CN107607058B - Automatic residual coal detection system and detection method - Google Patents
Automatic residual coal detection system and detection method Download PDFInfo
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- CN107607058B CN107607058B CN201710883939.0A CN201710883939A CN107607058B CN 107607058 B CN107607058 B CN 107607058B CN 201710883939 A CN201710883939 A CN 201710883939A CN 107607058 B CN107607058 B CN 107607058B
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Abstract
The invention discloses an automatic residual coal detection system and a detection method, comprising the following steps: scanning the internal contour of the carriage in the coal-free state to obtain the original contour data of the coal-free carriage, and processing the original contour data to obtain the image data of the original contour; scanning the internal contour of each carriage after coal unloading to obtain contour data of each carriage after coal unloading; screening out non-original contour data in contour data of each carriage after coal unloading, and processing the non-original contour data to obtain image data of the non-original contour; and overlapping and comparing the image data of the non-original contour of each carriage with the image data of the original contour, and judging whether residual coal exists in each carriage. The invention can automatically detect the residual coal and the residual coal quantity in the carriage, accurately position the carriage where the residual coal is located, enable operators to quickly and accurately find the carriage where the residual coal is located, process the residual coal, save manpower and improve the working efficiency.
Description
Technical Field
The invention belongs to the technical field of hopper cars with bottom doors, and particularly relates to an automatic residual coal detection system and method for a hopper car with bottom doors.
Background
The hopper car with the bottom door is widely applied to special lines for power plants and coal transportation at home and abroad due to high coal unloading efficiency. The coal stored in the hopper car with the bottom door can absorb moisture in the transportation process, so that the self-adhesion of the coal is large, and residual coal appears in a carriage after discharging the coal; when the air temperature is in a low position for a long time, the coal is frozen, and the residual coal phenomenon of the carriage after the coal is discharged is serious. In order to ensure normal operation, the residual coal needs to be judged and processed. At present, residual coal detection is mainly judged by naked eyes, and because the top of a carriage of the hopper car with the bottom door is higher (about 4 m) from the ground, sightseeing cannot be carried out from two sides of the carriage, a sightseeing platform is required to be arranged above a vehicle, and in the movement process of the hopper car with the bottom door, the residual coal is checked by manual bench by bench.
Disclosure of Invention
Aiming at the defects or improvement demands of the prior art, the invention provides an automatic residual coal detection system and an automatic residual coal detection method, which not only can carry out automatic residual coal detection on a carriage of which the hopper car with a bottom door is used for discharging coal, but also can accurately position the carriage where the residual coal is located.
In order to achieve the above object, according to one aspect of the present invention, there is provided an automatic residual coal detection system including a detection module, an image data processing module, and an output terminal;
the detection module is used for acquiring original contour data of the interior of the carriage in a coal-free state and contour data of each carriage after coal unloading by adopting laser scanning;
the image data processing module is used for performing image processing on the original contour data to obtain image data of the original contour; the method comprises the steps of acquiring contour data of each carriage, wherein the contour data of the carriage is obtained by the image processing; and the method is used for carrying out overlapping comparison on the image data of the non-carriage outline and the image data of the original outline, judging whether residual coal exists in the carriage or not, and outputting a residual coal detection result through the output terminal.
Preferably, the image data processing module of the automatic residual coal detection system comprises an image processing unit, a data conversion unit and a processor;
the image processing unit is used for performing image processing on the original contour data to obtain image data of the original contour; the method comprises the steps of acquiring contour data of each carriage, wherein the contour data of each carriage is obtained by carrying out image processing on contour data of each carriage;
the data conversion unit is used for converting the image data of the original contour and the image data of the non-carriage contour into digital data which can be recognized by the processor;
the processor performs overlapping comparison on the digital data of the non-carriage profile and the digital data of the original profile, judges whether residual coal exists in the carriage or not, and calculates the residual coal amount according to the comparison result of the digital data of the non-carriage profile and the digital data of the original profile.
Preferably, the automatic residual coal detection system further comprises a positioning module, wherein the positioning module is used for acquiring counting information corresponding to the position of the carriage, the processor determines the position of the carriage through the counting information, and matches the carriage position information with a residual coal detection result to position the carriage where the residual coal is located; the residual coal detection result contains carriage position information.
