CN103899901B - Oil-air lubrication intelligent monitor system and method - Google Patents
Oil-air lubrication intelligent monitor system and method Download PDFInfo
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- CN103899901B CN103899901B CN201210571416.XA CN201210571416A CN103899901B CN 103899901 B CN103899901 B CN 103899901B CN 201210571416 A CN201210571416 A CN 201210571416A CN 103899901 B CN103899901 B CN 103899901B
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Abstract
The invention discloses a kind of oil-air lubrication intelligent monitor system, comprise oil site condition monitoring station, oil-air lubrication PLC controller, industrial control computer, intelligent vision sensor, fuzzy controller, fuzzy controller is processed by the oil gas quantity delivered pre-set parameter from oil-air lubrication PLC controller with from the oil film status data of intelligent vision sensor, provide oil gas quantity delivered parameter adjustment amount, oil gas quantity delivered parameter to oil-air lubricating device is adjusted, and assess oil film status data and whether meet predefined requirement, thereby be ejected into each oil site by meeting the predefined oil film requiring of oil-air lubrication. the present invention utilizes intelligent vision sensor directly to gather, process oil-film images, and from oil-film images pixel, extracts corresponding oil film status data, and by fuzzy controller, oil film state index is assessed, and makes it more meet the predefined requirement of oil-air lubrication. the invention also discloses a kind of oil-air lubrication intelligent control method.
Description
Technical field
The present invention relates to a kind of supervising device, be specifically related to a kind of oil-air lubrication intelligent monitor system. The present invention relates to a kind of oil gasLubricated intelligent control method.
Background technology
Oil Gas Lubrication Technology is widely used in line, bar mill in recent years, on the metallurgical equipments such as conticaster. So-called oil gas profitSliding, refer to that lubricating oil is under compressed-air actuated effect, dispelled as tiny oil film in inner-walls of duct surrounding, waveform ground is forwardMobile, be finally ejected into oil site with extremely meticulous continuous oil film.
Oil-air lubrication equipment is in the market many, but the definition from above-mentioned oil-air lubrication having also has very large distance, incorrectOil gas quantity delivered setting value, the oil film forming is different, if oil is gentle the same at pipeline medium velocity, so from lubricatedIn the air that discharge at position, will contain oily molecule, so not only can cause lubrication oil consumption high, and can cause environmentHarm. Therefore calculate suitable oil gas quantity delivered parameter and assess the required oil film state index of oil site and whether meet oil gas profitSliding predefined requirement just seems particularly important.
Conventional electric control system for oil-gas lubrication is to precompute fuel delivery according to oil site quantity to carry out in greasingOil gas distributes. But in the actual moving process of lubricating system, the quantity of oil site and duty are to change in the moment,Fixing oil gas quantity delivered setting value can not meet operating mode demand.
Chinese patent literature 20110387632.4 discloses a kind of electric control system for oil-gas lubrication, its lubricating oil detecting sensorThe signal data of collection is passed to PLC controller, and wherein said lubricating oil detecting sensor cannot be assessed actual ejection to lubricatedWhether the oil film state index of point meets the requirements; Wherein said PLC controller cannot be according to oil site duty and oil film stateData are carried out the dynamic auto adjustment of oil gas quantity delivered parameter.
The means of conventional supervision oil film are to use ambulatory monitor to monitor air velocity, when flow velocity is too low or stop flowingTime, monitor will be reported to the police, and this can only obtain the information whether compressed air in pipeline or lubricating oil stop up, but high for priceExpensive oil site, for it can long-continuedly be worked under good lubricating status, only keeps the smooth of compressed air or lubricating oilLogical is inadequate, does not also reach the lubricant effect of expection, and cause energy even if undesirable oil film is injected into oil siteSource waste.
Chinese patent literature 200480020550.4 discloses one and by means of schlieren sensor, oil-air lubricating device has been monitoredMethod, the schlieren signal producing by detecting schlieren temporal evolution, belongs to and indirectly obtains oil film schlieren signal and to signalItself carry out a kind of method of filtering calculating, operating personnel cannot directly pass judgment on this schlieren signal.
Summary of the invention
Technical problem to be solved by this invention is to provide a kind of oil-air lubrication intelligent monitor system, and it can be to oil film state indexAssess, make it more meet the predefined requirement of oil-air lubrication, and can automatically adjust oil gas quantity delivered parameter.
For solving the problems of the technologies described above, the technical solution of oil-air lubrication intelligent monitor system of the present invention is:
Comprise oil site condition monitoring station 110, oil-air lubrication PLC controller 111, industrial control computer 114, intelligent visionSensor 120, fuzzy controller 101, intelligent vision sensor 120 is vertically installed in the transparent conveying of oil-air lubricating device 112Pipeline top, intelligent vision sensor 120 gathers and processes the transparent conveying pipeline inner wall four that is attached to oil-air lubricating device 112The oil-film images in week, and calculate oil film status data according to oil-film images; Intelligent vision sensor 120 is by oil-film images and oil filmStatus data is transferred to industrial control computer 114 by holding wire; Intelligent vision sensor 120 passes through oil film status dataHolding wire transfers to fuzzy controller 101; Oil site condition monitoring station 110 is monitored oil site 113, gathers reflection profitThe variable data of sliding point 113 duties, and the variable data collecting is transferred to oil-air lubrication PLC control by holding wireDevice 111; Oil-air lubrication PLC controller 111 is according to this variable data dynamic calculation oil gas quantity delivered pre-set parameter, and by oilGas quantity delivered pre-set parameter transfers to by holding wire in the Database Unit 103 of fuzzy controller 101; Fuzzy controller 101By the oil gas quantity delivered pre-set parameter from oil-air lubrication PLC controller 111 with from the oil film of intelligent vision sensor 120Status data is processed, and provides oil gas quantity delivered parameter adjustment amount, and the oil gas quantity delivered parameter of oil-air lubricating device 112 is enteredRow is adjusted, and assesses the whether satisfied predefined requirement of oil film status data, thereby will meet the predefined oil film requiring of oil-air lubricationBe ejected into each oil site 113.
