CN109559314B - Electromagnetic suspension ball system based on machine vision and image processing method thereof - Google Patents
Electromagnetic suspension ball system based on machine vision and image processing method thereof Download PDFInfo
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Abstract
The invention relates to an electromagnetic levitation ball system based on machine vision and an image processing method thereof.A high-speed industrial camera is used for collecting a levitation gap image of a levitation ball, the image is transmitted to a PC (personal computer), the PC processes the image to extract an actual levitation gap value of the magnetic levitation ball, the actual levitation gap value is transmitted to a levitation controller, the levitation controller judges whether the current needs to be increased or decreased by comparing the actual gap value with a given gap value, the size of the current of an electromagnet winding is adjusted by a chopper, the levitation control of the magnetic levitation ball is completed, and the levitation ball is stabilized at a rated gap. The invention can realize stable control on the suspension ball, the suspension gap detection result is not influenced by temperature and the surface roughness of the object to be detected, the output value of the suspension gap is digital quantity and can be directly connected into a control system without calibration and correction of a sensor.
Description
Technical Field
The invention relates to the field of image processing and automatic control, in particular to a system for recognizing a magnetic levitation ball levitation gap through machine vision and completing levitation control of a levitation ball by using the gap value.
Background
The magnetic levitation ball system mainly comprises an electromagnet, a levitation ball, a gap sensor, a levitation control circuit and a chopper. The magnetic suspension ball system is a closed-loop control system, a gap sensor is used for detecting the distance change between a steel ball and an electromagnet, when the steel ball is disturbed and reduced, the distance between the steel ball and the electromagnet is increased, the output voltage of the sensor is changed, a voltage signal is subjected to analog-to-digital conversion and sent to a suspension controller for processing, the current of the electromagnet is adjusted through a chopper, so that the current of an electromagnet winding is increased, the electromagnetic attraction is increased, the steel ball is attracted back to a balance position, and otherwise, the same principle is adopted, so that the steel ball can be suspended at the balance position. In order to ensure that the levitation ball can realize stable levitation, the gap sensor must provide a reliable and real-time gap value for the levitation control system, and therefore the gap sensor plays an important role in the levitation control system. At present, eddy current gap sensors are mostly adopted for measuring the suspension gap of the magnetic suspension ball. The working principle of the device is that according to the Faraday electromagnetic induction principle, when a metal conductor is placed in a changing magnetic field or does motion of cutting magnetic lines of force in the magnetic field, vortex-shaped induced current is generated in the conductor, the current is called eddy current, and the phenomenon is called eddy current effect. When the value of the suspension gap changes, the size of the eddy current changes along with the value of the suspension gap, so that the equivalent inductance of the detection coil of the gap sensor changes, the inductance value and the gap value are in one-to-one correspondence, and the measurement of the suspension gap value is completed according to the principle.
Although the eddy current sensor is widely used, the eddy current sensor has many disadvantages and shortcomings, for example, the measurement accuracy is greatly affected by the temperature and the surface roughness of the measured object, the cost is high, the installation process is complex, the output value is analog, the analog-to-digital conversion is needed to be converted into digital, and then the digital analog-to-digital conversion can be accessed into a control system, and the digital analog-to-digital conversion can be calibrated strictly to work normally.
At present, with the rapid progress of hardware equipment and intelligent algorithms, machine vision technology is also widely applied. The distance or length measurement by using the machine vision technology has the advantages of good effect, high measurement speed and accurate result.
Disclosure of Invention
Aiming at the defects of the existing eddy current gap sensor, the invention provides an electromagnetic suspension ball system based on machine vision and an image processing method thereof, which can control the suspension ball to stably suspend in a rated gap and the control process is not influenced by temperature and the surface roughness of a measured object.
The purpose of the invention is realized as follows: the utility model provides an electromagnetism suspension ball system based on machine vision, includes the chopper, and the suspension clearance image of suspension ball under the high-speed industrial camera catches light source irradiation, and the image is transmitted to the PC, and the PC is handled the image, draws the suspension clearance value of calculating the suspension ball through corresponding characteristic, and the suspension clearance value sends suspension control circuit, suspension control circuit with actual suspension clearance value and given suspension clearance value comparison, confirm to increase or reduce the electromagnet current, its signal output to the chopper, the chopper adjusts the electromagnet winding current, adjusts electromagnetic suction to adjust the suspension clearance size of suspension ball, make the suspension ball stabilize at rated clearance.
The high-speed industrial camera is fixedly installed on the side surfaces of the electromagnet and the suspension ball, so that the bottom surface of the electromagnet in the acquired image is a horizontal straight line.