Preferably, the positioning module of the automatic residual coal detection system comprises a power supply, a photoelectric sensing unit and a control unit;
the photoelectric sensing unit is connected with a power supply to form a light path, and outputs a switching signal when the light path is blocked by a carriage; the control unit counts the received switch signals in turn to obtain count information corresponding to the carriage position.
Preferably, the photoelectric sensing unit of the automatic residual coal detection system comprises brackets oppositely arranged at two sides of the track, and a photoelectric switch illuminator and a photoelectric switch receiver respectively arranged on the brackets at two sides; the photoelectric switch light receiver is used for receiving the light source emitted by the photoelectric switch light emitter, and when the light source is blocked, the photoelectric switch light receiver outputs a switch signal.
Preferably, in the automatic residual coal detection system, the photoelectric switch light emitter and the photoelectric switch light receiver can move up and down along the support, and the installation heights of the photoelectric switch light emitter and the photoelectric switch light receiver are kept consistent and are positioned in a height range with continuous gaps between adjacent carriages.
Preferably, the detection module of the automatic residual coal detection system comprises a laser scanner and a camera, wherein the laser scanner is used for emitting laser to acquire carriage profile data; the camera is used for shooting video inside the carriage, and when the residual coal is detected, the video is replayed to observe the condition of the residual coal carriage.
According to another aspect of the present invention, there is provided a residual coal detection method based on a residual coal automatic detection system, comprising the steps of:
(1) Scanning the internal contour of the carriage in the coal-free state to obtain the original contour data of the coal-free carriage, and processing the original contour data to obtain the image data of the original contour;
(2) Scanning the internal contour of each carriage after coal unloading to obtain contour data of each carriage after coal unloading;
(3) Screening out non-original contour data in contour data of each carriage after coal unloading, and processing the non-original contour data to obtain image data of the non-original contour;
(4) And overlapping and comparing the image data of the non-original contour of each carriage with the image data of the original contour, and judging whether residual coal exists in each carriage.
Preferably, the residual coal detection method further comprises the following steps: and acquiring counting information corresponding to the carriage position, obtaining carriage position information according to the counting information, and matching the carriage position information with the residual coal detection result.
Preferably, the residual coal detection method further comprises the step of calculating the residual coal amount according to the comparison result of the non-carriage contour image data and the original contour image data.
In general, the above technical solutions conceived by the present invention, compared with the prior art, enable the following beneficial effects to be obtained:
(1) According to the automatic residual coal detection system and method provided by the invention, the laser scanning technology is adopted to obtain the internal contour data of the carriage after coal unloading, and the contour data after coal unloading is overlapped and compared with the original contour data in a coal-free state through the comprehensive processing computer, so that the residual coal and the residual coal quantity of each carriage can be automatically detected, the manual naked eye is not required to check the carriage one by one, and the labor is saved;
(2) According to the automatic residual coal detection system and method provided by the invention, the counting information corresponding to the carriage position is acquired through the positioning module based on the photoelectric sensing technology, the comprehensive processing computer determines the carriage position through the counting information, so that the accurate positioning of the residual coal carriage is realized, an operator can quickly and accurately find the carriage where the residual coal is located, the residual coal is processed, the accuracy is high, and the working efficiency is improved.
Drawings
FIG. 1 is a schematic diagram of the composition structure of an automatic residual coal detection system according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of the installation positions of a 2D laser scanner and a photoelectric sensing unit according to an embodiment of the present invention;
FIG. 3 is a front view of an installation position of a photoelectric sensing unit provided in an embodiment of the present invention;
Detailed Description
The present invention will be described in further detail with reference to the drawings and examples, in order to make the objects, technical solutions and advantages of the present invention more apparent. It should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the invention. In addition, the technical features of the embodiments of the present invention described below may be combined with each other as long as they do not collide with each other.