Described intelligent vision sensor 120 comprises CCD industrial camera 125, image processing module 121, CCD industrial camera 125Gather oil-film images, and oil-film images is transferred to image processing module 121 by holding wire, image processing module 121 is to oilFilm image carries out image processing.
Described image processing module 121 comprises image filtering unit 124, picture contrast enhancement unit 123, oil film state computationUnit 122, oil-film images increases through the filtering of image filtering unit 124 and the contrast of picture contrast enhancement unit 123Qiang Hou, is calculated width, spacing and the quantity of oil film, and this oil film status data is transferred to by oil film state computation unit 122Fuzzy controller 101.
Described fuzzy controller 101 comprises base module 102, obfuscation module 106, precision module 107, wherein knowledgeLibrary module 102 comprises Database Unit 103, rule base unit 105 and on-the-spot expert's control module 104; From oil-air lubricationThe oil gas quantity delivered pre-set parameter of PLC controller 111 and being stored in from the oil film status data of intelligent vision sensor 120Database Unit 103; On-the-spot expert's control module 104 is by the oil gas quantity delivered pre-set parameter in Database Unit 103 and oilMembrane stage data are set up initial mapping relation, and deposit this initial mapping relation in rule base unit 105 as predefined rule;The oil film status data in Database Unit 103 is carried out Fuzzy processing by obfuscation module 106, and set up corresponding degree of membershipFunction; Rule base unit 105 carries out fuzzy reasoning according to predefined rule by oil film status data, in oil film status dataReflection oil film size, the value of oil film flow velocity size compares with corresponding predefined value respectively, judges that oil film state index isNo satisfied predefined requirement, and represent output with corresponding fuzzy language variable, in the time not meeting, carry out corresponding early warning, warningOutput; Precision module 107 is carried out precision calculating to the fuzzy output quantity that comes from rule base unit 105, determines oil gasQuantity delivered parameter adjustment amount, and be transferred to oil-air lubrication PLC controller 111, controlled by oil-air lubrication PLC controller 111Fuel tap in oil-air lubricating device 112 processed, keying moment and the cycle of air valve.
Described on-the-spot expert's control module 104 is modified to the predefined rule in rule base unit 105, by the scene of recordingInput when expert controls, output relation, set up corresponding control law, makes rule base unit 105 possess self-learning function.
The present invention also provides a kind of oil-air lubrication intelligent control method, and its technical solution is, comprises the following steps:
The first step, intelligent vision sensor 120 gathers and processes the transparent conveying pipeline inner wall that is attached to oil-air lubricating device 112The oil-film images of surrounding, obtains oil film status data according to oil-film images, oil film state data packets oil scraper film width, oil film spacing,Oil film quantity; Then oil film status data is transferred to fuzzy controller 101 by Ethernet cable;
Described intelligent vision sensor 120 obtains the method for oil film status data, specifically comprises the following steps:
Step 401, carries out filtering by oil-film images and contrast strengthens;
The CCD industrial camera 125 of intelligent vision sensor 120 obtains oil-film images, in image filtering unit 124 to oil filmImage carries out medium filtering, and it is right then in picture contrast enhancement unit 123, by histogram equalization, oil-film images to be carried outStrengthen than degree;
Step 402, is treated to bianry image by oil-film images;
The gray value of each pixel in oil-film images and predetermined threshold are compared, by the oil-film images picture lower than predetermined thresholdThe gray value of element is set to 0, and the gray value of the oil-film images pixel higher than predetermined threshold is set to 1; Image after treatment is only depositedAt two kinds of pixels, i.e. bianry images of gray value 0 and 1; Predetermined threshold represents to meet the grey scale pixel value of oil film pixel value;
The oil-film images pixel that step 403 is 1 by gray value is numbered according to affiliated area;
Press column or row scanning bianry image, after to run into gray value be 1 oil-film images pixel, retrieve its around all the other 8Pixel; If its around 8 pixels to have at least one gray value be 1 pixel, by its numbering; Add up numbered pixel,Classify according to different continuums;
Step 404, obtains oil film quantity;
Add up numbered pixel, carry out the classification of continuum according to difference numbering number; All pictures in retrieval oil-film imagesElement, obtains all different numberings, and the number of the different numberings of statistics is also sorted out; The pixel of all identical numberings is classified as oneContinuum, that is an oil film region; The region of all different numberings of retrieval oil-film images, the quantity of zones of different is oilFilm quantity;
Step 405, obtains oil film spacing;
The regions of the each different numberings of retrieval in oil-film images, according to oil-film images pixel abscissa maximum in each region withThe abscissa of the mean value calculation corresponding region geometric center of minimum of a value sum, according to oil-film images pixel ordinate in each regionThe ordinate of the mean value calculation corresponding region geometric center of maximum and minimum of a value sum; According to adjacent two regions of oil-film imagesThe distance of geometric center poor, calculates the distance between region, i.e. the spacing of oil film;
Step 406, obtains oil film width;
Laterally each pixel in each region in retrieval oil-film images, obtains and laterally retrieves each time abscissa maximum and minimum imageElement, and calculate both abscissa differences, the abscissa difference of region laterally being retrieved to acquisition is averaged, and obtains mean breadth,For oil film width.
