CN107255498B - Conveying belt material weight measuring system and method based on binocular vision - Google Patents
Conveying belt material weight measuring system and method based on binocular vision Download PDFInfo
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- CN107255498B CN107255498B CN201710408959.2A CN201710408959A CN107255498B CN 107255498 B CN107255498 B CN 107255498B CN 201710408959 A CN201710408959 A CN 201710408959A CN 107255498 B CN107255498 B CN 107255498B
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- G01—MEASURING; TESTING
- G01F—MEASURING VOLUME, VOLUME FLOW, MASS FLOW OR LIQUID LEVEL; METERING BY VOLUME
- G01F22/00—Methods or apparatus for measuring volume of fluids or fluent solid material, not otherwise provided for
Abstract
The invention discloses a binocular vision-based conveying belt material weight measuring system.A front bracket is arranged at the initial position of a weighing area of a conveying belt, a rear bracket is arranged at the final position, the initial position is arranged right above a roller of the conveying belt, and a speed sensor is arranged at the shaft end of the roller; a laser batten array is arranged on the front bracket at the initial position, two CCD cameras are arranged on the rear bracket at the final position, and a light source is arranged between the front bracket and the rear bracket; the two CCD cameras and the speed sensor are connected with a computer through respective cables. The invention also discloses a binocular vision-based conveyer belt material weight measuring method. According to the device and the method, the weighing area is flexibly changed by adjusting the view field of the CCD imaging system, the weight of the material at intervals of delta t is stored, and the weight of the material at each time can be checked at any time.
Description
Technical Field
The invention belongs to the technical field of conveying belt material weighing, relates to a conveying belt material weight measuring system based on binocular vision, and further relates to a conveying belt material weight measuring method based on binocular vision.
Background
The conveying belt is applied to various industries, and the assembly, detection, debugging, packaging, transportation and the like of objects are realized. The materials which can be conveyed by the conveyor belt are various in types, various bulk materials can be conveyed, and various single-piece goods with small weight such as cartons and packaging bags can also be conveyed. At present, weighing devices for conveying by a conveying belt are mostly applied to a nuclear scale and an electronic scale.
The measurement error of the nuclear scale has the following influence reasons: the natural abrasion of the thickness of the conveyor belt and the dust on the surface area of the ionization chamber can be considered as the change of the penetrating thickness of the ray, and the measurement result can be influenced; if the conveying belt deviates, the conveying belt and even materials run out of a ray coverage area, and a large or even serious measurement error can be generated; the change of material variety, components and moisture can cause the change of mass absorption coefficient and generate measurement error; increased particle size causes multiple refractions of the radiation, which degrades the measurement.
The measurement principle of the conveying belt electronic scale is that a pressure sensor is utilized to complete on-line material weighing, and the conveying belt electronic scale mainly adopts a lever type and a suspension type scale frame structure at present. The unit load or material weight of the conveying belt electronic scale is transferred to a weighing sensor through a series of mechanical devices such as a conveying belt, a bearing carrier roller, a lever, a connecting mechanism and the like, and measurement errors can be introduced when any link in the middle is improper. The weight of the material is transferred to the next stage under the action of the conveyer belt, and if the tension of the conveyer belt is unstable, a measurement error is inevitably caused; the natural wear of the conveyer belt and the dust and material accumulation of the scale frame can also influence the stress of the sensor, so that the measurement error is caused; if the scale frame and the sensor connecting mechanism are not properly installed, internal stress exists, and if weather and weather such as cold, heat and humidity change obviously, the change of the internal stress is caused, so that measurement errors are inevitably caused; rolling friction exists between the conveying belt and the weighing carrier roller during operation, the friction force changes along with the load of the conveying belt, and the friction force can generate non-metering torque to the weighing lever system, so that weighing errors are caused; the conveyer belt electronic scale belongs to a suspension cable weighing system, the weight of materials is transmitted to a stress system through a conveyer belt, and the stress of a sensor is inevitably reduced due to the fact that the weighing frame moves downwards after being loaded, so that a measuring error is generated; if the eccentric load debugging is not carried out in the installation process, the deviation of the conveying belt can generate measurement errors in the working process.
Disclosure of Invention
The invention aims to provide a binocular vision-based conveying belt material weight measuring system, which solves the problems that in the prior art, a conveying belt electronic scale has a plurality of influence factors on material measuring errors in conveying, the measuring errors are difficult to control, and the measuring precision is unreliable.
The invention also aims to provide a conveying belt material weight measuring method based on binocular vision.
