CN101949721A - Method for measuring coal bunker material level based on laser and binocular vision and device thereof - Google Patents
Method for measuring coal bunker material level based on laser and binocular vision and device thereof Download PDFInfo
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Abstract
The invention relates to a method for measuring coal bunker material level based on laser and binocular vision and a device thereof, belonging to the field of machine vision. The device comprises two CCD cameras with the same parameters, two lenses with consistent parameters, one or a plurality of lasers, a light source, a processing element and an explosion-proof case provided with a window. A rotating mechanism is also included when one laser is used. The method includes that the laser emits variable size laser beams, so as to form a light spot on coal surface, image parallax of the light spot between the two cameras is utilized to measure material level, and an image pair is acquired by the two cameras; corrosion expansion pre-treatment is carried out on the obtained images by utilizing an improved algorithm; for the two images after being pretreated, a new rapid stereoscopic vision algorithm is utilized to calculate a depth map; depth is obtained according to the depth map, and finally high efficiency, real time and accurate coal bunker material level measurement is realized. The device has two measuring modes, namely real-time detection mode and sensor detection mode.
Description
Technical field
The present invention is a kind of coal bunker material level measuring method and device based on laser and binocular vision, belongs to machine vision, measurement in space and automatic field, is used for the correct fast three dimensional local information that obtains the coal bunker material level.
Background technology
The detection of coal bunker material level is the important measures of Safety of Coal Mine Production, along with coal is sent into coal bunker continuously, the coal face is more and more littler from the distance at coal bunker top, as the untimely coal that stops, just might overflow, cause dump long-pending, thereby cause long-pending coal pile things on of rubber conveyer head and sealing-tape machine heavy load starting phenomenon, and then cause a series of major accidents; After if coal drops to the minimum material level of regulation, if untimely stopping to be unloaded coal, its following mouth structure is hit and destroys on the one hand, can guarantee bottom staff's safety on the other hand.Simultaneously, also can prevent to cause dust concentration sharply to increase, may cause blast, lead to coal mining accident owing to the flying upward of leaking out of causing of the distinguished and admirable negative pressure of bunker upper and lower opening and coal dust dust.The detection of coal bin coal position is extremely important, by the coal position of real-time detection coal bunker, grasps coal bunker coal storage situation, is convenient to control the amount of delivering coal of each sealing-tape machine, and the generation of having stopped coal bunker coal piling accident is removed a hidden danger, and realizes transporting safely production.
Coal bunker material level detection method commonly used at present has: Weight type, electric pole type, condenser type, machine rod-type, Weighing type, revolution wing wheel formula, radar type, ultrasonic type, laser type, nucleon formula etc.Wherein Weight type, electric pole type, condenser type, machine rod-type, Weighing type and revolution wing wheel formula belong to contact measurement method, and remaining is a contactless measurement.The most frequently used have based on the radio frequency capacitance technology, based on ultrasonic technology with based on three kinds of measuring methods of Radar Technology, based on radio frequency capacitance technology measuring method a radio frequency is sent on the probe, the variation by continuous analysis electric capacity realizes measuring; Utilize the mistiming of ultrasound wave transmission and acceptance to realize measuring based on the measuring method of ultrasonic technology; Utilize electromagnetic transmitted wave and reflection wave mistiming to realize measuring based on the measuring method of Radar Technology.
Chinese patent application numbers 200710038493.8, open day 2008.9.24, a kind of high confidence level method and device thereof of the contactless continuous coverage fine granularity material material level based on machine vision are disclosed, device is by the particular point light source, the image acquisition machine, compositions such as machine vision module, the high-luminance light circular image that the light beam that the collection of image acquisition machine is launched by pointolite forms on the material surface, adopt checking type light circle detection algorithm to analyze and handle by machine vision module, calculate bright dipping diameter of a circle or area size, and then obtain the material value, thereby realize the material measurement.
Chinese patent application number 01107328.4, open day 2002.11.6, a kind of digital video frequency level indicator is disclosed, by video input unit, image pick-up card, microprocessor and display screen etc. interconnect and form, video input unit is aimed at tested material, video input unit is connected to the video inputs of image pick-up card again, microprocessor control image pick-up card is gathered the material level image by the sampling period that the user sets, and image handled, the material level coordinate figure of analysis and the calibration gauge of demarcation are relatively calculated the material level actual value, simultaneously with the material level image, the variation tendency of material level actual value and this value is presented on the display screen.
The present coal bunker material level measuring method that exists has multiple, and these method and apparatus have following problem.
1) the contact measuring method is because probe contact material easily cling material and damage, and most of method measuring distance is also smaller, mostly the Weight type charge level sensor is mechanical, comprise that the display part total is very complicated, functional reliability is poor, easy break-down.