The PC processes the image as follows: the PC machine calculates the suspension clearance value of the suspension ball through corresponding characteristic extraction, and the calculation process is as follows: after the image is input into a PC, the edge detection is carried out on the image, the coordinate values of the upper vertex of the floating ball and the lower boundary of the electromagnet are determined, the length of the floating gap in the image is worked out, and the actual floating gap value of the floating ball is worked out according to the corresponding relation between the pixel and the actual length.
The flow of the PC machine for processing the suspension gap image is as follows: after the image is input into a PC (personal computer), edge detection is carried out on the image, and the vertex P on the floating ball is determined 1 (x 1 ,y 1 ) And electromagnet lower boundary y 2 The pixel length L of the suspension gap in the image is calculated, and the actual suspension gap value of the suspension ball is calculated according to the corresponding relation between the pixel and the actual length; the corresponding relation calculation method of the pixel and the actual length is as follows:
determining the position of the suspension ball when the suspension ball is not suspended, namely the initial position, and determining the top point P of the suspension ball at the moment 0 (x 0 ,y 0 ) And then the pixel length of the initial position of the floating ball and the lower boundary of the electromagnet in the graph is as follows: l is 0 ＝y 2 -y 0 And the initial position of the floating ball is fixed, so the distance between the floating ball and the lower boundary of the electromagnet is also fixed, and L can be obtained by measuring the distance from the top end of the floating ball to the lower boundary of the electromagnet when the floating ball is not suspended in a real object system 0 The corresponding actual length x mm, so as to obtain the corresponding relation between one pixel in the image and the actual length:
when the floating ball rises to a certain position, the pixel length of the lower boundary of the floating ball and the electromagnet in the figure is as follows: l = y 2 -y 1 (ii) a According to the proportional relation between one pixel in the image and the actual lengthP and the pixel length L of the lower boundary of the levitation ball and the electromagnet in the graph to obtain the actual distance between the levitation ball and the lower boundary of the electromagnet, namely the actual levitation gap value L 1 ：/>
The suspension control circuit compares an actual suspension gap value input by the PC with a given rated suspension gap value, and if the actual suspension gap value is smaller than the rated suspension gap value, the suspension control circuit controls the chopper to reduce the current of the electromagnet winding and reduce the electromagnetic attraction force, so that the actual suspension gap is enlarged; on the contrary, if the actual suspension gap value is larger than the rated suspension gap value, the suspension control circuit controls the chopper to increase the current of the electromagnet winding and increase the electromagnetic attraction force, so that the actual suspension gap is reduced, the suspension ball is stabilized in the rated suspension gap through continuous adjustment, and the suspension ball can suspend in a balance position; the signal of the suspension control circuit is output to the chopper, the chopper adjusts the current of the electromagnet winding and adjusts the electromagnetic attraction force, thereby adjusting the size of the suspension gap of the suspension ball and stabilizing the suspension ball at the rated gap.
The invention has the beneficial effects that: the suspension control method comprises the steps of collecting suspension ball suspension gap images by using a high-speed industrial camera, transmitting the images to a PC, processing the images by the PC to extract an actual suspension gap value of the magnetic suspension ball, sending the actual suspension gap value to a suspension controller, judging whether the current needs to be increased or decreased by comparing the actual gap value with a given gap value by the suspension controller, adjusting the current of an electromagnet winding by a chopper, completing the suspension control of the magnetic suspension ball, and stabilizing the suspension ball at a rated gap.
The electromagnetic suspension ball system realized according to the invention can realize relatively stable control on the suspension ball, the suspension gap detection result is not influenced by the temperature and the surface roughness of the object to be detected, the suspension gap output value is digital quantity and can be directly input into the control system without calibrating and correcting a sensor.
Drawings
FIG. 1 is a schematic diagram of the overall structure of the present invention.
Fig. 2 is a step of processing an image on a PC.
FIG. 3 is a schematic diagram of a method for measuring a levitation gap value in an image.
FIG. 4 is a schematic structural diagram of a magnetic levitation ball closed-loop control system using machine vision.
Detailed Description
The electromagnetic suspension ball system based on machine vision can realize closed-loop control, and the structure of the whole system is shown in figure 1. The method comprises the steps that a high-speed industrial camera 1 captures a suspension gap image of a suspension ball 3 irradiated by a light source 2, the image is transmitted to a PC 4, the actual suspension gap value of the suspension ball is calculated through processing of the image on the PC, the actual suspension gap value is sent to a suspension control circuit 5, the actual suspension gap value is compared with a given suspension gap value through the suspension control circuit, the fact that the current of an electromagnet needs to be increased or reduced is determined, the current of a winding of the electromagnet 7 is adjusted through a chopper 6, electromagnetic suction is adjusted, and therefore the size of the suspension gap of the suspension ball is adjusted.