The invention adopts the technical scheme that a conveying belt material weight measuring system based on binocular vision is characterized in that a front bracket is arranged at the initial position of a weighing area of a conveying belt, a rear bracket is arranged at the final position, the initial position is arranged right above a roller of the conveying belt, and a speed sensor is arranged at the shaft end of the roller; a laser batten array is arranged on the front bracket at the initial position, two CCD cameras are arranged on the rear bracket at the final position, and a light source is arranged between the front bracket and the rear bracket; the two CCD cameras and the speed sensor are connected with a computer through respective cables.
The invention adopts another technical scheme that a conveying belt material weight measuring method based on binocular vision is implemented by utilizing the conveying belt material weight measuring system based on the binocular vision according to the following steps:
step 1, installing a weight measuring system
Enabling the two CCD cameras to be close to the material as much as possible, and keeping the view fields of the two CCD cameras to cover the weighing area at the same time;
The distance d from the light spot to a binocular imaging mechanism is obtained by utilizing a binocular distance measuring principle, and the material height h of the divided different small blocks is further obtainedi；
And 4, calculating the weight data of the materials.
The beneficial effects of the invention are as follows:
1) respectively collecting different numbers of calibration images for multiple times, re-projecting scene points in a space coordinate system to an image plane of the CCD camera based on calibration parameters, comparing the scene points with corresponding positions on an actual image, and obtaining the difference between the scene points and the corresponding positions as the absolute error of the calibration of the CCD camera; through calibrating the binocular imaging mechanism, the height of the surface of the material is well obtained, and the precision is high.
2) The main determining factor of the weight measurement is the number of the segmentation blocks, the more segmentation is, the higher the precision is, and the laser bar array is adopted in the invention, so that the surface of the material can be well segmented.
3) The size of the weighing area can be flexibly adjusted, and the material transporting amount in any time period can be inquired and a material transporting amount report can be generated according to the weight of the material in the weighing area stored every time.
Drawings
FIG. 1 is a schematic diagram of the construction of the weight measurement system of the present invention;
FIG. 2 is a schematic diagram of the image acquisition employed in the weight measurement method of the present invention;
FIG. 3 is a geometric schematic diagram of binocular distance measurement used in the weight measurement method of the present invention;
FIG. 4 is a schematic view of binocular ranging spots used in the weight measuring method of the present invention.
In the figure, 1, a CCD camera, 2, a cable, 3, a laser bar array, 4, a light source, 5, a computer, 6, a front bracket, 7, a roller, 8, a speed sensor, 9, a conveying belt and 10, a rear bracket.
Detailed Description
The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.
Referring to fig. 1 and 4, the hardware structure of the weight measuring system of the present invention is that a front bracket 6 is arranged at the initial position of the weighing area of a conveyer belt 9, a rear bracket 10 is arranged at the final position, the initial position is arranged right above a roller 7 of the conveyer belt 9, and a speed sensor 8 is arranged at the shaft end of the roller 7; a laser bar array 3 is arranged on a front bracket 6 at an initial position, two CCD cameras 1 are arranged on a rear bracket 10 at a final position, and a light source 4 is arranged between the front bracket 6 and the rear bracket 10; the two CCD cameras 1 and the speed sensor 8 are signal-connected to the computer 5 via respective cables 2.
The fields of view of the two CCD cameras 1 (together called a binocular imaging mechanism) can completely cover the weighing area, and the optical axes of the two CCD cameras 1 are parallel and the central line is positioned on the longitudinal central line of the conveying belt 9; after the relative positions of the two CCD cameras 1 are fixed, the two CCD cameras can rotate around respective supports so as to be convenient to adjust to a proper shooting angle.
When the environment is dark, the errors are large because objects cannot be seen clearly, and therefore the light source 4 is required to provide supplementary lighting; the laser bar array 3 is a bar-shaped structure formed by a plurality of lasers, generates mutually parallel laser beams and vertically shoots the laser beams to the surface of the conveying belt 9, and the falling points are uniformly distributed round light spots; the speed sensor 8 is a Hall device, and transmits the obtained information to the computer 5 to process so as to obtain the transmission speed v of the material; because when having the material on the conveyer belt 9, conveyer belt 9 can sink and bring measuring error, consequently the laser instrument ba Ban array 3 is installed and is being gone up the position at conveyer belt 9 running roller 7, avoids conveyer belt 9 to sink measuring error that brings. When the conveyer belt is unloaded and has the material, the facula that laser instrument ba list array 3 produced is also different from the distance of binocular imaging mechanism, obtains the distance of facula to binocular imaging mechanism through binocular range finding.