2) contactless measuring method, in case measuring head pollutes, measuring accuracy descends significantly, and these class methods generally require coal face regular shape, and inside surface is smooth, and it is bigger to measure the blind area, the measuring accuracy instability, when ripple was propagated in addition, humidity also influenced measuring accuracy in the storehouse in, and much method has certain requirement to the diameter and the depth ratio of coal bunker.
3) based on the distance-finding method of single camera because there are many analyticities of too many blind spot and image in imaging, as Fig. 7 real world 5 in different its 2D images of object is, measuring error is big;
4) precision is low, and when the space three-dimensional object scene projected to two dimensional image, same scenery differed greatly at the different points of view hypograph, and because inclement condition in the coal bunker, the geometric configuration of coal and physical characteristics, noise etc. are all by comprehensively in single gradation of image.From the image that comprises so many unfavorable factors, be difficult to try to achieve high-precision, depth information, cause very mistake probably.
5) initiative is poor; Because the high depth of coal bunker, particle degree difference unglazed, coal is very big, does not have obviously consistent feature, and initiative is poor.
6) be difficult for disposing, dispose, based on the vision system of PC, compare difficulty, and be difficult to realize the characteristic of Safety of Coal Mine Production in the extreme position that has of down-hole coal bunker.
In order to improve the initiative of coal bunker level gauging, high precision obtains the depth information of coal in the coal bunker in real time, and is easy to dispose, and the invention provides a kind of coal bunker material level measuring method and device based on laser and binocular vision.
Summary of the invention
The objective of the invention is to propose a kind of coal bunker material level measuring method and device based on laser and binocular vision, in order to improve the initiative of coal bunker level gauging, high precision obtains the depth information of coal in the coal bunker in real time, and is easy to dispose.It is subjected to the enlightenment of people's eyes observed range, utilizes lower-cost generating laser and two cameras, with the degree of depth of higher relatively precision measure coal bunker material level.
Aforementioned purpose of the present invention will realize that described device comprises by a kind of coal bunker apparatus for measuring charge level based on laser and binocular vision proposed below:
One or more laser instruments connect first laser instrument at every turn and are used to produce laser beam, and the laser beam variable size;
Image-generating unit is made up of with two consistent camera lenses of parameter the CCD camera of two parameter unanimities, and it is right to be used to obtain the light spot image that described laser beam forms on the coal face;
Main processor unit, it utilizes described image to calculating at hot spot parallax in a pair of image, and then calculates the actual range between coal face auto levelizer;
Light source is made up of led array, the illumination when being used to the camera images acquired is provided, and adjustable brightness; Antibomb unit is used for realizing the requirement of explosion proof under the coal mine.
When installing with a plurality of laser instrument, connect a laser instrument at every turn, connect successively until on the coal face, forming suitable hot spot point;
When installing with a laser instrument, device also comprises the motor rotating mechanism;
The motor rotating mechanism drives two cameras and laser rotation, and the relative position of two cameras and laser is constant, to guarantee to form suitable spot.
When being operated in optional pattern detecting sensor, device further comprises the unload coal sensor and the sensor of coalingging.
Laser emitting module is made up of a plurality of laser beam emitting heads, determines to connect the quantity of laser beam emitting head according to the degree of depth of coal bunker; Light source is made up of led array, determines to connect the quantity of LED in the led array according to the degree of depth of coal bunker, thereby makes illumination a suitable scope.
Described processor mainly comprises:
Image fetching unit links to each other with two cameras, is used to read two image of camera to data, and stores designated memory locations into.
Image storage unit is used for the image log certificate that the memory image reading unit reads, and according to the requirement of three-dimensional processing unit image log according to being input to processing unit.
Three-dimensional processing unit is used for two images are carried out pre-service, three-dimensional coupling and depth calculation.
Control module is used for controlling the quantity of light source igniting led array, is used for controlling Laser emission and closes, and is used for controlling two cameras and begins images acquired and stop to gather the processing of control sensor signal.
Aforementioned purpose of the present invention will be achieved by a kind of coal bunker material level measuring method based on laser and binocular vision proposed below, and described method comprises the steps
1) laser emitting module emission of lasering beam on coal bunker coal face forms laser spot at the coal face and utilizes two CCD camera images acquired right: image 1:f
1(x is y) with image 2:f
2(x, y);
2) inner parameter of demarcation CCD camera and camera lens;
3) image graph of two same frames that step 1 is gathered is as f
1(x, y) and f
2(x y) utilizes improved gray scale morphology, carries out elder generation's corrosion after expansion pre-service, the steps include:
(1). to image f
1(x, y) and f
2(x y) corrodes operation, and formula is as follows:
(2). to image graph as f
1(x, y) and f
2(x y) carries out expansive working, and formula is as follows:
In the formula, and f representing input images f (x, y), b representative structure element b (x, y), Mean{A} represents the average of element in the set A, Median{A} represents the intermediate value of element in the set A, D
bBe the field of definition of b, T is a threshold value.
