CN110196010B - Material height measuring device and method - Google Patents
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- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
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Abstract
The embodiment of the invention provides a material height measuring device and a material height measuring method, wherein the measuring device is used for measuring the stacking height of materials in a bin, and comprises the following components: the scale is arranged on the ground of the bin, and the scales are arranged on the surfaces of two opposite wall bodies in the bin; the image acquisition devices are respectively arranged on the two opposite wall surfaces of the bin, and the shooting range of each image acquisition device can cover all scales and numerical value information of the scale on the ground of the bin when no materials are stacked in the bin and all scales and numerical value information of the scale on the wall surface below the image acquisition device opposite to the image acquisition device; the image acquisition device is used for shooting and sampling the interior of the bin in which the materials are stacked and sending sampling image information to the image processing device. The device and the method can measure the height of the material in the bin in real time, and improve the efficiency of material transportation management.
Description
Technical Field
The invention relates to the field of measurement, in particular to a material height measuring device and a material height measuring method.
Background
During the production process, the height of the material pile is in a dynamically changing state. Generally, the measurement and the dynamic management of the height of the materials need to be manually measured and estimated, the efficiency is low, and the transportation of the feeder needs to be stopped at regular intervals, so that the production continuity is influenced. Therefore, to realize the automatic management of the stockyard, it is necessary to realize the digitization technology of the stockyard, and the key point of the digitization technology of the stockyard is how to realize the automatic measurement and dynamic observation of the height of the stockpile. Therefore, the automatic detection of the height of the material pile is an important link which cannot be ignored and is also a key technology for realizing the automatic control of the whole production chain.
Disclosure of Invention
The method and the device aim to realize automatic measurement and dynamic observation of the height of the material pile and timely and accurately acquire the height of the material.
In order to achieve the above object, in a first aspect of the present invention, there is provided a material height measuring device, comprising:
the scale is arranged on the ground of the bin, and the scales are arranged on the surfaces of two opposite wall bodies in the bin;
the image acquisition devices are respectively arranged on the two opposite wall surfaces of the bin, and the shooting range of each image acquisition device can cover all scales and numerical value information of the scale on the ground of the bin when no materials are stacked in the bin and all scales and numerical value information of the scale on the wall surface below the image acquisition device opposite to the image acquisition device; the image acquisition device is used for shooting and sampling the interior of the bin in which the materials are stacked and sending sampling image information to the image processing device;
the image processing device is remotely connected with the image acquisition device and used for carrying out image processing on the sampling image information, identifying part of scale marks and numerical information on the surface of the bin ground and the wall body after the sampling image information is shielded by the material, and calculating the stacking height of the material according to the identified scale marks and the numerical information.
Optionally, the image acquisition device is a CCD camera, and the image processing device is an industrial computer.
Optionally, the bin floor is a horizontal surface.
Optionally, the surface of the wall body is a plane or a curved surface perpendicular to the floor of the bin.
Optionally, the scale arranged on the ground of the bin is a horizontal scale, and the scale arranged on the surface of the wall is a vertical scale.
Further, the surface of the scale and the numerical value of the scale are marked in different colors.
Further, the scale surface is coated with a luminescent material, and the luminescent brightness and color of the luminescent material change with the change of the ambient light source.
Furthermore, the number of the image acquisition devices is two, and the two image acquisition devices are mutually symmetrical relative to the center point of the ground of the bin.
In a second aspect of the present invention, there is also provided a material height measuring method for measuring a stacking height of a material in a bin, wherein a bin floor of the bin and two opposite wall surfaces in the bin are provided with a scale, the measuring method comprising the steps of:
the two opposite wall surfaces of the bin are respectively provided with an image acquisition device, wherein the shooting range of each image acquisition device can cover all scales and numerical information of a scale on the ground of the bin when the bin is not stacked with materials, and all scales and numerical information of a scale on the wall surface below the image acquisition device opposite to the scale;
shooting and sampling the interior of the bin in which the materials are stacked by adopting the image acquisition device, and sending sampling image information to an image processing device remotely connected with the image acquisition device;
and performing image processing on the sampling image information by adopting the image processing device, identifying partial scale marks and numerical information on the surfaces of the bin ground and the wall body after being shielded by the material, and calculating the stacking height of the material according to the identified scale marks and numerical information.