Second step, the oil film status data that fuzzy controller 101 feeds back intelligent vision sensor 120 carry out obfuscation place successivelyReason, degree of membership calculating, fuzzy reasoning and precision output, calculate oil gas quantity delivered parameter adjustment value, controls oil-air lubricating device112, and assess current oil membrane stage index and whether meet the predefined requirement of oil-air lubrication.
Described fuzzy controller 101 is controlled the method for oil-air lubricating device 112, specifically comprises the following steps:
Step 501, data input; By oil gas quantity delivered pre-set parameter and the intelligent vision of oil-air lubrication PLC controller 111Oil film status data in sensor 120, comprises oil film width, oil film spacing, oil film quantity, is transferred to Database Unit 103In;
Step 502, data storage and processing; The data Storage and Processing that completes Database Unit 103, comprises input and output skyBetween division, using oil gas quantity delivered pre-set parameter, oil film width, oil film spacing, oil film quantity as input variable; ?To oil film state index, comprise the assessment of oil film size, oil film flow velocity size, and oil gas quantity delivered parameter adjustment amount is as defeatedGo out variable;
Step 503, carries out Fuzzy processing to input data;
In obfuscation module 106, complete the fuzzification process to input variable, by oil film quantity and oil gas quantity delivered actual valueCarry out relationship map, be converted into the fuzzy language variable that oil gas quantity delivered actual value is little, moderate, large; By oil gas quantity delivered parameterSetting value is converted into the deviation of oil gas quantity delivered actual value the fuzzy language variable that deviation is little, moderate, large; By oil film width withOil film size is carried out relationship map, is converted into the fuzzy language variable that oil film is little, moderate, large; By oil film spacing and oil film flow velocityCarry out relationship map, be converted into the fuzzy language variable that oil film flow velocity is little, moderate, large; Set up respectively oil gas quantity delivered parameter realThe membership function of border value, deviation, oil film size, oil film flow velocity, wherein membership function calculates and adopts triangular function;
Step 504, rule-based reasoning;
For setting up logical communication link between input and output variable, i.e. one of given input variable group of situation, just has a kind of fuzzy defeatedGo out corresponding; In rule base unit 105, have predefined rule, oil gas quantity delivered pre-set parameter and oil film status data itBetween mapping relations, that is scanning current time oil gas quantity delivered pre-set parameter, according to predetermined time interval gather respectively intelligenceThe oil film quantity, oil film spacing, the oil film width that in energy vision sensor 120, calculate, these three reflection oil film status datasVariate-value, and using this as the predefined required value of oil-air lubrication;
Step 505, precision processing;
Adopt gravity model appoach to carry out precision output to output membership function, oil gas quantity delivered parameter adjustment amount is transferred to oil gas profitIn sliding PLC controller 111, control the fuel tap in oil-air lubricating device 112, keying moment and the cycle of air valve, finally make fullThe predefined oil film requiring of foot oil-air lubrication is ejected into oil site, and wherein gravity model appoach is to get fuzzy membership function and abscissa surroundsThe center of gravity of area is the final output valve of fuzzy reasoning;
Step 506, rule is from amendment and study;
On-the-spot expert's control module adopts method of expertise to modify to predefined rule base, comprises and increasing or deletion rule languageSentence, input and output state when recording on-the-spot expert and operating, and set up corresponding mapping relations, and using these mapping relations asNew rule adds rule base unit 105, or irrational rule in replacement, delete procedure control, makes rule base unit 105There is self-learning function.
The technique effect that the present invention can reach is:
The present invention utilizes intelligent vision sensor directly to gather, process oil-film images, and from oil-film images pixel, extracts correspondingOil film status data, and by fuzzy controller, oil film state index is assessed, make it more meet oil-air lubrication predefinedRequirement.
The present invention has overcome oil gas quantity delivered setting value in conventional open loop electric control system and has filled a prescription by preset value, causesOil gas quantity delivered waste problem; Having overcome oil gas quantity delivered parameter needs artificial adjustment, and adjustment amount is subject to personal experience's impact,The problem that the adjustment amount precision causing cannot ensure, has realized and can automatically adjust oil gas confession according to the operating mode of on-the-spot oil siteGive amount setting value, reach efficient, energy-conservation effect.
The present invention has overcome conventional monitoring and has lacked oil film state is directly passed judgment on, and it is lubricated that cannot judging of causing is injected intoWhether the oil film of point meets the predefined problem requiring of oil-air lubrication, by fuzzy control, oil film state index is carried out to real-time onlineAssessment, early warning and warning output function, thus realize the checking to application and parameter setting.
The present invention is a kind of numerical control system with closed-loop structure, adopts digital image processing method, fuzzy control method in factShow the real-time monitoring to oil film state, the whole function of dynamic self of oil gas quantity delivered setting value.