4) with pretreated two width of cloth images as input, utilize quick stereo vision matching algorithm, compute depth figure the steps include:
(1). at first utilize maximum variance between clusters to ask for respectively to image f
1(x, y) and f
2(x, y) threshold value T
i, i=1,2, carry out binaryzation then, pixel value is more than or equal to threshold value, and pixel value is arranged to 255, otherwise pixel value is arranged to 0;
(2). scan image f
1(x, y) all pixels obtain pixel value and are the minimum boundary rectangle of all pixels that are interconnected of 255
Its upper left corner coordinate is
Lower right corner coordinate is
(3). scan image f
2(obtaining pixel value is the minimum boundary rectangle of 255 all pixels that are interconnected for x, y) all pixels
Its upper left corner coordinate is
Lower right corner coordinate is
(4). produce new image
And image
New image
And image
Width be w
New, highly be h
New, image
Pixel by image f
1(x is y) from (x
Min, y
Min) be starting point, width is w
New, highly be h
NewCopying image in the interior rectangle obtains; New images
Pixel by image f
2(x is y) from (x
Min, y
Min) be starting point, width is w
New, highly be h
NewCopying image in the interior rectangle obtains wherein,
w
new＝x
max-x
min+1
h
new＝y
max-y
min+1
(5). to image
And image
Carry out the solid coupling and obtain disparity map, matching criterior is the absolute difference sum.
(6). according to formula
Wherein f is that focal length, b are base length, and d is a parallax, recovers depth map by disparity map, and then realizes the coal bunker level gauging.
A kind of coal bunker material level measuring method and device based on laser and binocular vision of the present invention has two kinds of working methods optional: real-time detecting pattern and pattern detecting sensor.
When being operated in real-time detecting pattern, can uneasyly load and unload the coal sensor and the sensor of coalingging, after the system start-up, at first measure coal bunker material level situation, if be minimum material level, then stop to unload coal, if, then stop to coaling for high charge level, otherwise " fathom-＞judge coal position variation-time-delay " step is carried out in circulation, but when the coal position changed, delaying time was the T3 millisecond, when the coal position does not change, time-delay is T2 millisecond, T2 〉=T3.
When being operated in mode sensor, device must be installed the unload coal sensor and the sensor of coalingging, after system start-up, when the sensor or the sensor of unloading coal have signal if coaling, carry out " fathom-＞judgement coal position variation-time-delay T3 millisecond " circulation, in case the coal bunker material level is minimum, then stop to unload coal, if the coal position is the highest, then stop to coaling.When the coaling sensor and the sensor of unloading coal did not all have signal, device was in holding state.
The luminous component of described light source is made up of led array, and the light of the transmission of light source is lighted LED quantity by processor according to the degree of depth decision of the coal bunker material level of measuring last time.
The invention has the beneficial effects as follows:
1) precision height, robustness is good.The binocular principle that the present invention utilizes the people to observe object utilizes matching algorithm efficiently to release the depth information of three-dimensional scene, and the precision height owing to can operation sensor only accept the light of certain band limits, has been got rid of a lot of external interference, and the robustness of measurement is good.
2) initiative is strong.Because the high depth of coal bunker, particle degree difference unglazed, coal is very big, does not have obviously consistent feature, utilizes laser spot that unified feature initiatively is provided, and reduces operand significantly, has good initiative.
3) real-time.Among the present invention in the coal bunker depth information of coal be to utilize Stereo Matching Algorithm fast, it is a fraction of disparity map at center that algorithm only calculates with the laser spot, fine low-power consumption and the high real-time that has guaranteed system.
4) be easy to dispose, the present invention adopts embedded architecture, adopts the multilayer circuit board design, and that can do is very little, in limited space, down-hole, is easy to dispose, and is easy to realize the requirement of explosion proof of mine safety.
5) favorable expandability.The present invention adopts embedded main the processing, and processor itself is integrated great amount of conventional interface is easy to expansion, so as with different equipment carry out mutual with communicate by letter.
Description of drawings
Fig. 1 is the present invention's laser and binocular vision coal bunker material level apparatus for measuring charge level floor map during with a plurality of laser instrument;
Fig. 2 is the present invention's laser and binocular vision coal bunker apparatus for measuring charge level floor map during with a laser instrument;
Fig. 3 is the laser emitting module of the present invention structural representation that is circular layout;
Fig. 4 is the block scheme of a kind of laser of the present invention and binocular vision coal bunker apparatus for measuring charge level;
Fig. 5 is the process flow diagram that laser of the present invention and binocular vision coal bunker apparatus for measuring charge level carry out the level gauging process;
Fig. 6 is the real-time detecting pattern process flow diagram of laser of the present invention and binocular vision coal bunker level gauging.Fig. 7 is the real-time detecting pattern process flow diagram of laser of the present invention and binocular vision coal bunker level gauging.