Specifically, the flow of the floating gap image processing on the PC is shown in fig. 2. Inputting the image into PC, performing edge detection on the image, and determining the top point P of the floating ball 1 (x 1 ,y 1 ) And electromagnet lower boundary y 2 The pixel length L of the suspension gap in the image is obtained, and the actual suspension gap value of the suspension ball is obtained according to the corresponding relation between the pixel and the actual length. The method for calculating the correspondence between the pixels and the actual length is shown in fig. 3, the dotted circle represents the position of the floating ball when the floating ball is not floating, namely the initial position, and the vertex P on the floating ball at the moment is determined 0 (x 0 ,y 0 ) And then the pixel length of the initial position of the floating ball and the lower boundary of the electromagnet in the graph is as follows: l is 0 ＝y 2 -y 0 . Because the initial position of the floating ball is fixed, the distance between the floating ball and the lower boundary of the electromagnet is also fixed, and L can be obtained by measuring the distance from the top end of the floating ball to the lower boundary of the electromagnet when the floating ball is not suspended in a real object system 0 The corresponding actual length x mm. Can be used forTo obtain the corresponding relation between one pixel in the image and the actual length:
when the floating ball rises to the position of the solid line circle, the pixel length of the lower boundary of the floating ball and the electromagnet in the figure is as follows: l = y 2 -y 1 . Obtaining the actual distance between the suspension ball and the lower boundary of the electromagnet, namely the suspension gap value, according to the proportional relation P between one pixel and the actual length in the image and the pixel length L of the lower boundary of the suspension ball and the electromagnet in the image:
after the actual gap value is obtained, the suspension gap value is sent to a suspension controller, the suspension controller compares the actual suspension gap value input by a PC with a given rated suspension gap value, and if the actual suspension gap value is smaller than the rated suspension gap value, the suspension controller controls a chopper to reduce the current of an electromagnet winding and reduce the electromagnetic attraction force, so that the actual suspension gap is enlarged; on the contrary, if the actual suspension gap value is larger than the rated suspension gap value, the suspension controller controls the chopper to increase the current of the electromagnet winding and increase the electromagnetic attraction force, so that the actual suspension gap is reduced. Through continuous adjustment, the suspension ball is stabilized in a rated suspension clearance, and the suspension ball can suspend in a balance position. The work flow of the whole system is shown in fig. 4. In fig. 4, the suspension controller is a suspension control circuit, and the suspension ball is a steel suspension ball.
Claims (5)
1. An electromagnetic suspension ball system based on machine vision comprises a chopper (6) and is characterized in that a high-speed industrial camera (1) captures an image of a suspension gap of a suspension ball (3) irradiated by a light source (2), the image is transmitted to a PC (4), the PC processes the image, the suspension gap value of the suspension ball is calculated through corresponding characteristic extraction, the suspension gap value is sent to a suspension control circuit (5), the suspension control circuit compares the actual suspension gap value with a given suspension gap value to determine whether the current of an electromagnet needs to be increased or decreased, a signal of the current is output to the chopper (6), the chopper (6) adjusts the winding current of the electromagnet (7) and adjusts the electromagnetic attraction force, so that the size of the suspension gap of the suspension ball is adjusted, and the suspension ball is stabilized at a rated gap; the flow of the PC machine for processing the suspension gap image is as follows:
inputting the image into PC, performing edge detection on the image, and determining the top point P of the floating ball 1 (x 1 ,y 1 ) And electromagnet lower boundary y 2 The pixel length L of the suspension gap in the image is obtained, and the actual suspension gap value of the suspension ball is obtained according to the corresponding relation between the pixel and the actual length, wherein the corresponding relation calculation method of the pixel and the actual length is as follows, the position of the suspension ball when the suspension ball is not suspended is the initial position, and the vertex P on the suspension ball at the moment is determined 0 (x 0 ,y 0 ) And then, the pixel length of the initial position of the levitation ball and the lower boundary of the electromagnet is as follows: l is a radical of an alcohol 0 ＝y 2 -y 0 And the initial position of the floating ball is fixed, so the distance between the floating ball and the lower boundary of the electromagnet is also fixed, and L can be obtained by measuring the distance from the top end of the floating ball to the lower boundary of the electromagnet when the floating ball is not suspended in a real object system 0 Obtaining the corresponding relation between one pixel in the image and the actual length by the corresponding actual length xmm:
when the floating ball rises to a certain position, the pixel length of the lower boundary of the floating ball and the electromagnet in the figure is as follows: l = y 2 -y 1 And obtaining the actual distance between the suspension ball and the lower boundary of the electromagnet, namely the suspension gap value, according to the proportional relation P between one pixel and the actual length in the image and the pixel length L of the lower boundary of the suspension ball and the electromagnet in the image:
2. the machine vision-based electromagnetic levitation ball system as recited in claim 1, wherein the high-speed industrial camera (1) is fixedly mounted on the side of the electromagnet and the levitation ball, so that the bottom surface of the electromagnet (7) in the acquired image is a horizontal straight line.