Brief description of the drawings
Below in conjunction with the drawings and specific embodiments, the present invention is further detailed explanation:
Fig. 1 is the schematic diagram of oil-air lubrication intelligent monitor system of the present invention;
Fig. 2 is the oil-film images schematic diagram of the conveying pipeline inner wall surrounding of oil-air lubricating device;
Fig. 3 is the oil-film images schematic diagram after intelligent vision sensor of the present invention filtering and picture contrast strengthen;
Fig. 4 is the schematic diagram that intelligent vision sensor of the present invention obtains the method for oil film status data;
Fig. 5 is the schematic diagram of the method for fuzzy Control oil-air lubricating device of the present invention.
Description of reference numerals in figure:
110 is oil site condition monitoring station, and 111 is oil-air lubrication PLC controller,
112 is oil-air lubricating device, and 113 is oil site,
114 is industrial control computer, and 101 is fuzzy controller,
102 is base module, and 103 is Database Unit,
104 is on-the-spot expert's control module, and 105 is rule base unit,
106 is obfuscation module, and 107 is precision module,
120 is intelligent vision sensor, and 121 is image processing module,
122 is oil film state computation unit, and 123 is picture contrast enhancement unit,
124 is image filtering unit, and 125 is CCD industrial camera.
Detailed description of the invention
As shown in Figure 1, oil-air lubrication intelligent monitor system of the present invention, comprises oil site condition monitoring station 110, oil-air lubrication PLC(FPGA) controller 111, industrial control computer 114, oil-air lubricating device 112, intelligent vision sensor 120,Fuzzy controller 101, intelligent vision sensor 120 is vertically installed in the transparent conveyance conduit top of oil-air lubricating device 112,Intelligent vision sensor 120 gathers and processes the oil film figure of the transparent conveying pipeline inner wall surrounding that is attached to oil-air lubricating device 112Picture, and calculate oil film status data, oil film state data packets oil scraper film width, oil film spacing, oil film quantity according to oil-film images;And oil-film images and oil film status data are transferred to the visible human machine operation of industrial control computer 114 by Ethernet cableInterface, visual man machine operation interface, for storage, inquiry oil-film images and oil film status data, monitors, adjusts oil gas and supply withAmount parameter; Intelligent vision sensor 120 transfers to fuzzy controller 101 by oil film status data by Ethernet cable;
Oil site condition monitoring station 110 is monitored oil site 113, gathers the variable number of reflection oil site 113 dutiesAccording to, comprise quantity, specification, rotating speed, electric current, the moment of torsion of oil site, and the variable data collecting is passed through to Ethernet cableTransfer to oil-air lubrication PLC controller 111; Oil-air lubrication PLC controller 111 supplies according to this variable data dynamic calculation oil gasGive amount pre-set parameter, and oil gas quantity delivered pre-set parameter is transferred to the data of fuzzy controller 101 by Ethernet cableIn library unit 103;
Fuzzy controller 101 is to the oil gas quantity delivered pre-set parameter from oil-air lubrication PLC controller 111 and look from intelligenceThe oil film status data of sense sensor 120, carries out Fuzzy processing, fuzzy rule reasoning, precision calculating successively, gives fuel-displacedGas quantity delivered parameter adjustment amount, adjusts the oil gas quantity delivered parameter of oil-air lubricating device 112, and assesses oil film status numberAccording to whether meeting predefined requirement, thereby be ejected into each oil site 113 by meeting the predefined oil film requiring of oil-air lubrication.
Intelligent vision sensor 120 comprises CCD (charge coupled cell) industrial camera 125, image processing module 121, CCDIndustrial camera 125 gathers oil-film images, and oil-film images is transferred to image processing module 121, image by Ethernet cableProcessing module 121 is carried out image processing to oil-film images; The image resolution ratio of CCD industrial camera 125 is 640 × 480 pixels;Image processing module 121 is by 122 groups of image filtering unit 124, picture contrast enhancement unit 123, oil film state computation unitBecome, oil-film images after the filtering of image filtering unit 124 and the contrast of picture contrast enhancement unit 123 strengthen,Calculated width, spacing and the quantity of oil film by oil film state computation unit 122, and this oil film status data is transferred to Fuzzy ControlDevice 101 processed;
As shown in Figure 2, the transparent conveying pipeline inner wall surrounding of oil-air lubricating device 112 is adhered to oil film, and oil film is compressed-air actuatedUnder promotion, wave moves forward, and intelligent vision sensor 120 is for gathering this oil-film images.