Fig. 8 is many analyticities of single camera pixel synoptic diagram;
Fig. 9 is the spectrum figure of parallax and the degree of depth in the binocular vision;
Figure 10 is the assembly front view fragmentary cross-sectional view of laser of the present invention and binocular vision coal bunker apparatus for measuring charge level.
Figure 11 is the front view sectional view of the present invention's laser and binocular vision coal bunker apparatus for measuring charge level during with a plurality of laser instrument;
Figure 12 is the front view sectional view of the present invention's laser and binocular vision coal bunker apparatus for measuring charge level during with a plurality of laser instrument;
Specific implementation method
Below in conjunction with example listed in the accompanying drawing the preferred embodiments of the present invention are carried out illustrating in detail, wherein use similar Reference numeral to represent like.
Fig. 1 is the present invention's laser and binocular vision coal bunker material level apparatus for measuring charge level floor map during with a plurality of laser instrument.As shown in Figure 1, coal bunker apparatus for measuring charge level of the present invention comprises the charge-coupled device (CCD) camera of a plurality of laser instrument 8, two parameter unanimities: camera 6 and camera 7, two parameters be camera lens always: camera lens 4 and camera lens 5, light source 3, flameproof enclosure 15 and shell form 16.When device was operated in optional working sensor pattern, device also comprised the coaling sensor 14 and the sensor 13 of unloading coal.Above-mentioned laser instrument 8 produces laser beam, and the size of laser beam is adjusted according to the degree of depth of coal bunker material level.One of described a plurality of laser instrument 818 each connection are connected successively until form suitable hot spot on the coal face; Described CCD camera 6 and CCD camera 7 obtain two width of cloth images by the same hot spot of taking laser beam simultaneously and forming on the coal face, it is right that two width of cloth images are formed image.Described light source 3 is made up of led array, lights the quantity of LED in the led array according to the degree of depth of coal bunker, for the image that obtains provides suitable illumination.Described flameproof enclosure 15 is to design in order to satisfy requirement of explosion proof under the coal mine, and the form of inlaying 16 wherein is high printing opacities.
Fig. 2 is the present invention's laser and binocular vision coal bunker apparatus for measuring charge level floor map during with a laser instrument.As shown in Figure 2, coal bunker apparatus for measuring charge level of the present invention comprises the charge-coupled device (CCD) camera of laser instrument 8, two parameter unanimities: camera 6 and camera 7, two parameters be camera lens always: camera lens 4 and camera lens 5, light source 3, motor rotating mechanism 86, flameproof enclosure 15 and shell form 16.When device was operated in optional working sensor pattern, device also comprised the coaling sensor 14 and the sensor 13 of unloading coal.Above-mentioned laser instrument 8 produces laser beam, and the size of laser beam is adjusted according to the degree of depth of coal bunker material level.Described CCD camera 6 and CCD camera 7 obtain two width of cloth images by the same hot spot of taking laser beam simultaneously and forming on the coal face, it is right that two width of cloth images are formed image.Described light source 3 is made up of led array, lights the quantity of LED in the led array according to the degree of depth of coal bunker, for the image that obtains provides suitable illumination.Described motor rotating mechanism 86 drives laser instrument 8 rotations, until form suitable hot spot point on the coal face; Described flameproof enclosure 15 is to design in order to satisfy requirement of explosion proof under the coal mine, and the form of inlaying 16 wherein is high printing opacities.
Fig. 3 is the laser instrument of the present invention structural representation that is circular layout; As shown in Figure 3, laser instrument 8 of the present invention comprises laser emitting module shell 26, fixed mount 27 and generating laser 28.Above-mentioned laser emitting module shell 26 is used for fixing whole laser instrument 8.Described fixed mount 27 is used for fixing generating laser 28.Laser instrument 8 is made up of a plurality of generating lasers 28, according to the definite quantity of connecting generating laser 28 of the degree of depth of coal bunker, provides appropriate information to guarantee spot size.
