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工学硕士学位论文纹理物体缺陷的视觉检测算法研究DEVELOPMENTOFAVISUALINSPECTIONALGORITHMTODETECTDEFECTFORTEXTURALOBJECT吴晶晶哈尔滨工业大学2008年12月国内图书分类号TP7511国际图书分类号620工学硕士学位论文纹理物体缺陷的视觉检测算法研究硕士研究生吴晶晶导师李泽湘教授副导师邓江汶博士申请学位工学硕士学科、专业控制科学与工程所在单位深圳研究生院答辩日期2008年12月授予学位单位哈尔滨工业大学CLASSIFIEDINDEXTP7511UDC620DISSERTATIONFORTHEMASTERDEGREEOFENGINEERINGDEVELOPMENTOFAVISUALINSPECTIONALGORITHMTODETECTDEFECTFORTEXTURALOBJECTCANDIDATEJINGJINGWUSUPERVISORCOSUPERVISORPROFZEXIANGLIDRJIANGWENDENGACADEMICDEGREEAPPLIEDFORMASTEROFENGINEERINGSPECIALTYCONTROLSCIENCEANDENGINEERINGAFFILIATIONSHENZHENGRADUATESCHOOLDATEOFDEFENCEDECEMBER,2008DEGREECONFERRINGINSTITUTIONHARBININSTITUTEOFTECHNOLOGYI摘要在竞争激烈的工业自动化生产过程中,机器视觉对产品质量的把关起着举足轻重的作用,机器视觉在缺陷检测技术方面的应用也逐渐普遍起来。与常规的检测技术相比,自动化的视觉检测系统更加经济、快捷、高效与安全。纹理物体在工业生产中广泛存在,像用于半导体装配和封装底板和发光二极管,现代化电子系统中的印制电路板,以及纺织行业中的布匹和织物等都可认为是含有纹理特征的物体。本论文主要致力于纹理物体的缺陷检测技术研究,为纹理物体的自动化检测提供高效而可靠的检测算法。纹理是描述图像内容的重要特征,纹理分析也已经被成功的应用与纹理分割和纹理分类当中。本研究提出了一种基于纹理分析技术和参考比较方式的缺陷检测算法。这种算法能容忍物体变形引起的图像配准误差,对纹理的影响也具有鲁棒性。本算法旨在为检测出的缺陷区域提供丰富而重要的物理意义,如缺陷区域的大小、形状、亮度对比度及空间分布等。同时,在参考图像可行的情况下,本算法可用于同质纹理物体和非同质纹理物体的检测,对非纹理物体的检测也可取得不错的效果。在整个检测过程中,我们采用了可调控金字塔的纹理分析和重构技术。与传统的小波纹理分析技术不同,我们在小波域中加入处理物体变形和纹理影响的容忍度控制算法,来实现容忍物体变形和对纹理影响鲁棒的目的。最后可调控金字塔的重构保证了缺陷区域物理意义恢复的准确性。实验阶段,我们检测了一系列具有实际应用价值的图像。实验结果表明本文提出的纹理物体缺陷检测算法具有高效性和易于实现性。关键字缺陷检测;纹理;物体变形;可调控金字塔;重构IIABSTRACTMACHINEVISIONPLAYSANIMPORTANTROLEINQUALITYCONTROLTASKSFORTODAYSHIGHLYCOMPETITIVEAUTOMATICMANUFACTURINGINTERMSOFDEFECTDETECTIONAPPLICATIONS,ANAUTOMATEDVISUALINSPECTIONSYSTEMISSUPERIORTOCONVENTIONALINSPECTIONTECHNIQUESINMANYASPECTS,SUCHASECONOMY,CONVENIENCE,HIGHEFFICIENCYANDSAFETYETCINTHISTHESIS,WEMAINLYCONCERNABOUTTHEDEFECTDETECTIONPROBLEMSFORTEXTURALOBJECTS,WHICHCANBEFOUNDINMANYINDUSTRIALINSPECTIONAPPLICATIONSLIKESUBSTRATEBOARDSANDLIGHTEMITTINGDIODESLEDSFORSEMICONDUCTORASSEMBLYANDPACKAGINGPROCESSES,PRINTEDCIRCUITBOARDSPCBSANDTEXTUREDMATERIALSASANIMPORTANTCHARACTERISTICFORTHEANALYSISOFIMAGES,TEXTUREHASBEENSUCCESSFULLYUTILIZEDFORAVARIETYOFMACHINEVISIONAPPLICATIONS,SUCHASTEXTURESEGMENTATION,TEXTURECLASSIFICATIONANDETCINTHISSTUDY,WEPRESENTANEWIMAGEREFERENCEAPPROACHFORINDUSTRIALINSPECTIONAPPLICATIONSTHEPROPOSEDMETHODDOESNOTREQUIREACCURATEIMAGEREGISTRATIONANDISROBUSTTOTHEINFLUENCEOFTEXTURESUNLIKEOTHERTEXTUREANALYSISTECHNIQUES,THEPROPOSEDMETHODPROVIDESUSEFULPHYSICALINFORMATIONFORTHECHARACTERISTICSOFDEFECTSDURINGTHEINSPECTIONPROCESS,WEADOPTANEFFICIENTWAVELETTEXTUREANALYSISTECHNIQUEOFSTEERABLEPYRAMIDANDITSRECONSTRUCTIONSCHEMEATOLERANCECONTROLALGORITHMFORHANDLINGOBJECTDISTORTIONANDTEXTURESINWAVELETDOMAINISINTRODUCEDAFTERCOMBINATIONOFTHEDIFFERENCESUBIMAGESINEACHDECOMPOSITIONLEVELFORBACKWARDSTEERABLEPYRAMID,DETECTIONRESULTSAREFINALLYOBTAINEDEXPERIMENTALRESULTSFROMASSEMBLEDSUBSTRATEBOARDSFORSEMICONDUCTORPACKAGE,PCB,LEDANDTEXTUREDMATERIALSAREAVAILABLEHAVEDEMONSTRATEDTHATTHEPROPOSEDMETHODISEASYTOIMPLEMENTANDVERYEFFECTIVEKEYWORDSDEFECTDETECTION,TEXTURE,OBJECTDISTORTION,STEERABLEPYRAMID,RECONSTRUCTIONIIIACKNOWLEDGEMENTSIWISHTOACKNOWLEDGEASMASSEMBLYAUTOMATIONLTDFORSPONSORINGTHEWHOLEWORKTHEN,IWOULDLIKETOEXPRESSMYSINCEREGRATITUDETOMYADVISORS,PROFZEXIANGLIANDDRJIANGWENDENG,FORTHEIRNUMEROUSENCOURAGEMENTS,GUIDANCE,ANDMANYVALUABLEDISCUSSIONSDURINGTHEWRITINGOFTHISDISSERTATIONANDTHERESEARCHIAMESPECIALLYGRATEFULTOMYFRIENDSHAIXIAMENGANDJUNZHANGFORBEINGAGREATHELPINGHANDTHROUGHOUTTHEPROJECTFINALLY,IWOULDLIKETOTHANKMYFAMILYANDTHEFRIENDSWHOCAREANDSUPPORTMEALLTHETIMEIVCONTENTSPAGELISTOFTABLESVILISTOFFIGURESVII1INTRODUCTION111BACKGROUND112MOTIVATION513RESEARCHCONTENT614THESISORGANIZATION62TEXTUREANALYSISTECHNIQUES721TEXTUREANALYSIS722STATISTICALMETHOD923MODELBASEDMETHOD1024SPECTRALMETHOD1125DEFECTDETECTIONUSINGTEXTUREANALYSISTECHNIQUES133WAVELETTRANSFORMFORINSPECTION1531TWODIMENSIONALWAVELETTRANSFORM1532WAVELETIMAGEDECOMPOSITIONANDRECONSTRUCTION1733DEFECTDETECTIONUSINGWAVELETTRANSFORM1834IMAGESUBTRACTIONUSINGWAVELETTRANSFORM204DEFECTDETECTIONFORTEXTURALOBJECT2241ALGORITHMDESCRIPTION2242THESTEERABLEPYRAMID2443TOLERANCECONTROLALGORITHM29V44EXPERIMENTALRESULTSANDDISCUSSION325GRAPHICUSERINTERFACEDESIGN4151INTRODUCTIONTOGUI4152GUIDESIGNFORTEXTURALOBJECTINSPECTIONSYSTEM4353GUIIMPLEMENTATIONFORTEXTURALOBJECTINSPECTIONSYSTEM46CONCLUSION52REFERENCES53VILISTOFTABLESTABLEPAGETABLE41PROPERTIESOFTHESTEERABLEPYRAMIDCOMPAREDTODYADICWAVELET29TABLE42THEDETAILEDDESCRIPTIONOFTOLERANCECONTROLALGORITHM31VIILISTOFFIGURESFIGUREPAGEFIGURE