Fig. 1 is a schematic diagram of the components of an automatic residual coal detection system provided by the embodiment of the invention, which comprises a detection module 1, an image data processing module 2, an output terminal 3 and a positioning module 4; the detection module 1, the output terminal 3 and the positioning module 4 are all connected with the image data processing module 2;
the detection module 1 is used for acquiring original contour data of the interior of a hopper wagon with a bottom door in a coal-free state and contour data of each wagon after coal unloading; the image data processing module 2 is used for performing image processing on the original contour data to obtain image data of the original contour; the method comprises the steps of acquiring contour data of each carriage, wherein the contour data of the carriage is obtained by the image processing; the method comprises the steps of obtaining the image data of the contour of a carriage, carrying out overlapping comparison on the image data of the contour of the carriage and the image data of the original contour, judging whether residual coal exists in the carriage, and calculating the residual coal quantity according to the comparison result to obtain a residual coal detection result; the positioning module 4 is used for acquiring counting information corresponding to the carriage position, the image data processing module 2 determines the carriage position through the counting information and matches the carriage position information with the residual coal detection result to realize the positioning of the residual coal carriage; the residual coal detection result containing the car position information is output through the output terminal 3.
The detection module 1 includes a 2D laser scanner 11 and a camera 12,2D, the laser scanner 11 obtains car contour data by emitting laser light and receiving reflected laser light, and the camera 12 is used for photographing a video of the inside of the car, and when the residual coal is detected, the video is played back to observe the condition of the residual coal car.
The image data processing module 2 comprises an image processing unit 21, a switch 22 and a comprehensive processing computer 23 which are connected in sequence; the image processing unit 21 performs image processing on the original contour data to obtain image data of the original contour, automatically screens out non-original contour data in the contour data after coal unloading of each carriage, and obtains image data of non-carriage contour through image processing; the data conversion unit 22 converts the image data of the original contour into digital data recognizable by the integrated processing computer 23, such as binary data, and stores in the integrated processing computer 23; converting the image data of the non-carriage profile into two-level system data and transmitting the two-level system data to the comprehensive processing computer 23; the comprehensive processing computer 23 performs overlapping comparison between binary data of the non-carriage profile and binary data of the original profile to judge whether residual coal exists in the carriage, and in addition, the comprehensive processing computer 23 can automatically calculate the residual coal amount of each carriage according to the comparison result.
The positioning module 4 comprises a power supply 41, a photoelectric sensing unit 42 and a control unit 43 which are sequentially connected, and the positioning module 4 is connected with the comprehensive processing computer 23 through the control unit 43;
the photoelectric sensing unit 42 comprises a bracket 423 oppositely arranged at two sides of the track, and a photoelectric switch light emitter 421 and a photoelectric switch light receiver 422 respectively arranged on the bracket 423; the photoelectric switch light emitter 421 and the photoelectric switch light receiver 422 form a correlation separation type photoelectric switch, the photoelectric switch light receiver 422 is used for receiving a light source sent by the photoelectric switch light emitter 421, when the light source is blocked by a certain carriage, the photoelectric switch light receiver 422 outputs a switch signal to the control unit 43, the control unit 43 counts the received switch control signal and transmits the count information to the comprehensive processing computer 23, the comprehensive processing computer 23 determines the carriage position through the count times, and matches the carriage position information with the residual coal information, so as to realize the positioning of the residual coal carriage.
Fig. 2 is a schematic diagram of the installation positions of the 2D laser scanner and the photoelectric sensing unit 42 provided in this embodiment, where the 2D laser scanner is disposed above the hopper wagon with the bottom door, and the residual coal detection process includes two links:
(1) Acquiring carriage profile data in a coal-free state: the 2D laser scanner scans the carriage internal contour of the hopper car with the bottom door under the state of no coal, obtains the original contour data of the carriage contour without coal, and stores the original contour data in a database of the comprehensive processing computer 23 after the original contour data is processed by an image and converted into digital data;
(2) Detecting residual coal: after the coal unloading of the hopper wagon with the bottom door is completed and the hopper wagon with the bottom door is closed, the 2D laser scanner scans the interiors of all carriages with the doors sequentially, and internal profile data of all carriages after the coal unloading is obtained; the image processing unit 21 performs image processing on the internal contour data, automatically screens out non-car contour data, and obtains non-car contour image data; the non-cabin contour image data is converted into digital data by the switch 22 and transmitted to the integrated processing computer 23; the comprehensive processing computer 23 compares the non-original contour digital data after the coal unloading of each carriage with the original contour digital data in an overlapping manner, judges whether residual coal exists in each carriage, and calculates the residual coal amount.