Fig. 4 is the block scheme of a kind of laser of the present invention and binocular vision coal bunker apparatus for measuring charge level.As shown in Figure 4, above-mentioned laser instrument 8 emission of lasering beam of control module 25 controls, and according to above-mentioned generating laser 28 quantity of the definite connection of the degree of depth of coal bunker material level, and then the size of change laser beam; Realize the control of light-source brightness by the quantity of LED in the led array in the control connection light source 3; And during as optional working sensor pattern, the sensor 13 and the sensor 14 of coalingging carry out communication with unloading coal.Image fetching unit 21 described CCD cameras 6 of control and CCD camera 7 obtain the image of the hot spot point that is formed by laser beam on the coal face, thereby obtain a pair of image log certificate.Described CCD camera 6, CCD camera 7 and image fetching unit 21 according to being stored in the storage unit 23, and being used to the image log that obtains three-dimensional processing unit 24 and carrying out image pre-service, three-dimensional coupling and calculate the coal bunker material level degree of depth.
Fig. 5 is the process flow diagram that laser of the present invention and binocular vision coal bunker apparatus for measuring charge level carry out the level gauging process.As shown in Figure 5, carry out level gauging, in operation steps 201, by two cameras and laser instrument vision sensor, so that obtaining of visual signature initiatively and visual signature to be provided for utilizing laser of the present invention and binocular vision coal bunker apparatus for measuring charge level.In operation steps 202, to the camera 6 and the camera 7 of two parameter unanimities, and the camera lens 3 of two parameter unanimities and camera lens 4 carries out composite calibration, obtains the comprehensive inner parameter of camera and camera lens.In operation steps 203, the generating laser 8 of connecting some produces laser beam, and forms laser spot on the coal face.Operation steps 204, it is right to obtain the spot image that formed on coal face 2 by CCD camera 6 and CCD camera 7.In operation steps 205, to carrying out elder generation's corrosion after expansion pre-service, its operation steps is as follows to the image of gained:
(1). to image f
1(x, y) and f
2(x y) corrodes operation, and formula is as follows:
(2). to image graph as f
1(x, y) and f
2(x y) carries out expansive working, and formula is as follows:
In the formula, and f representing input images f (x, y), b representative structure element b (x, y), Mean{A} represents the average of element in the set A, Median{A} represents the intermediate value of element in the set A, D
bBe the field of definition of b, T is a threshold value.Corrosion and the purpose that expands be in order to eliminate the dazzle of laser spot on the coal face, and eliminate the reflective sparklet that causes of dust and remove noise.
In operation steps 206, utilize the quick stereo matching algorithm to carry out the solid coupling, search matched point is right, produces disparity map, and its quick stereo matching algorithm is as follows:
(1). at first utilize maximum variance between clusters to ask for respectively to image f
1(x, y) and f
2(x, y) threshold value T
i, i=1,2, carry out binaryzation then, pixel value is more than or equal to threshold value, and pixel value is arranged to 255, otherwise pixel value is arranged to 0;
(2). scan image f
1(x, y) all pixels obtain pixel value and are the minimum boundary rectangle of all pixels that are interconnected of 255
Its upper left corner coordinate is
Lower right corner coordinate is
(3). scan image f
2(obtaining pixel value is the minimum boundary rectangle of 255 all pixels that are interconnected for x, y) all pixels
Its upper left corner coordinate is
Lower right corner coordinate is
(4). produce new image
And image
New image
And image
Width be w
New, highly be h
New, image
Pixel by image f
1(x is y) from (x
Min, y
Min) be starting point, width is w
New, highly be h
NewCopying image in the interior rectangle obtains; New images
Pixel by image f
2(x is y) from (x
Min, y
Min) be starting point, width is w
New, highly be h
NewCopying image in the interior rectangle obtains wherein,
w
new＝x
max-x
min+1
h
new＝y
max-y
min+1
(5). to image
And image
Carry out the solid coupling and obtain disparity map, matching criterior is the absolute difference sum.
In operation steps 207, according to the above-mentioned disparity map that obtains, compute depth figure, and then obtain the coal bunker material level degree of depth.
Fig. 6 is the real-time detecting pattern process flow diagram of laser of the present invention and binocular vision coal bunker level gauging.Detecting pattern is as one of two kinds of optional mode of operations of device in real time, and embodiment can not install the coaling sensor 14 and the sensor 13 of unloading coal, and as shown in Figure 6, in operation steps 31, start-up system detects behind the system initialization.In operation steps 300, carry out level gauging one time.In operation steps 32, carry out the judgement whether material level is in minimum material level, if on earth or be lower than the minimum material level of coal bunker requirement, then carry out operation steps 33, otherwise, enter operation steps 300.In operation steps 33, processor 10 output material level low signals stop to unload coal.In operation steps 36, judge whether the coal bunker material level is changing, if material level then enters operation steps 37 changing, otherwise continuous cycling step 301 changes up to material level.In operation steps 301, carry out the order of operation steps 300, operation steps 36, operation steps 34 and carry out.In operation steps 34, the T2 millisecond of delaying time is with power consumption and the safety that reduces device.In operation steps 37, carry out the judgement whether the coal bunker material level uprises, if not, then enter operation steps 32, otherwise enter operation 302.In operation steps 302, the executable operations that constantly circulates step 300, operation steps 39 and operation steps 38 change up to the coal bunker material level.In operation steps 40, to the work T3 millisecond of delaying time of device, to reach high real-time and to reduce reasonable balance between the power consumption.In operation steps 41, judge whether material level reaches and surpass the high charge level of coal bunker regulation, in coal bunker if it is full then to export the coal position, stops to coaling.