11AUTOMATEDVISUALINSPECTIONSYSTEM2FIGURE21THEINTERPRETATIONOFTEXTURES8FIGURE22BASICFLOWFORDEFECTDETECTIONBYUSINGTEXTUREANALYSISTECHNIQUES13FIGURE31SYSTEMDIAGRAMOFWAVELETTRANSFORM17FIGURE32BASICFLOWOFTEXTUREDEFECTDETECTIONUSINGWAVELETTRANSFORM19FIGURE41OVERALLBLOCKDIAGRAMOFTHEPROPOSEDALGORITHM23FIGURE42REFERENCEINFORMATIONEXTRACTEDFROMTHEREFERENCEIMAGE24FIGURE43SYSTEMDIAGRAMOFSTEERABLEPYRAMID25FIGURE44STRUCTUREOFSTEERABLEPYRAMID26FIGURE45SPECTRALDECOMPOSITIONOFSTEERABLEPYRAMID27FIGURE46THEEFFECTOFSPACEPATTERNINSPECTION32FIGURE47THEEFFECTOFMINUTEDEFECTINSPECTION34FIGURE48THEEFFECTOFDECOMPOSITIONLEVELSFORP1435FIGURE49THEEFFECTOFDECOMPOSITIONLEVELSFORP3636FIGURE410LEDINSPECTION137FIGURE411LEDINSPECTION238FIGURE412PCBINSPECTION138FIGURE413PCBINSPECTION239FIGURE414TEXTUREINSPECTION140FIGURE415TEXTUREINSPECTION240FIGURE51THEPROCESSOFGUIDESIGN43FIGURE52MAINFLOWOFGUIDESIGNFORTEXTURALOBJECTINSPECTIONSYSTEM44VIIIFIGURE53MENUEDITOR45FIGURE54GUICOMPONENTSASSIGNMENTEDITING45FIGURE55THEMAININTERFACEOFGUI47FIGURE56LOADINPUTIMAGESANDIMAGENORMALIZATION48FIGURE57DEFECTDETECTIONRESULTSDISPLAY48FIGURE58THEINTERFACEFORIMAGECOMPARISONDETAILSDISPLAY49FIGURE59HIGHPASSBANDCOEFFICIENTIMAGES49FIGURE5103SCALEAND4ORIENTATIONLOWPASSBANDCOEFFICIENTIMAGES50FIGURE5112SCALEBANDPASSCOEFFICIENTIMAGESINORIENTATIONOFZERO50FIGURE5122SCALEBANDPASSCOEFFICIENTIMAGESINORIENTATIONOF/4P51CHAPTER1INTRODUCTION1CHAPTER1INTRODUCTION11BACKGROUNDQUALITYCONTROLISDESIGNEDTOENSURETHATDEFECTIVEPRODUCTSARENOTALLOWEDTOREACHTHECUSTOMERFORTHISREASON,QUALITYCONTROLACTIVITIESFORMANESSENTIALINFORMATIONFEEDBACKLOOPFORTHEWHOLEBUSINESS,WITHPOTENTIALINFLUENCEONTHEDESIGN,PROCESSPLANNINGANDLOGISTICSFUNCTIONSASWELLASONMANUFACTURING1THEGLOBALECONOMICPRESSURESHAVEGRADUALLYLEDBUSINESSESTOASKMOREOFTECHNICALINNOVATIONINORDERTOBECOMEMORECOMPETITIVEANDDOBETTERINQUALITYCONTROLOBVIOUSLY,MANUALINSPECTORSLOWSDOWNTHEENTIREQUALITYCONTROLPROCESSASITBECOMESCOSTLY,TIMECONSUMINGANDALSOMAYIMPACTTHEEFFECTIVENESSOFHUMANLABORDUETOTHEHAZARDOUSATMOSPHEREOFINDUSTRYHOWEVER,WITHTHEDEVELOPMENTOFCOMPUTERSCIENCEANDTECHNOLOGY,THEAPPLICATIONOFMACHINEVISIONSYSTEMSFORTHEAUTOMATIONOFQUALITYCONTROLTASKSHASBECOMEQUITEPOPULARINTHEASPECTOFDEFECTDETECTIONAPPLICATIONS,ANAUTOMATEDVISUALINSPECTIONSYSTEMISEXPECTEDTOPROVIDEASOLUTIONWITHRELIABLEANDEFFECTIVEPERFORMANCEAUTOMATEDVISUALINSPECTIONTHETERMINSPECTIONIMPLIESAPROCEDUREOFDETERMININGWHETHERTHEPRODUCTHASDEVIATEDFROMAGIVENSETOFSPECIFICATIONSVISUALINSPECTIONISCOMMONLYDEFINEDAS“THEEXAMINATIONOFAMATERIAL,COMPONENT,ORPRODUCTFORCONDITIONSOFNONCONFORMANCEUSINGLIGHTANDTHEEYES,ALONEORINCONJUNCTIONWITHVARIOUSAIDS”VISUALINSPECTIONSYSTEMINTHISTHESISISRELATEDBYUSINGVISIBLELIGHT,ALTHOUGHITCANCHAPTER1INTRODUCTION2BECARRIEDOUTBYUSINGOTHERFORMSOFRADIATIONLIKEULTRASOUND,ULTRAVIOLET,INFRAREDANDXRAYVISUALINSPECTIONSYSTEMCANBEDESCRIBEDASTHEINTEGRATIONOFIMAGEACQUISITIONDEVICES,COMPUTERS,ANDIMAGINGSOFTWARETHEAUTOMATEDMANUFACTURINGALSOREQUIRESAPPLICATIONSPECIFICMATERIALHANDLING,MOTIONCONTROLLERS,PARTTRACKINGCONTROLLERSANDSENSORS,ANDCONTROLSOFTWARE2FIGURE11SHOWSANEXAMPLEOFAUTOMATEDVISUALINSPECTIONSYSTEM2FIGURE11AUTOMATEDVISUALINSPECTIONSYSTEMIMAGEACQUISITIONDEVICESLIGHTINGTOILLUMINATETHEOBJECT,OPTICS/LENSTOCOUPLETHEIMAGETOACAMERASENSOR,ACAMERATOCONVERTOPTICALIMAGETOANANALOGSIGNAL,ANDFORAUTOMATEDMANUFACTURINGATRIGGERSENSORTOINITIATETHEIMAGEACQUISITIONCOMPUTERTYPICALLYAPCWITHACPUDECISIONMAKINGANDCONTROL,ANOPERATORCONSOLETHEOPERATORINTERFACE,ANDIMAGINGHARDWARETYPICALLYANANALOGTODIGITALCONVERTERANDIMAGEPROCESSINGTHEAUTOMATEDMANUFACTURINGALSOREQUIRESANADDITIONOFI/OINTERFACE,MATERIALHANDLINGANDCOMMUNICATIONSTOCUSTOMERPROCESSINFORMATIONANDCONTROLSYSTEMSOFTWAREMODEMNETWORKOPERATORCONSOLEI/OINTERFACECOMPUTERIMAGINGELECTRONICSIMAGINGELECTRONICSCAMERACAMERALIGHTINGLIGHTINGLENSLENSMATERIALHANDLINGCHAPTER1INTRODUCTION3SOFTWAREOPERATINGSYSTEMSOFTWAREEGWINDOWSNT/2000/XPANDIMAGINGSOFTWARETHEUSERINTERFACE,IMAGEACQUISITIONANDPROCESSING,IMAGEANALYSISANDDECISIONMAKING,HISTORICALDATACOLLECTIONANDANALYSISTODAYSHIGHSPEED,COMPLEXMANUFACTURINGSYSTEMSREQUIREAVISUALINSPECTIONSYSTEMTOHAVETWOOBJECTIVESONEISQUALITYCONTROLTHEOTHERISFORMONITORINGTHEPRODUCTIONPROCESSWITHTHEADVANCEMENTOFTECHNICALINNOVATION,MOREANDMOREBENEFITSBECAMEAPPARENTTHEAUTOMATEDVISUALINSPECTIONSYSTEMCANBEDESIGNEDTOHAVETHEFOLLOWINGADVANTAGES1LOWERCOST2HIGHERSPEED3QUALITYASSURANCE4ACCURACYANDRELIABILITY5IMPROVEDSAFETYHOWEVER,AUTOMATEDVISUALINSPECTIONSYSTEMSALSOHAVELIMITATIONS3FIRSTLY,THEDESIGNANDINSTALLATIONISAVERYCOMPLEXPROBLEMANDREQUIRESTECHNICALEXPERTISEINTHEAREASOFILLUMINATION,CAMERAS,NETWORKING,PATTERNRECOGNITIONANDPROGRAMMINGANOTHERISTHECURRENTLYAVAILABLEAUTOMATEDVISUALINSPECTIONSYSTEMSARECUSTOMERORIENTEDFORASPECIFICTASKANDLACKOFFLEXIBILITYSOMETIMESOTHERKINDSOFPROBLEMS,SUCHASHIGHINITIALCOSTOFTHESYSTEM,NEEDTOBECONSIDEREDINSPECTIONOFTEXTURALOBJECTTEXTUREISAPHENOMENONTHATISWIDESPREAD,EASYTORECOGNIZEANDHARDTODEFINEHUMANSOFTENDESCRIBETEXTUREASFINE,COARSE,GRAINED,ANDSMOOTH,BUTTHESEDESCRIPTIONSAREQUITEIMPRECISEANDNONQUANTITATIVEINSPITEOFNOPRECISEDEFINITION,ONETHINGABOUTTEXTUREISGENERALLYASSUMEDTOBETRUETEXTUREISABOUTAREGION,ANDTEXTUREOFAPOINTISUNDEFINEDMOREFORMALLY,TEXTURECANBEDESCRIBEDASTHESETOFLOCALNEIGHBORHOODPROPERTIESOFANIMAGEREGIONTEXTUREEXISTSINVARIOUSINDUSTRIALINSPECTIONAPPLICATIONSLIKESUBSTRATEBOARDSANDLIGHTEMITTINGDIODESLEDSFORSEMICONDUCTORASSEMBLYANDPACKAGINGPROCESSES,PRINTEDCIRCUITBOARDSPCBSANDCHAPTER1INTRODUCTION4TEXTUREDMATERIALSINTHISTHESIS,WEDEFINEOBJECTSTHATCONTAINTEXTUREPROPERTIESASTEXTURALOBJECTWITHTHISDEFINITION,ASETOFINDUSTRIALINSPECTIONPROBLEMSCANBECONSIDEREDASASINGLEONEPROBLEM,WHICHENHANCESTHEINSPECTIONCAPABILITIESINGENERAL,SURFACEINSPECTIONFALLSINTOONEOFTHETHREECATEGORIESREFERENCECOMPARI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RTANTASPECTFORDEFECTINSPECTIONALGORITHMSINTHISCHAPTER,WEWILLRESEARCHONASETOFTEXTUREANALYSISTECHNIQUES,ANDFINDPROPERTEXTUREANALYSISMETHODSFORTEXTURALOBJECTINSPECTIONITISSUPPOSEDTOPROVIDEUSEFULPHYSICALMEANINGSINCHARACTERIZATIONOFDEFECTPATTERNS21TEXTUREANALYSISASANIMPORTANTCUEFORTHEANALYSISOFMANYTYPESOFIMAGES,TEXTUREISUSEDTOPOINTTOINTRINSICPROPERTIESOFSURFACES,ESPECIALLYTHOSETHATDONTHAVEASMOOTHLYVARYINGINTENSITY14ITINCLUDESINTUITIVEPROPERTIESLIKEROUGHNESS,GRANULATIONANDREGULARITYACTUALLYTHE“DEFINITION”OFTEXTURECANOFTENBEFORMULATEDBYDIFFERENTPEOPLEDEPENDINGUPONTHEPARTICULARAPPLICATIONINSPITEOFNOGENERALDEFINITION,THEREAREANUMBEROFINTUITIVEPROPERTIESOFTEXTUREWHICHAREGENERALLYASSUMEDTOBETRUE151TEXTUREISAPROPERTYOFAREASTHETEXTUREOFAPOINTISUNDEFINED2TEXTUREINVOLVESTHESPATIALDISTRIBUTIONOFGRAYLEVELSCHAPTER2TEXTUREANALYSISTECHNIQUES83TEXTURECANBEPERCEIVEDATDIFFERENTSCALESORLEVELSOFRESOLUTION4AREGIONISPERCEIVEDTOHAVETEXTUREWHENTHENUMBEROFPRIMITIVEOBJECTSINTHEREGIONISLARGETEXTUREISACONTEXTUALPROPERTYANDITSDEFINITIONINVOLVESGRAYVALUESDISTRIBUTIONINASPATIALNEIGHBORHOODTHESIZEOFTHISNEIGHBORHOODDEPENDSUPONTHETEXTURETYPE,ORTHESIZEOFTHEPRIMITIVESDEFININGTHETEXTUREMOREFORMALLY,TEXTURECANBEDEFINEDASTHESETOFLOCALNEIGHBORHOODPROPERTIESOFTHEGREYLEVELSOFANIMAGEREGIONTAKEFIGURE21ASAREFERENCEDIFFERENTNEIGHBORHOODSOFTHEPIXELSWITHTHESAMEGRAYLEVELMAYHAVEDIFFERENTTEXTUREPROPERTIESFIGURE21THEINTERPRETATIONOFTEXTURESTHEREARETHREESTANDARDPROBLEMSTODOWITHTEXTURE251TEXTURECLASSIFICATIONSEEKSTOPRODUCEACLASSIFICATIONMAPOFTHEINPUTIMAGEWHEREEACHUNIFORMTEXTUREDREGIONISIDENTIFIEDWITHTHETEXTURECLASSITBELONGSTO2TEXTURESEGMENTATIONISTHEPROBLEMOFBREAKINGANIMAGEINTOCOMPONENTSWITHINWHICHTHETEXTUREISCONSTANTTEXTURESEGMENTATIONINVOLVESBOTHREPRESENTINGATEXTURE,ANDDETERMININGTHEBASISONWHICHSEGMENTBOUNDARIESARETOBEDETERMINED3TEXTURESYNTHESISSEEKSTOCONSTRUCTLARGEREGIONSOFTEXTUREFROMSMALLEXAMPLEIMAGESWEDOTHISBYUSINGTHEEXAMPLEIMAGESTOBUILDPROBABILITYMODELSOFTHETEXTURE,ANDTHENDRAWINGONTHEPROBABILITYMODELTOOBTAINTEXTUREDIMAGESNEIGHBORHOODPROPERTIESPIXELALONECHAPTER2TEXTUREANALYSISTECHNIQUES9TEXTUREANALYSISISCONSIDEREDASACHALLENGINGTASKTEXTUREANALYSISMETHODSHAVEBEENUTILIZEDINAVARIETYOFAPPLICATIONDOMAINS,SUCHASAUTOMATEDINSPECTION,DOCUMENTPROCESSING,ANDREMOTESENSINGTEXTUREDEFECTDETECTIONISONEOFTHEASPECTSOFAUTOMATEDINSPECTIONITMEANSTODECIDEWHETHERATEXTUREISASITISEXPECTEDTOBE26FORMALLY,ITCANBEDEFINEDASTHEPROCESSOFDETERMININGTHELOCATIONAND/OREXTENDOFACOLLECTIONOFPIXELSINATEXTUREDIMAGEWITHREMARKABLEDEVIATIONINTHEIRINTENSITYVALUESORSPATIALARRANGEMENTWITHRESPECTTOTHEBACKGROUNDTEXTUREMANYTEXTUREANALYSISMETHODSHAVEBEENPROPOSEDINTHEPASTSEVERALDECADESTHEAVAILABLEMETHODSMIGHTBECATEGORIZEDINTOSTATISTICAL,MODELBASEDANDSPECTRALMETHODS22STATISTICALMETHODINSTATISTICALMETHOD,ASETOFGRAYVALUEDISTRIBUTIONFEATURESHAVEBEENEXTRACTEDFORFURTHERANALYSISALARGENUMBEROFSTATISTICALTEXTUREFEATURESHAVEBEENPROPOSED,TYPICALLYTEXTUREDESCRIPTIONSFROMGRAYLEVELCOOCCURRENCEMATRICESGLCM2628ANDLOCALBINARYPATTERNSLBP29,30HAVEBEENAPPLIEDTO

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