Because the 2D laser scanner is in a fixed state and can not be positioned by adopting an encoder, in order to accurately position the carriage where the residual coal is located, the invention utilizes the characteristic that a certain gap exists between adjacent carriages of the hopper car with the bottom door, adopts a photoelectric sensing technology, and sets photoelectric sensing units 42 on two sides of a running rail of the hopper car with the bottom door, when the vehicle drives in, a light path is blocked, the photoelectric sensing units 42 act to output a switching signal, the control unit 43 counts the received switching signal and sends the counting information to the comprehensive processing computer 23, and the comprehensive processing computer 23 determines the carriage position through counting times and realizes the positioning of the carriage of the residual coal by matching with the carriage residual coal information obtained in the residual coal detection process.
As shown in fig. 3, in this embodiment, two brackets 423 are respectively placed on the left and right sides of the travelling rail of the hopper wagon with the bottom door, the photoelectric switch light emitter 421 and the photoelectric switch light receiver 422 are respectively installed on the brackets 423 on the two sides, the photoelectric switch light emitter 421 and the photoelectric switch light receiver 422 can move up and down along the brackets 423, the installation heights of the photoelectric switch light emitter 421 and the photoelectric switch light receiver 422 need to be kept consistent, the installation heights are between the bottom (excluding the bottom hopper) and the top of the carriage, the preferred height from the ground in this embodiment is about 3700mm, and a continuous gap exists between adjacent carriages with the height, and the adjacent carriages cannot be disturbed.
The opposite-emission separated photoelectric switch composed of the photoelectric switch light-emitting device 421 and the photoelectric switch light-receiving device 422 is connected with the power supply 41, the photoelectric switch light-receiving device 422 receives the light source emitted by the photoelectric switch light-emitting device 421, and each carriage of the tractor traction bottom-opening hopper car sequentially passes through the photoelectric sensing unit 42;
when the tractor is positioned between the photoelectric switch light-emitting device 421 and the photoelectric switch light-receiving device 422, the 1 st time of the light source is blocked, the photoelectric switch light-receiving device 422 outputs the 1 st switching signal to the control unit 43, and the control unit 43 counts the 1 st time and transmits the counting information to the comprehensive processing computer 23;
when the 1 st section hopper car carriage adjacent to the tractor is positioned between the photoelectric switch light-emitting device 421 and the photoelectric switch light-receiving device 422, the 2 nd time of the light source is blocked, the photoelectric switch light-receiving device 422 outputs the 2 nd switching signal to the control unit 43, and the control unit 43 counts the 2 nd time and transmits the counting information to the comprehensive processing computer 23; …
When the nth section hopper car carriage is positioned between the photoelectric switch light-emitting device 421 and the photoelectric switch light-receiving device 422, the light source is blocked for the (n+1) th time, the photoelectric switch light-receiving device 422 outputs the (n+1) th switching signal to the control unit 43, and the control unit 43 counts the (n+1) th time and transmits the counting information to the comprehensive processing computer 23;
the comprehensive processing computer 23 determines the carriage position through counting times, the n+1th counting corresponds to the nth hopper car carriage, and matches carriage position information with the residual coal detection result to realize the positioning of the residual coal carriage, and the positioning precision is carriage level; the residual coal detection result containing the carriage position information is output through the output terminal 3, and a worker can acquire the residual coal condition and the residual coal quantity of each carriage through the result displayed by the output terminal 3 without checking by naked eyes.
Compared with the existing residual coal detection by manpower, the automatic residual coal detection system and method provided by the invention can automatically detect the residual coal and the residual coal quantity of the carriage, accurately position the carriage where the residual coal is located, enable operators to quickly and accurately find the carriage where the residual coal is located, process the residual coal, save manpower and further improve the working efficiency.
It will be readily appreciated by those skilled in the art that the foregoing description is merely a preferred embodiment of the invention and is not intended to limit the invention, but any modifications, equivalents, improvements or alternatives falling within the spirit and principles of the invention are intended to be included within the scope of the invention.