Fig. 7 is laser of the present invention and binocular vision coal bunker level measurement sensor detecting pattern process flow diagram.Pattern detecting sensor is as one of two kinds of optional mode of operations of device, and embodiment will install the coaling sensor 14 and the sensor 13 of unloading coal, and as shown in Figure 7, in operation steps 51, start-up system detects behind the system initialization.In operation steps 61, judge whether the sensor 13 of unloading coal has signal.In operation steps 62, judge whether the sensor 14 of coalingging has signal.In operation steps 300, carry out the coal bunker level gauging one time.In operation steps 58, operation steps 59 is to the measurement device material level T3 millisecond of delaying time.In operation steps 60, the T2 millisecond of delaying time operation.In operation steps 54, judge and to carry out the judgement whether material level is in minimum material level, if on earth or be lower than the minimum material level of coal bunker requirement, then carry out operation steps 56.In operation steps 55, judge that whether material level reaches and surpass the high charge level of coal bunker regulation, if then executable operations step 57 output coal position is full, stops to coaling in coal bunker.When device is operated in pattern detecting sensor, if unload coal sensor 13 and the sensor 14 of coalingging all do not have signal, device enters operation steps 53, is in holding state.Sensor 13 has signal in case unload coal, and then continuous executable operations step 501 arrives the minimum regulatory material level or sensor 13 no signals of unloading coal up to material level.In operation steps 501, order executable operations step 300, operation steps 54 and operation steps 58.Sensor 14 has signal in case coaling, and the executable operations step 502 that then constantly circulates arrives the high charge level of regulation or sensor 14 no signals of coalingging up to the coal bunker material level.In operation steps 502, order executable operations step 300, operation steps 55 and operation steps 59.
Fig. 8 is many analyticities of single camera pixel synoptic diagram.As shown in Figure 8, in the real world in 5 the image of different objects all be the same, this has just caused many analyticities of single camera image, thereby may cause measuring error big based on the coal bunker level gauging of single camera, poor robustness.
Fig. 9 is the spectrum figure of parallax and the degree of depth in the binocular vision; As shown in Figure 9, P is on the tested coal face a bit; O
1, O
2For being respectively the photocentre of two groups of optical systems; F is the focal length of camera lens; B is a base length; p
1, p
2Be respectively the picture point of P in two width of cloth images, its horizontal coordinate is respectively x
1, x
2Parallax d=x
2-x
1, according to triangle shown in Figure 8, the depth calculation formula is as follows:
Figure 10 is the assembly front view fragmentary cross-sectional view of laser of the present invention and binocular vision coal bunker apparatus for measuring charge level.As shown in figure 10, camera substrate 88 is connected with flameproof enclosure 15 screws with light source substrate 93; Light source 3 is connected with light source substrate 93 screws; Laser instrument 8 and camera fixed mount 92 interference fit; Camera 6 is connected with camera fixed mount 92 screws with camera 7; Camera lens 4 and camera 6 are threaded; Camera lens 5 and camera 7 are threaded; Motor 86 is connected with camera substrate 88 screws with motor fixing plate 87; Bearing holder (housing, cover) 90 is connected with camera substrate 88 screws; Bearing holder (housing, cover) 80 and bearing 91 interference fit; Camera fixed mount 92 is connected with rotating shaft 89 screws; The axle of motor 86 is connected with rotating shaft 89 keys;
Figure 11 is the front view sectional view of the present invention's laser and binocular vision coal bunker apparatus for measuring charge level during with a plurality of laser instrument; As shown in figure 11, phase board 127 and light source platform 130 and flameproof enclosure 15 welding; Light source fixing frame 129 is connected with light source platform 130 screws; Light source 3 is connected with the light source fixing frame screw; Camera fixed mount 128 is connected with phase board 127 screws; Camera 6 is connected with camera fixed mount 128 screws with camera 7; Camera lens 4 and camera 6 are threaded; Camera lens 5 and camera 7 are threaded; A plurality of laser instrument 818 shells are connected with camera fixed mount 128 screws.
