{
    if(m_pGlassData == NULL || m_pRecipe == NULL)
@@ -5938,13 +5900,11 @@

BOOL CInspectCamera::OnThreadEnd(int iThread, CInspectThread *pInspectThread)
{

    return TRUE;
}

BOOL CInspectCamera::OnThreadEndAll()
{

    return TRUE;
}