The assembly process of the weight measuring system of the invention is as follows:
1) when the conveyer belt 9 conveys materials, the weight of the materials can cause the conveyer belt 9 to sink, so that a front bracket 6 is arranged right above one roller 7 and is used as a starting position of a weighing area, and the laser bar array 3 is arranged on the front bracket 6 at the starting position.
2) Two CCD cameras 1 are arranged on a rear bracket 10 and used as the final positions of a weighing area, the optical axes of the two CCD cameras 1 are parallel to each other and perpendicular to a conveying belt 9 and are arranged on the same horizontal line, the central axes of the two CCD cameras 1 are positioned on the longitudinal axis of the conveying belt 9, and the imaging view field of each CCD camera 1 completely covers the weighing area.
3) Adjusting the laser bar array 3 to enable the laser bar array 3 to generate uniformly distributed parallel light beams downwards to strike a conveying belt 9 to form light spots;
4) a rotating speed sensor 8 (the model is a Hall device SS413A) for measuring the rotating speed is arranged on the rotating shaft of the roller 7 at the initial position of the conveyer belt 9.
5) Software is preinstalled in the computer 5 to control the two CCD cameras 1 to acquire images, the images are acquired once every time delta t to obtain light spot images of the weighing area, and then the computer 5 utilizes the software to process the images.
The invention relates to a binocular vision-based conveyer belt material weight measuring method, which is implemented according to the following steps:
step 1, installing the weight measuring system on the conveyer belt 9
When two CCD cameras 1 are installed, the distance between the two optical axes, i.e., the base line of binocular vision, needs to be considered. Since each pixel of the CCD camera 1 has a certain area, the precise position of an ideal point (without size) on the pixel of the CCD camera 1 cannot be reflected on the image, thereby fundamentally causing an image point coordinate error, i.e., an image recognition error. The larger the object distance, i.e. the farther the scene point is from the CCD camera 1, the larger the error; the error is larger when the pixel size of the CCD camera 1 is larger, and the error is smaller when the parallax is larger. Therefore, it is desirable to keep the two CCD cameras 1 close to the material, but it is also desirable to keep the fields of view of the two CCD cameras 1 covering the weighing area at the same time.
The length of the base line is an important parameter for representing the mutual position relationship between two CCD cameras 1 in a vision system, the change of the length of the base line can not only cause the change of the system structure, but also directly influence the measurement precision, for a specific lens and a specific space point, the measurement error is reduced along with the increase of the length T of the base line, and the measurement error is smaller when the focal length is larger.
After the CCD camera 1 is installed, the CCD camera needs to be calibrated, and the conveying belt 9 is in an idle state during calibration.
The method is characterized in that the material width is divided, the material height of the divided blocks is measured by utilizing a binocular ranging principle, and a lens has certain radial distortion due to the manufacturing error of the lens of the CCD camera 1. Tangential distortion is brought by lens installation errors, and the purpose of calibration of the CCD camera 1 is to obtain internal parameters of the CCD camera 1 for distortion correction. The calibration result of a single CCD camera 1 has a close relation with the number of the acquired calibration images, generally speaking, the more the number of the acquired images is, the higher the calibration precision is, and the number of the acquired images is at least more than 12.
Referring to fig. 2, the principle of image acquisition is that since the real system is not ideal pinhole imaging, it is necessary to perform nonlinear calibration on the CCD camera 1 using optimization, and then correct the taken picture according to the calibrated parameters.
The calibration process is as follows: assuming that the template plane is on the plane of the world coordinate system Z-0,
wherein s is a scale factor, which is only for convenience of calculation, and the coordinate value of the scale factor of the homogeneous coordinate is not changed, A is an internal parameter matrix of the CCD camera 1, [ X Y1 ]]THomogeneous coordinates of points on the template plane, [ u v1 ]]TIs the homogeneous coordinate of the point on the template plane projected onto the corresponding point on the image plane, [ r ]1r2r3]And t are the rotation matrix and translation vector, respectively, of the CCD camera 1 coordinate system relative to the world coordinate system, where the homogeneous coordinates of m represent the pixel coordinates of the image plane [ u v1]TThe homogeneous coordinate of M represents a coordinate point [ X Y1 ] of the world coordinate system]TLet H be A [ r1r2t]：
λ is a constant factor, and H is calculated by minimizing the algebraic distance between the extracted actual image coordinates and the calculated image coordinates, according to the nature of the rotation matrix, i.e. r1 Tr20 and r1||＝||r21, each image gets the following two basic constraints on the intra-parameter matrix:
because the CCD camera 1 has five unknown internal parameters, when the number of the collected images is more than or equal to 3, the internal parameter matrix A can be linearly and uniquely solved, corresponding external parameters are immediately obtained, and the calibration of the CCD camera 1 is completed.