3. The machine-vision-based electromagnetic levitation ball system as recited in claim 1, wherein the PC processes the image as follows: the PC machine calculates the suspension clearance value of the suspension ball through corresponding characteristic extraction, and the calculation process is as follows: after the image is input into a PC, the edge detection is carried out on the image, the coordinate values of the upper vertex of the floating ball and the lower boundary of the electromagnet are determined, the length of the floating gap in the image is worked out, and the actual floating gap value of the floating ball is worked out according to the corresponding relation between the pixel and the actual length.
4. The levitation gap image processing method of the electromagnetic levitation ball system according to claim 1, wherein the flow of the PC processing the levitation gap image is as follows: after the image is input into a PC (personal computer), edge detection is carried out on the image, and the vertex P on the floating ball is determined 1 (x 1 ,y 1 ) And electromagnet lower boundary y 2 The pixel length L of the suspension gap in the image is calculated, and the actual suspension gap value of the suspension ball is calculated according to the corresponding relation between the pixel and the actual length; the corresponding relation calculation method of the pixel and the actual length is as follows:
determining the position of the suspension ball when the suspension ball is not suspended, namely the initial position, and determining the top point P of the suspension ball at the moment 0 (x 0 ,y 0 ) And then the pixel length of the initial position of the levitation ball and the lower boundary of the electromagnet in the graph is as follows: l is 0 ＝y 2 -y 0 And the initial position of the floating ball is fixed, so the distance between the floating ball and the lower boundary of the electromagnet is also fixed, and L can be obtained by measuring the distance from the top end of the floating ball to the lower boundary of the electromagnet when the floating ball is not suspended in a real object system 0 The corresponding actual length xmm, thereby obtaining the corresponding relation between one pixel in the image and the actual length:
when the floating ball rises to a certain position, the lower boundary of the floating ball and the electromagnet is positionedPixel length in the figure: l = y 2 -y 1 (ii) a Obtaining the actual distance between the suspension ball and the lower boundary of the electromagnet, namely the actual suspension gap value L according to the proportional relation P between one pixel in the image and the actual length and the pixel length L of the lower boundary of the suspension ball and the electromagnet in the image 1 ：/>
5. The levitation gap image processing method of the electromagnetic levitation ball system according to claim 4, characterized in that the levitation control circuit compares an actual levitation gap value obtained by the PC through the levitation gap image processing with a given rated levitation gap value, and if the actual levitation gap value is smaller than the rated levitation gap value, the levitation control circuit controls the chopper to reduce the current of the electromagnet winding and reduce the electromagnetic attraction force, so that the actual levitation gap becomes larger; on the contrary, if the actual suspension gap value is larger than the rated suspension gap value, the suspension control circuit controls the chopper to increase the current of the electromagnet winding and increase the electromagnetic suction force, so that the actual suspension gap is reduced, the suspension ball is stabilized in the rated suspension gap through continuous adjustment, and the suspension ball can suspend in a balance position; the signal of the suspension control circuit (5) is output to the chopper (6), the chopper (6) adjusts the winding current of the electromagnet (7) and adjusts the electromagnetic attraction force, so that the size of the suspension gap of the suspension ball is adjusted, and the suspension ball is stabilized at the rated gap.
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| CN110930407B (en) * | 2020-02-07 | 2020-05-15 | 西南交通大学 | Suspension gap visual detection method based on image processing |
| CN113148537A (en) * | 2021-04-30 | 2021-07-23 | 安徽理工大学 | Magnetic repulsion type magnetic suspension belt conveyor based on machine vision |
| CN114043879B (en) * | 2022-01-13 | 2022-03-29 | 西南交通大学 | Medium-low speed maglev train track-passing seam control system based on image processing |
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