Fuzzy controller 101 comprises base module 102, obfuscation module 106, precision module 107, wherein knowledge base mouldPiece 102 is made up of Database Unit 103, rule base unit 105 and on-the-spot expert's control module 104; Fuzzy controller 101In the process of oil-air lubricating device failure-free operation, fed back by intelligent vision sensor 120 according to predetermined time interval collectionOil film status data, and deposit in Database Unit 103;
From the oil gas quantity delivered pre-set parameter of oil-air lubrication PLC controller 111 with from the oil of intelligent vision sensor 120Membrane stage data are stored in Database Unit 103; On-the-spot expert's control module 104 is supplied with the oil gas in Database Unit 103Amount pre-set parameter and oil film status data are set up initial mapping relation, and this initial mapping relation is deposited as predefined ruleEnter rule base unit 105; On-the-spot expert's control module 104 can also close the predefined rule in rule base unit 105The amendment of reason, input, output relation while control by recording on-the-spot expert, set up corresponding control law, makes rule base listUnit 105 possesses self-learning function;
The oil film status data in Database Unit 103 is carried out the conversion of fuzzy language variable by obfuscation module 106, and set up phaseThe membership function of answering; Rule base unit 105 carries out fuzzy reasoning according to predefined rule by oil film status data, oil filmIn status data, reflect oil film size, the value of oil film flow velocity size compares with corresponding predefined value respectively, judges oil filmWhether state index meets predefined requirement, and represents output with corresponding fuzzy language variable, carries out corresponding in the time not meetingEarly warning, the output of reporting to the police; Precision module 107 is carried out precision calculating to fuzzy output quantity, determines oil gas quantity delivered parameter tuneWhole amount, and be transferred to oil-air lubrication PLC controller 111, control oil-air lubrication dress by oil-air lubrication PLC controller 111Put the fuel tap in 112, keying moment and the cycle of air valve.
Oil-air lubrication intelligent control method of the present invention, comprises the following steps:
The first step, intelligent vision sensor 120 gathers and processes the transparent conveying pipeline inner wall that is attached to oil-air lubricating device 112The oil-film images of surrounding, the continuous oil film district that in the image after cutting apart by calculating and predetermined threshold according to oil-film images, gray scale is 1Territory obtains oil film status data, oil film state data packets oil scraper film width, oil film spacing, oil film quantity; Then by oil film shapeState data transfer to fuzzy controller 101 by Ethernet cable;
As shown in Figure 3, to obtain the method for oil film status data as follows for intelligent vision sensor 120:
Oil-film images is carried out, after filtering and contrast enhancing, utilizing predetermined threshold to cut apart rear generation bianry image region, andSet up respectively the scanning direction of abscissa and ordinate; Pixel is numbered to and counts successively oil film quantity by region, lastExtract oil film width, oil film spacing;
As shown in Figure 4, intelligent vision sensor 120 obtains the method for oil film status data, specifically comprises the following steps:
Step 401, carries out filtering by oil-film images and contrast strengthens;
The CCD industrial camera 125 of intelligent vision sensor 120 obtains oil-film images, in image filtering unit 124 to oil filmImage carries out medium filtering, and it is right then in picture contrast enhancement unit 123, by histogram equalization, oil-film images to be carried outStrengthen than degree; Image filtering and contrast strengthen as prior art, and the present invention no longer describes in detail;
Step 402, is treated to bianry image by oil-film images;
The gray value of each pixel in oil-film images and predetermined threshold are compared, by the oil-film images picture lower than predetermined thresholdThe gray value of element is set to 0, and the gray value of the oil-film images pixel higher than predetermined threshold is set to 1; Image after treatment is only depositedAt two kinds of pixels, i.e. bianry images of gray value 0 and 1; Predetermined threshold represents to meet the grey scale pixel value of oil film pixel value;
The oil-film images pixel that step 403 is 1 by gray value is numbered according to affiliated area;
Press column or row scanning bianry image, after to run into gray value be 1 oil-film images pixel, retrieve its around all the other 8Pixel; If its around 8 pixels to have at least one gray value be 1 pixel, by its numbering; Add up numbered pixel,Classify according to different continuums;
Method for numbering serial is: if its pixel that around gray value is 1 in 8 pixels has had at least one to be numbered, as numberCode 100, number is identical therewith for the number of its numbering, is also 100; If it does not around exist the pixel of compiling number, scanWhole image, obtains all numbering numbers, gets maximum number and adds 1 for self numbering number; Scanning all images, untilAll pixels are all processed;
Step 404, obtains oil film quantity;
Add up numbered pixel, carry out the classification of continuum according to difference numbering number; All pictures in retrieval oil-film imagesElement, obtains all different numberings, and the number of the different numberings of statistics is also sorted out; The pixel of all identical numberings is classified as oneContinuum, that is an oil film region; The region of all different numberings of retrieval oil-film images, the quantity of zones of different is oilFilm quantity;
Step 405, obtains oil film spacing;
The regions of the each different numberings of retrieval in oil-film images, according to oil-film images pixel abscissa maximum in each region withThe abscissa of the mean value calculation corresponding region geometric center of minimum of a value sum, according to oil-film images pixel ordinate in each regionThe ordinate of the mean value calculation corresponding region geometric center of maximum and minimum of a value sum; According to adjacent two regions of oil-film imagesThe distance of geometric center poor, calculates the distance between region, i.e. the spacing of oil film;
Step 406, obtains oil film width;
Laterally each pixel in each region in retrieval oil-film images, obtains and laterally retrieves each time abscissa maximum and minimum imageElement, and calculate both abscissa differences, the abscissa difference of region laterally being retrieved to acquisition is averaged, and obtains mean breadth,For oil film width;