Claims (9)
1. The automatic residual coal detection system is characterized by comprising a detection module (1), an image data processing module (2) and an output terminal (3);
the detection module (1) is used for acquiring original contour data of the interior of the carriage in a coal-free state and contour data of each carriage after coal unloading by adopting laser scanning;
the image data processing module (2) is used for performing image processing on the original contour data to obtain image data of the original contour; the method comprises the steps of acquiring contour data of each carriage, wherein the contour data of the carriage is obtained by the image processing; the method is used for carrying out overlapping comparison on the image data of the non-carriage outline and the image data of the original outline, judging whether residual coal exists in the carriage or not, and outputting a residual coal detection result through the output terminal (3);
the system also comprises a positioning module (4), wherein the positioning module (4) is used for acquiring counting information corresponding to the position of the carriage, the processor (23) determines the position of the carriage through the counting information, and matches the carriage position information with the residual coal detection result to realize the positioning of the carriage where the residual coal is located; and the residual coal detection result contains carriage position information.
2. The residual coal automatic detection system according to claim 1, wherein the image data processing module (2) includes an image processing unit (21), a data conversion unit (22), and a processor (23);
the image processing unit (21) is used for performing image processing on the original contour data to obtain image data of the original contour; the method comprises the steps of acquiring contour data of each carriage, wherein the contour data of each carriage is obtained by carrying out image processing on contour data of each carriage;
the data conversion unit (22) is used for converting the image data of the original contour and the image data of the non-carriage contour into digital data which can be identified by the processor (23);
the processor (23) performs overlapping comparison on the digital data of the non-carriage profile and the digital data of the original profile, judges whether residual coal exists in the carriage, and calculates the residual coal amount according to the comparison result of the digital data of the non-carriage profile and the original profile.
3. The automatic residual coal detection system according to claim 2, wherein the positioning module (4) comprises a power supply (41), a photoelectric sensing unit (42) and a control unit (43);
the photoelectric sensing unit (42) is connected with the power supply (41) to form a light path, and each time the light path is blocked by a carriage, the photoelectric sensing unit (42) outputs a switching signal; the control unit (43) counts the received switching signals in turn to obtain count information corresponding to the car position.
4. A residual coal automatic detection system as claimed in claim 3, characterized in that said photoelectric sensing unit (42) comprises brackets (423) placed opposite to each other on both sides of the track, and photoelectric switch light emitters (421) and photoelectric switch light receivers (422) respectively mounted on the brackets (423) on both sides; the photoelectric switch light receiver (422) is used for receiving the light source emitted by the photoelectric switch light emitter (421), and when the light source is blocked, the photoelectric switch light receiver (422) outputs a switch signal.
5. The automatic residual coal detection system according to claim 4, wherein the photoelectric switch light emitter (421) and the photoelectric switch light receiver (422) can move up and down along the support (423), and the installation heights of the photoelectric switch light emitter (421) and the photoelectric switch light receiver (422) are kept consistent and are located in a height range where a continuous gap exists between adjacent carriages.
6. The residual coal automatic detection system according to any one of claims 1 to 5, wherein the detection module (1) includes a laser scanner (11) and a camera (12), the laser scanner (11) being configured to emit laser light to acquire cabin profile data; the camera (12) is used for shooting video inside the carriage, and when the residual coal is detected, the video is replayed to observe the condition of the residual coal carriage.
7. A residual coal detection method based on the residual coal automatic detection system according to any one of claims 1 to 6, characterized by comprising the steps of:
(1) Scanning the internal contour of the carriage in the coal-free state to obtain the original contour data of the coal-free carriage, and processing the original contour data to obtain the image data of the original contour;
(2) Scanning the internal contour of each carriage after coal unloading to obtain contour data of each carriage after coal unloading;
(3) Screening out non-original contour data in contour data of each carriage after coal unloading, and processing the non-original contour data to obtain image data of the non-original contour;
(4) And overlapping and comparing the digital data of the non-original contour of each carriage with the image data of the original contour, and judging whether residual coal exists in each carriage.
8. The residual coal detection method according to claim 7, further comprising the steps of: and acquiring counting information corresponding to the carriage position, obtaining carriage position information according to the counting information, and matching the carriage position information with a residual coal detection result.
9. The residual coal detection method according to claim 8, further comprising the step of calculating a residual coal amount based on a comparison result of the non-car contour digital data and the original contour digital data.
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| CN108931458A (en) * | 2018-03-12 | 2018-12-04 | 四川广安发电有限责任公司 | It is a kind of come coal quality amount detection systems and method |
| CN110861683A (en) * | 2019-11-14 | 2020-03-06 | 交控科技股份有限公司 | Automatic passenger clearing method for train |
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