Figure 12 is the front view sectional view of the present invention's laser and binocular vision coal bunker apparatus for measuring charge level during with a plurality of laser instrument; As shown in figure 12, a plurality of laser instruments 818 along the even or non-homogeneous layout of circumference, are connected a laser instrument by a plurality of laser instruments 8 at every turn, connect successively until form suitable hot spot point on the coal face; Light source 3 is made up of a plurality of LED11; Camera lens 4 and camera 6 are threaded; Camera lens 5 and camera 7 are threaded.
As mentioned above, the invention provides a kind of coal bunker material level measuring method and device based on laser and binocular vision.Its principle be laser emitting module as the active light source, on the coal face, form hot spot, ask for hot spot is realized the coal bunker material level at the parallax of two width of cloth camera images measurement by binocular vision.So the present invention utilizes generating laser and CCD camera simple in structure and that structure is cheap, make this coal bunker apparatus for measuring charge level use not only convenient but also economical.In addition, the invention has the advantages that the quick stereo matching algorithm makes Measuring Time shorten by providing efficiently, and then satisfies the real-time of coal bunker level gauging.Have again, the invention has the advantages that, owing to utilize laser as the active light source, on the coal face, form laser facula, efficiently solve the complicacy of coal bunker material level feature, make that the robustness of total system is good, because laser forms the hot spot point as the active light source on the coal face, lighting requirement to vision system reduces significantly, thereby has solved dark coal bunker illumination the biggest problem.
Although described some embodiments of the present invention, for the people who is familiar with this area, be clearly, these embodiment are done multiple remodeling and do not cause disengaging principle of the present invention and marrow; Appended claim and equivalent term thereof limit the present invention and ask for protection.
Claims (15)
1. coal bunker material level measuring method based on laser and binocular vision, it is characterized in that: laser instrument produces laser beam as the active light source, the size of laser beam changes according to the coal bunker degree of depth and the material level degree of depth, on the coal face, form laser spot, the binocular camera that is arranged in parallel obtains the image of same spot simultaneously, the formation image is right, to the improved algorithm of imagery exploitation to image to pre-service, pretreated image is detected spot parallax in two width of cloth images by new Stereo Matching Algorithm realizes the coal bunker level gauging.Measuring process is:
(1.) laser instrument forms laser spot to coal surface-emission laser bundle on the coal face, and it is right to utilize two CCD cameras to obtain image;
(2.) intrinsic parameter of two CCD cameras of demarcation and two camera lenses;
(3.) the improved corrosion of imagery exploitation of two same frames that step (1.) is gathered and expansion algorithm carry out elder generation and corrode the after expansion pre-service;
(4.) with pretreated two width of cloth images as input, utilize new quick stereo vision algorithm computation depth map;
(5.) obtain the degree of depth of coal bunker material level according to depth map, finally realize efficiently, in real time, coal bunker level gauging purpose accurately.
Two kinds of optional measurement strategies are arranged: real-time detecting pattern and pattern detecting sensor.
2. coal bunker material level measuring method according to claim 1 is characterized in that: the described image that utilizes two CCD cameras to obtain of step (1.) is right, two width of cloth images of the same laser spot of gathering for same moment.
3. coal bunker material level measuring method according to claim 1 is characterized in that: step (3.) is described carries out elder generation's corrosion after expansion pre-service to improved corrosion of imagery exploitation and the expansion algorithm of gathering, and is implemented as follows:
(1.) to image f
1(x, y) and f
2(x y) corrodes operation, and formula is as follows:
(2.) to image f
1(x, y) and f
2(x y) carries out expansive working, and formula is as follows:
In the formula, and f representing input images f (x, y), b representative structure element b (x, y), Mean{A} represents the average of element in the set A, Median{A} represents the intermediate value of element in the set A, D
bBe the field of definition of b, T is a threshold value.
4. coal bunker material level measuring method according to claim 1 is characterized in that: the quick stereo vision algorithm computation depth map that the described utilization of step (4.) is new, and the specific implementation step is as follows:
(1.) at first utilize maximum variance between clusters to ask for respectively to image f
1(x, y) and f
2(x, y) threshold value T
i, i=1,2, carry out binaryzation then, pixel value is more than or equal to threshold value, and pixel value is arranged to 255, otherwise pixel value is arranged to 0;
(2.) scan image f
1(x, y) all pixels obtain pixel value and are the minimum boundary rectangle of all pixels that are interconnected of 255
Its upper left corner coordinate is
Lower right corner coordinate is
(3.) scan image f
2(obtaining pixel value is the minimum boundary rectangle of 255 all pixels that are interconnected for x, y) all pixels
Its upper left corner coordinate is
Lower right corner coordinate is
(4.) produce new image
And image
New image
And image
Width be w
New, highly be h
New, image
Pixel by image f
1(x is y) from (x
Min, y
Min) be starting point, width is w
New, highly be h
NewCopying image in the interior rectangle obtains; New images
Pixel by image f
2(x is y) from (x
Min, y
Min) be starting point, width is w
New, highly be h
NewCopying image in the interior rectangle obtains wherein,
w
new＝x
max-x
min+1
h
new＝y
max-y
min+1
(5.) to image
And image
Carry out the solid coupling and obtain disparity map, matching criterior is the absolute difference sum.
