The primary task in calculating the tobacco shred blending ratio is identifying the four tobacco shred types: expanded tobacco silk, cut stem, tobacco silk, and reconstituted tobacco shred. The classification precision directly affects the subsequent determination of tobacco shred components. However, the tobacco shred types, especially expanded tobacco silk and tobacco silk, have no apparent differences in macro-scale characteristics. The tobacco shreds have small size and irregular shape characteristics, creating significant challenges in their recognition and classification based on machine vision. This study provides a complete set of solutions aimed at this problem for screening tobacco shred samples, taking images, image preprocessing, establishing datasets, and identifying types. A block threshold binarization method is used for image preprocessing. Parameter setting and method performance are researched to obtain the maximum number of complete samples with acceptable execution time. ResNet50 is used as the primary classification and recognition network structure. By increasing the multi-scale structure and optimizing the number of blocks and loss function, a new tobacco shred image classification method is proposed based on the MS-X-ResNet (Multi-Scale-X-ResNet) network. Specifically, the MS-ResNet network is obtained by fusing the multi-scale Stage 3 low-dimensional and Stage 4 high-dimensional features to reduce the overfitting risk. The number of blocks in Stages 1–4 are adjusted from the original 3:4:6:3 to 3:4:N:3 (A-ResNet) and 3:3:N:3 (B-ResNet) to obtain the X-ResNet network, which improves the model’s classification performance with lower complexity. The focal loss function is selected to reduce the impact of identification difficulty for different sample types on the network and improve its performance. The experimental results show that the final classification accuracy of the network on a tobacco shred dataset is 96.56%. The image recognition of a single tobacco shred requires 103 ms, achieving high classification accuracy and efficiency. The image preprocessing and deep learning algorithms for tobacco shred classification and identification proposed in this study provide a new implementation approach for the actual production and quality detection of tobacco and a new way for online real-time type identification of other agricultural products.

IntroductionThe classification of the four tobacco shred varieties, tobacco silk, cut stem, expanded tobacco silk, and reconstituted tobacco shred, and the subsequent determination of tobacco shred components, are the primary tasks involved in calculating the tobacco shred blending ratio. The identification accuracy and subsequent component area calculation error directly affect the composition determination and quality of the tobacco shred. However, tiny tobacco shreds have complex physical and morphological characteristics; in particular, there is substantial similarity between the expanded tobacco silk and tobacco silk varieties, and this complicates their classification. There must be a certain amount of overlap and stacking in the distribution of tobacco shreds on the actual tobacco quality inspection line. There are 24 types of overlap alone, not to mention the stacking phenomenon. Self-winding does not make it easier to distinguish such varieties from the overlapped types, posing significant difficulties for machine vision-based tobacco shred classification and component area calculation tasks.MethodsThis study focuses on two significant challenges associated with identifying various types of overlapping tobacco shreds and acquiring overlapping regions to calculate overlapping areas. It develops a new segmentation model for tobacco shred images based on an improved Mask region-based convolutional neural network (RCNN). Mask RCNN is used as the segmentation network’s mainframe. Convolutional network and feature pyramid network (FPN) in the backbone are replaced with Densenet121 and U-FPN, respectively. The size and aspect ratios of anchors parameters in region proposal network (RPN) are optimized. An algorithm for the area calculation of the overlapped tobacco shred region (COT) is also proposed, which is applied to overlapped tobacco shred mask images to obtain overlapped regions and calculate the overlapped area.ResultsThe experimental results showed that the final segmentation accuracy and recall rates are 89.1% and 73.2%, respectively. The average area detection rate of 24 overlapped tobacco shred samples increases from 81.2% to 90%, achieving high segmentation accuracy and overlapped area calculation accuracy.DiscussionThis study provides a new implementation method for the type identification and component area calculation of overlapped tobacco shreds and a new approach for other similar overlapped image segmentation tasks.