Second step, the oil film status data that fuzzy controller 101 feeds back intelligent vision sensor 120 carry out obfuscation place successivelyReason, degree of membership calculating, fuzzy reasoning and precision output, calculate oil gas quantity delivered parameter adjustment value, assessment current oil membrane stageWhether index meets the predefined requirement of oil-air lubrication; Fuzzy controller 101 is applied fuzzy control technology, processes Industry Control mistakeIn journey, the model of complicated controlled device, especially controlled device is uncertain or be difficult to set up accurate Mathematical Modeling;
As shown in Figure 5, fuzzy controller 101 is controlled the method for oil-air lubricating device 112, specifically comprises the following steps:
Step 501, data input; By ethernet communication mode, by the oil gas quantity delivered of oil-air lubrication PLC controller 111Oil film status data in pre-set parameter and intelligent vision sensor 120, comprises oil film width, oil film spacing, oil film quantity,Be transferred in Database Unit 103;
Step 502, data storage and processing; Complete the data Storage and Processing of Database Unit 103 by ethernet communication,Comprise the division of input-output space, oil gas quantity delivered pre-set parameter, oil film width, oil film spacing, oil film quantity are doneFor input variable; To oil film state index, comprise the assessment of oil film size, oil film flow velocity size, and oil gas quantity delivered ginsengNumber adjustment amount is as output variable;
Step 503, carries out Fuzzy processing to input data;
In obfuscation module 106, complete the fuzzification process to input variable, by oil film quantity and oil gas quantity delivered actual valueCarry out relationship map, be converted into the fuzzy language variable that oil gas quantity delivered actual value is little, moderate, large; By oil gas quantity delivered parameterSetting value is converted into the deviation of oil gas quantity delivered actual value the fuzzy language variable that deviation is little, moderate, large; By oil film width withOil film size is carried out relationship map, is converted into the fuzzy language variable that oil film is little, moderate, large; By oil film spacing and oil film flow velocityCarry out relationship map, be converted into the fuzzy language variable that oil film flow velocity is little, moderate, large; Set up respectively oil gas quantity delivered parameter realThe membership function of border value, deviation, oil film size, oil film flow velocity, wherein membership function calculates and adopts triangular function, forPrior art, does not describe in detail at this;
Step 504, rule-based reasoning;
For setting up logical communication link between input and output variable, i.e. one of given input variable group of situation, just has a kind of fuzzy defeatedGo out corresponding; In rule base unit 105, have predefined rule, oil gas quantity delivered pre-set parameter and oil film status data itBetween mapping relations, that is scanning current time oil gas quantity delivered pre-set parameter, according to predetermined time interval gather respectively intelligenceThe oil film quantity, oil film spacing, the oil film width that in energy vision sensor 120, calculate, these three reflection oil film status datasVariate-value, and using this as the predefined required value of oil-air lubrication;
Rule base unit 105 by some " IF ... THEN ... " statement forms, wherein, and oil gas quantity delivered parameter adjustment amount sizeCan be by following rule judgment:
IF oil gas quantity delivered parameter error little THEN oil gas quantity delivered parameter adjustment amount is little;
IF oil gas quantity delivered parameter moderate THEN oil gas quantity delivered parameter adjustment amount is zero;
IF oil gas quantity delivered parameter error large THEN oil gas quantity delivered parameter adjustment amount is large;
Wherein, between oil film width and oil film size, mapping relations can be by following rule judgment:
The little THEN oil film of IF oil film width is little;
The moderate THEN oil film of IF oil film width is of moderate size;
The large THEN oil film of IF oil film width is large;
Wherein, between oil film spacing and oil film flow velocity, mapping relations can be by following rule judgment:
The little THEN oil film of IF oil film spacing flow velocity is little;
The moderate THEN oil film of IF oil film spacing flow velocity is moderate;
The large THEN oil film of IF oil film spacing flow velocity is large;
Wherein, assessment oil film state index whether meet the predefined requirement of oil-air lubrication can be by following rule judgment:
IF oil film is of moderate size and the moderate THEN oil film of oil film flow velocity state meets the demands;
IF oil film is large and the little THEN warning of oil film flow velocity compressed air pressure is low or early warning is stopped up;
IF oil film is large and the large THEN early warning of oil film flow velocity fuel delivery is large;
IF oil film is little and the large THEN early warning of oil film flow velocity fuel delivery is little;
Step 505, precision processing;
Adopt gravity model appoach to carry out precision output to output membership function, oil gas quantity delivered parameter adjustment amount is transferred to oil gas profitIn sliding PLC controller 111, control the fuel tap in oil-air lubricating device 112, keying moment and the cycle of air valve, finally make fullThe predefined oil film requiring of foot oil-air lubrication is ejected into oil site, and wherein gravity model appoach is to get fuzzy membership function and abscissa surroundsThe center of gravity of area is the final output valve of fuzzy reasoning, and gravity model appoach is prior art, does not describe in detail at this;
Step 506, rule is from amendment and study;
On-the-spot expert's control module adopts method of expertise to modify to predefined rule base, comprises and increasing or deletion rule languageSentence, input and output state when recording on-the-spot expert and operating, and set up corresponding mapping relations, and using these mapping relations asNew rule adds rule base unit 105, or irrational rule in replacement, delete procedure control, makes rule base unit 105There is self-learning function.
Should be understood that, for those of ordinary skills, can be improved according to the above description or convert, and instituteThere are these improvement and conversion all should belong to the protection domain of claims of the present invention.