(6.) according to formula
Wherein f is that focal length, b are base length, and d is a parallax, recovers depth map by disparity map, and then realizes the coal bunker level gauging.
5. coal bunker material level measuring method according to claim 1, it is characterized in that: described real-time detecting pattern, the coaling sensor and the sensor of unloading coal can be installed, be meant real-time measurement material level, after it is characterized in that measuring at every turn, judge the material level situation of change, if material level less than changing, is measured behind the time-delay T2 millisecond and is judged the material level situation of change, if material level changes next time, measure behind the time-delay T3 millisecond next time and judge the material level situation of change, T3 is smaller or equal to T2.
6. coal bunker material level measuring method according to claim 1, it is characterized in that: described pattern detecting sensor, device further comprises and unloads the coaling sensor and the sensor of coalingging, situation according to sensor detects, and it is characterized in that, if the sensor of unloading coal does not all have signal with the sensor of coalingging, device is in holding state, the sensor or the sensor of coalingging have signal in case unload coal, and just begin level gauging, and that measures images acquired for twice is spaced apart the T2 millisecond.
7. coal bunker apparatus for measuring charge level based on laser and binocular vision comprises:
One or more laser instruments are used to produce laser beam, and the laser beam variable size;
Image-generating unit is made up of with two consistent camera lenses of parameter the CCD camera of two parameter unanimities, and it is right to be used to obtain the light spot image that described laser beam forms on the coal face;
Processing unit, it utilizes described image right, calculates at hot spot parallax in a pair of image, and then the actual range between calculating coal face auto levelizer;
Light source is made up of led array, the illumination when being used to the camera images acquired is provided, and adjustable brightness; Antibomb unit is used for realizing the requirement of explosion proof under the coal mine.
When with a laser instrument, device also comprises the motor rotating mechanism;
The motor rotating mechanism drives two cameras and laser rotation, and the relative position of two cameras and laser is constant, to guarantee to form suitable spot.
8. coal bunker apparatus for measuring charge level according to claim 7, it is characterized in that: described two CCD cameras are concentric with two camera lenses respectively, and two optical center relative distances are called baseline, length is 120mm, guarantees the camera lens axis parallel by Precision Machining and small adjustment.
9. coal bunker apparatus for measuring charge level according to claim 7 is characterized in that: described laser instrument is made up of a plurality of laser beam emitting heads, determines to connect the number of laser beam emitting head according to the degree of depth of coal bunker, thereby changes the size of laser beam.And laser emitting module is the module of essential safe type.
10. coal bunker apparatus for measuring charge level according to claim 7 is characterized in that: described a plurality of laser instruments, connect a laser instrument emission light beam at every turn, and connecting successively has suitable hot spot point on the coal face.
11. coal bunker apparatus for measuring charge level according to claim 7 is characterized in that: described a plurality of laser instruments are along the even or non-homogeneous layout of circumference.
12. coal bunker apparatus for measuring charge level according to claim 7, it is characterized in that: described motor rotating mechanism, but during with a laser instrument, when not having suitable hot spot, rotating mechanism is by driving the rotation of two cameras and laser instrument, and the relative position of two cameras and laser is constant, to guarantee to form suitable spot.
13. coal bunker apparatus for measuring charge level according to claim 7 is characterized in that: described processor unit further comprises:
Image fetching unit links to each other with the CCD camera, and it is right to be used to read two image of camera, and stores designated memory locations into.
Image storage unit is used for the view data that memory image reads reading unit, and according to the requirement of three-dimensional processing unit image log according to being input to processing unit.
Three-dimensional processing unit is used for to image to carrying out pre-service, three-dimensional coupling and depth calculation.
Control module is used for controlling the quantity of light source igniting led array, is used for controlling Laser emission and closes, and is used for controlling two CCD cameras and begins images acquired and stop to gather the processing of control sensor signal.
14. coal bunker apparatus for measuring charge level according to claim 7 is characterized in that: described explosion-resistant enclosure with form is explosion-proof, and form is high printing opacity.
15. coal bunker apparatus for measuring charge level according to claim 7 is characterized in that: described light source, its luminophor is an infrared LED array, according to the situation of the coal bunker material level that recorded last time, the quantity of LED is lighted in control.
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