The method comprises the steps of starting to collect images after a camera is calibrated, enabling sampling interval time to be delta t, processing the collected images in real time, and solving the distance d from a light spot to a binocular imaging mechanism by utilizing the binocular distance measurement geometrical principle and utilizing the inverse proportion relationship between the difference (namely parallax) of the horizontal coordinates of the images formed by a target point on a left view and a right view and the distance Z from the target point to an imaging plane.
Referring to fig. 3, the binocular distance measurement geometry principle is that after two CCD cameras 1 are calibrated, the main optical axes of the two CCD cameras 1 are parallel, and T is the distance between the optical centers of the two cameras, i.e., the base length; o islAnd Or is the optical centers of the left and right cameras, the shortest distance from the optical centers to the image plane X is the focal length f, P is the light spot generated by the laser on the material, namely the target point to be measured, the imaging points of the laser on the left and right image planes are pl and pr, and the distances between the pl and pr and the left edges of the respective image planes are xl and xr respectively; the binocular distance measurement mainly utilizes the relationship that the difference (namely, the parallax l is pl-pr) of the horizontal coordinates of the images of the target point on the left view and the right view is inversely proportional to the distance Z from the target point to the imaging plane:
and (5) obtaining the distance d between the light spot and the binocular imaging mechanism.
After the distance d from the light spot to the binocular imaging mechanism is obtained by using a binocular ranging principle, the material height h of the divided different small blocks is further obtained by using the mathematical geometric relationship of the systemi。
Referring to fig. 4, which is a light spot schematic diagram of a conveyor belt material weight measuring system, in two CCD cameras 1, k is a single laser source, when a conveyor belt 9 is unloaded, k is a light spot projected on the surface of the conveyor belt 9 as k1, the distance from k to k1 is a fixed value c, when a material is on the conveyor belt 9, the position of the light spot is k2, the distance from k2 to the CCD camera 1 is d, a rear bracket 10 where the two CCD cameras 1 are located and a front bracket 6 where a laser batten array 3 is located are arranged in parallel, and the distance is a fixed value q; the laser source is vertical to the conveying belt 9, and the distance between the laser source and the surface of the conveying belt 9 is a fixed value c; according to the triangular pythagorean theoremKnowing the distance between k and k2
The distance h from the light spot to the plane of the conveyor belt 9 with the material is c-p.
Because the surface of the material in the weighing area is fluctuated, namely the height of the surface of the material from the surface of the conveying belt 9 is changed, the laser bar array 3 is adopted for distributed irradiation, the generated light beam disperses the weighing area into N small blocks for calculation, hiIs the height corresponding to the ith light spot, (i is 1 … N), the width of the conveyer belt 9 is u, the conveying speed of the conveyer belt 9 is V, the bottom area of the material on the conveyer belt 9 in the time of delta t is S-u × V × delta t, the volume of the material on the conveyer belt 9 in the time of delta t is V-S × h, h is the height of the material in the time of delta t, u is the height of the material in the time of the ith light spot, u is the height of the material iniThe spacing between two adjacent lasers is such that the area of each block is ui×v×Δt；
Measuring the weight of the material by using a formula m ═ rho × V, wherein m is the weight of the material, rho is the density of the material, and the volume V of the material is S × h;
continuously collecting and accumulating the weight of the material within each sampling interval time delta t to be delta m from the start of weighing and timing,
to obtain the material weight m from the beginning of the timing to the current time (i.e. to the w-th sampling time interval)General assemblyThen, then
mjThe weight of the material at the jth sampling time.
Since the surface of the material in the weighing area is fluctuated, which means that the height of the surface of the material is changed, the weighing area is scattered into a plurality of small blocks by using parallel light beams for calculation, and the weight of the material in each sampling interval time delta t is continuously sampled and accumulated, so that the total weight of the material on the conveying belt 9 from the beginning of timing to the current moment can be obtained. The weighing area can be flexibly changed by adjusting the view field of the CCD camera 1. And (3) storing the weight of the material at intervals of delta t from the moment of weighing, wherein the weight of the material at each time can be checked at any time or a report of the weight of the material is generated.
The invention is verified by experiments, has good weighing effect and is supported by the project of 'Shaanxi province modern equipment green manufacturing collaborative innovation center (No. 304-210891702').
Claims (1)
1. A conveyer belt material weight measuring method based on binocular vision utilizes a conveyer belt material weight measuring system based on binocular vision, and the structure is as follows: the method comprises the following steps that a front support (6) is arranged at the initial position of a weighing area of a conveying belt (9), a rear support (10) is arranged at the final position, the initial position is arranged right above a roller (7) of the conveying belt (9), a speed sensor (8) is arranged at the shaft end of the roller (7), a laser bar array (3) is arranged on the front support (6) at the initial position, the laser bar array (3) is of a bar-shaped structure formed by a plurality of lasers, parallel laser beams are generated and vertically irradiate the surface of the conveying belt (9), the falling points are uniformly distributed round light spots, the laser bar array (3) is adopted for distributed irradiation, and the generated light beams disperse the weighing area into N small blocks for calculation; two CCD cameras (1) are mounted on a rear support (10) at the final position, the weighing area is changed by adjusting the view field of the CCD cameras (1), the material weight at intervals of delta t is stored from the moment of starting weighing, the material weight at each time is checked at any time, and a report of the material weight is generated; a light source (4) is arranged between the front bracket (6) and the rear bracket (10); the two CCD cameras (1) and the speed sensor (8) are in signal connection with the computer (5) through respective cables (2); the fields of view of the two CCD cameras (1) completely cover the weighing area, the optical axes of the two CCD cameras (1) are parallel, the central line is positioned on the longitudinal central line of the conveyer belt (9),
the method is characterized by comprising the following steps:
step 1, installing a weight measuring system
The two CCD cameras (1) are close to the material as much as possible, and the weighing areas can be covered by the view fields of the two CCD cameras (1) at the same time;
step 2, calibrating the two CCD cameras (1), wherein the conveying belt (9) is in an idle state during calibration, and the specific calibration process is as follows:
assuming that the template plane is on the plane of the world coordinate system Z-0,
wherein s is a scale factor, and A is an internal parameter matrix of the CCD camera (1) for which the coordinate value is not changed by the scale factor of the homogeneous coordinate, [ X Y1 ]]THomogeneous coordinates of points on the template plane, [ u v1 ]]TIs the homogeneous coordinate of the point on the template plane projected onto the corresponding point on the image plane, [ r ]1r2r3]And t are the rotation matrix and translation vector, respectively, of the CCD camera (1) coordinate system relative to the world coordinate system, where the homogeneous coordinates of m represent the pixel coordinates of the image plane [ u v1 ]]TThe homogeneous coordinate of M represents a coordinate point [ X Y1 ] of the world coordinate system]TLet H be A [ r1r2t]：
H＝[h1h2h3]＝λA[r1r2t]
λ is a constant factor, and H is calculated by minimizing the algebraic distance between the extracted actual image coordinates and the calculated image coordinates, according to the nature of the rotation matrix, i.e. r1 Tr20 and r1||＝||r21, each image gets the following two basic constraints on the intra-parameter matrix:
because the CCD camera (1) has five unknown internal parameters, when the number of the collected images is more than or equal to 3, the internal parameter matrix A can be linearly and uniquely solved, corresponding external parameters are immediately obtained, and the calibration of the CCD camera (1) is completed;
step 3, collecting and processing images of the materials on the conveyer belt (9)
The distance d from the light spot to a binocular imaging mechanism is obtained by utilizing a binocular distance measuring principle, and the material height h of the divided different small blocks is further obtainedi；
Step 4, calculating the weight data of the materials,
the specific process for calculating the weight data of the materials is as follows:
distributed irradiation is carried out by adopting a laser bar array (3), a generated light beam disperses a weighing area into N small blocks for calculation, hiThe height corresponding to the ith light spot is i 1,2, … and N, the width of the conveying belt (9) is u, the conveying speed of the conveying belt (9) is V, the bottom area of the material on the conveying belt (9) in the time of delta t is S u × V × delta t, the volume of the material on the conveying belt (9) in the time of delta t is V S × h, h is the height of the material in the time of delta t, u is equal to 1,2, … and N, u is the width of the conveying belt (9), u is the conveying speed of the conveying belt (9), u is equal to u 35iThe spacing between two adjacent lasers is such that the area of each block is ui×v×Δt；
Measuring the weight of the material by using a formula m ═ rho × V, wherein m is the weight of the material, rho is the density of the material, and the volume V of the material is S × h;
continuously collecting and accumulating the weight of the material within each sampling interval time delta t to be delta m from the start of weighing and timing,
to obtain the weight m of the material from the beginning of the timing to the current timeGeneral assemblyThen, then
mjThe weight of the material at the jth sampling time.
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