Claims (8)
1. an oil-air lubrication intelligent monitor system, is characterized in that: comprise oil site condition monitoring station (110), oil gas profitSliding PLC controller (111), industrial control computer (114), intelligent vision sensor (120), fuzzy controller (101),Intelligent vision sensor (120) is vertically installed in the transparent conveyance conduit top of oil-air lubricating device (112), and intelligent vision passesSensor (120) gathers and processes the oil-film images of the transparent conveying pipeline inner wall surrounding that is attached to oil-air lubricating device (112),And calculate oil film status data according to oil-film images; Intelligent vision sensor (120) passes through oil-film images and oil film status dataHolding wire is transferred to industrial control computer (114); Intelligent vision sensor (120) passes oil film status data by holding wireTransport to fuzzy controller (101);
Oil site condition monitoring station (110) is monitored oil site (113), gathers reflection oil site (113) work shapeThe variable data of state, and the variable data collecting is transferred to oil-air lubrication PLC controller (111) by holding wire; Oil gasLubricate PLC controller (111) according to this variable data dynamic calculation oil gas quantity delivered pre-set parameter, and oil gas quantity delivered is joinedNumber setting value transfers in the Database Unit (103) of fuzzy controller (101) by holding wire;
Fuzzy controller (101) will from the oil gas quantity delivered pre-set parameter of oil-air lubrication PLC controller (111) and fromThe oil film status data of intelligent vision sensor (120) is processed, and provides oil gas quantity delivered parameter adjustment amount, to oil-air lubricationThe oil gas quantity delivered parameter of device (112) is adjusted, and assesses the whether satisfied predefined requirement of oil film status data, thereby willMeet the predefined oil film requiring of oil-air lubrication and be ejected into each oil site (113).
2. oil-air lubrication intelligent monitor system according to claim 1, is characterized in that: described intelligent vision sensor(120) comprise CCD industrial camera (125), image processing module (121), CCD industrial camera (125) gathers oil film figurePicture, and oil-film images is transferred to image processing module (121) by holding wire, image processing module (121) is to oil-film imagesCarry out image processing.
3. oil-air lubrication intelligent monitor system according to claim 2, is characterized in that: described image processing module (121)Comprise image filtering unit (124), picture contrast enhancement unit (123), oil film state computation unit (122), oil film figurePicture is after the filtering of image filtering unit (124) and the enhancing of the contrast of picture contrast enhancement unit (123), by oilMembrane stage computing unit (122) calculates width, spacing and the quantity of oil film as oil film status data, and by this oil film status numberReportedly be passed to fuzzy controller (101).
4. oil-air lubrication intelligent monitor system according to claim 1, is characterized in that: described fuzzy controller (101)Comprise base module (102), obfuscation module (106), precision module (107), wherein base module (102) bagDraw together Database Unit (103), rule base unit (105) and on-the-spot expert's control module (104); Control from oil-air lubrication PLCThe oil gas quantity delivered pre-set parameter of device processed (111) and being stored in from the oil film status data of intelligent vision sensor (120)Database Unit (103); On-the-spot expert's control module (104) is established the oil gas quantity delivered parameter in Database Unit (103)Definite value and oil film status data are set up initial mapping relation, and deposit this initial mapping relation in rule base as predefined ruleUnit (105);
The oil film status data in Database Unit (103) is carried out Fuzzy processing by obfuscation module (106), and set up phaseThe membership function of answering; Rule base unit (105) carries out fuzzy reasoning according to predefined rule by oil film status data, oilIn membrane stage data, reflect oil film size, the value of oil film flow velocity size compares with corresponding predefined value respectively, judgement oilWhether membrane stage index meets predefined requirement, and represents output with corresponding fuzzy language variable, carries out corresponding in the time not meetingEarly warning, report to the police output; Precision module (107) is carried out accurately the fuzzy output quantity that comes from rule base unit (105)Change and calculate, determine oil gas quantity delivered parameter adjustment amount, and be transferred to oil-air lubrication PLC controller (111), by oil gasLubricated PLC controller (111) is controlled the fuel tap in oil-air lubricating device (112), keying moment and the cycle of air valve.
5. oil-air lubrication intelligent monitor system according to claim 4, is characterized in that: described on-the-spot expert controls listUnit (104) modifies to the predefined rule in rule base unit (105), input while control by recording on-the-spot expert,Output relation, sets up corresponding control law, makes rule base unit (105) possess self-learning function.
6. an oil-air lubrication intelligent control method, is characterized in that, comprises the following steps:
The first step, intelligent vision sensor (120) gathers and processes the transparent carrier pipe that is attached to oil-air lubricating device (112)The oil-film images of road inwall surrounding, obtains oil film status data according to oil-film images, oil film state data packets oil scraper film width, oilIntermembranous distance, oil film quantity; Then oil film status data is transferred to fuzzy controller (101) by Ethernet cable;
Second step, the oil film status data of intelligent vision sensor (120) feedback is carried out successively mould by fuzzy controller (101)Gelatinization processing, degree of membership calculating, fuzzy reasoning and precision output, calculate oil gas quantity delivered parameter adjustment value, controls oil gas profitSliding device (112), and assess current oil membrane stage index and whether meet the predefined requirement of oil-air lubrication.
7. oil-air lubrication intelligent control method according to claim 6, is characterized in that: in the described first step, intelligence is lookedSense sensor (120) obtains the method for oil film status data, specifically comprises the following steps:
Step 401, carries out filtering by oil-film images and contrast strengthens;
The CCD industrial camera (125) of intelligent vision sensor (120) obtains oil-film images, in image filtering unit (124)In oil-film images is carried out to medium filtering, then in picture contrast enhancement unit (123) by histogram equalization to oil filmImage carries out contrast enhancing;
Step 402, is treated to bianry image by oil-film images;
The gray value of each pixel in oil-film images and predetermined threshold are compared, by the oil-film images picture lower than predetermined thresholdThe gray value of element is set to 0, and the gray value of the oil-film images pixel higher than predetermined threshold is set to 1; Image after treatment is only depositedAt two kinds of pixels, i.e. bianry images of gray value 0 and 1; Predetermined threshold represents to meet the grey scale pixel value of oil film pixel value;
The oil-film images pixel that step 403 is 1 by gray value is numbered according to affiliated area;
Press column or row scanning bianry image, after to run into gray value be 1 oil-film images pixel, retrieve its around all the other 8Pixel; If its around 8 pixels to have at least one gray value be 1 pixel, by its numbering; Add up numbered pixel,Classify according to different continuums;
Step 404, obtains oil film quantity;
Add up numbered pixel, carry out the classification of continuum according to difference numbering number; All pictures in retrieval oil-film imagesElement, obtains all different numberings, and the number of the different numberings of statistics is also sorted out; The pixel of all identical numberings is classified as oneContinuum, that is an oil film region; The region of all different numberings of retrieval oil-film images, the quantity of zones of different is oilFilm quantity;
Step 405, obtains oil film spacing;
The regions of the each different numberings of retrieval in oil-film images, according to oil-film images pixel abscissa maximum in each region withThe abscissa of the mean value calculation corresponding region geometric center of minimum of a value sum, according to oil-film images pixel ordinate in each regionThe ordinate of the mean value calculation corresponding region geometric center of maximum and minimum of a value sum; According to adjacent two regions of oil-film imagesThe distance of geometric center poor, calculates the distance between region, i.e. the spacing of oil film;
Step 406, obtains oil film width;
Laterally each pixel in each region in retrieval oil-film images, obtains and laterally retrieves each time abscissa maximum and minimum imageElement, and calculate both abscissa differences, the abscissa difference of region laterally being retrieved to acquisition is averaged, and obtains mean breadth,For oil film width.
8. oil-air lubrication intelligent control method according to claim 6, is characterized in that: Fuzzy Control in described second stepDevice processed (101) is controlled the method for oil-air lubricating device (112), specifically comprises the following steps:
Step 501, data input; Oil gas quantity delivered pre-set parameter and the intelligence of oil-air lubrication PLC controller (111) are lookedOil film status data in sense sensor (120), comprises oil film width, oil film spacing, oil film quantity, is transferred to Database Unit(103) in;
Step 502, data storage and processing; The data Storage and Processing that completes Database Unit (103), comprises input and outputThe division in space, using oil gas quantity delivered pre-set parameter, oil film width, oil film spacing, oil film quantity as input variable;To oil film state index, comprise the assessment of oil film size, oil film flow velocity size, and the conduct of oil gas quantity delivered parameter adjustment amountOutput variable;
Step 503, carries out Fuzzy processing to input data;
In obfuscation module (106), complete the fuzzification process to input variable, real by oil film quantity and oil gas quantity deliveredBorder value is carried out relationship map, is converted into the fuzzy language variable that oil gas quantity delivered actual value is little, moderate, large; By oil gas quantity deliveredThe deviation of pre-set parameter and oil gas quantity delivered actual value is converted into the fuzzy language variable that deviation is little, moderate, large; Oil film is wideDegree carries out relationship map with oil film size, is converted into the fuzzy language variable that oil film is little, moderate, large; By oil film spacing and oil filmFlow velocity carries out relationship map, is converted into the fuzzy language variable that oil film flow velocity is little, moderate, large; Set up respectively oil gas quantity delivered ginsengThe membership function of number actual value, deviation, oil film size, oil film flow velocity, wherein membership function calculates and adopts triangular function;
Step 504, rule-based reasoning;
For setting up logical communication link between input and output variable, i.e. one of given input variable group of situation, just has a kind of fuzzy defeatedGo out corresponding; In rule base unit (105), there is predefined rule, i.e. oil gas quantity delivered pre-set parameter and oil film status dataBetween mapping relations, that is scanning current time oil gas quantity delivered pre-set parameter, according to predetermined time interval gather respectivelyThe oil film quantity, oil film spacing, the oil film width that in intelligent vision sensor (120), calculate, these three reflection oil film status numbersAccording to variate-value, and using this as the predefined required value of oil-air lubrication;
Step 505, precision processing;
Adopt gravity model appoach to carry out precision output to output membership function, oil gas quantity delivered parameter adjustment amount is transferred to oil gas profitIn sliding PLC controller (111), control the fuel tap in oil-air lubricating device (112), keying moment and the cycle of air valve,Make eventually to meet the predefined oil film requiring of oil-air lubrication and be ejected into oil site, wherein gravity model appoach is to get fuzzy membership function and horizontal seatThe center of gravity that mark surrounds area is the final output valve of fuzzy reasoning;
Step 506, rule is from amendment and study;
On-the-spot expert's control module adopts method of expertise to modify to predefined rule base, comprises and increasing or deletion rule languageSentence, input and output state when recording on-the-spot expert and operating, and set up corresponding mapping relations, and using these mapping relations asNew rule adds rule base unit (105), or irrational rule in replacement, delete procedure control, makes rule base unit(105) there is self-learning function.
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