According to the technical scheme, the height of the material is sampled in real time through the image acquisition device, the sampled image is analyzed through the industrial computer, the height information of the material is digitalized, and the real-time sampling and monitoring of the height of the material pile are realized.
The invention has the following advantages and technical effects:
1. compared with other material pile height detection technologies, the method has low hardware cost;
2. this patent uses machine vision processing technology, discerns scale numerical value image in the bin, participates in logic control with the scale numerical value after discerning, compares single-point distance measurement, and detection efficiency is high, measure more accurately.
Additional features and advantages of embodiments of the invention will be set forth in the detailed description which follows.
Drawings
The accompanying drawings, which are included to provide a further understanding of the embodiments of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the embodiments of the invention without limiting the embodiments of the invention. In the drawings:
FIG. 1 is a schematic view of the installation and measurement of a material height measuring device according to the present invention;
FIG. 2 is a flow chart of the steps of a method of measuring material level according to the present invention;
FIG. 3 is a schematic view of the measurement of the material height when the material height is high in the material height measuring method according to the present invention;
fig. 4 is a schematic view of the measurement of the material height when the material height is low in the material height measuring method of the present invention.
Detailed Description
The following detailed description of embodiments of the invention refers to the accompanying drawings. It should be understood that the detailed description and specific examples, while indicating the present invention, are given by way of illustration and explanation only, not limitation.
In the embodiments of the present invention, unless otherwise specified, the use of directional terms such as "upper, lower, top, and bottom" is generally used with respect to the orientation shown in the drawings or the positional relationship of the components with respect to each other in the vertical, or gravitational direction.
Fig. 1 is a schematic view of the installation of a material height measuring device according to the present invention. As shown in fig. 1, a material conveying platform is provided at the top of the bin, through which material is thrown into the bin. The invention provides a material height measuring device, which comprises: the scale is arranged on the ground of the bin, and the scales are arranged on the surfaces of two opposite wall bodies in the bin; the image acquisition devices are respectively arranged on the two opposite wall surfaces of the bin; and an image processing apparatus.
Specifically, the staff gauges arranged on the ground of the bin and the staff gauges arranged on the surfaces of two opposite walls have the advantages that the image acquisition device can visually know the internal length and the height of the bin conveniently, and meanwhile, the effect of sign reminding is achieved.
The image acquisition devices are respectively arranged on the two opposite wall surfaces of the bin, and the shooting range of each image acquisition device can cover all scales and numerical value information of the scale on the ground of the bin when no materials are stacked in the bin and all scales and numerical value information of the scale on the wall surface below the image acquisition device opposite to the image acquisition device; the shooting range of the image acquisition device can be understood to be similar to the recognition range of human eyes, all scales and numerical information of the scales on the ground and the wall surface must be contained in the recognition range, otherwise, when the height of the material is measured, the condition that the final height of the material cannot be calculated due to lack of data occurs.
The image acquisition device is used for shooting and sampling the interior of the bin in which the materials are stacked and sending sampling image information to the image processing device; this sample has contained material, scale and scale numerical information.
The image processing device is remotely connected with the image acquisition device and used for carrying out image processing on the sampling image information, identifying part of scale marks and numerical information on the surface of the bin ground and the wall body after the sampling image information is shielded by the material, and calculating the stacking height of the material according to the identified scale marks and the numerical information.
According to one embodiment, the image acquisition device is a CCD camera and the image processing device is an industrial computer. The pixels of the CCD camera are high enough (e.g., 1000 thousand pixels) so that the sampled picture can clearly distinguish the scale and numerical information on the scale. The industrial computer is mainly used for receiving the pictures sampled by the CCD camera, identifying the images and calculating the height of the materials.
Preferably, the bin floor is a horizontal surface. The bin ground is a horizontal plane, so that the arrangement of the ruler is convenient, and the image recognition and the material height calculation at the later stage are facilitated. In some material storage bins, the material height may also be calculated if the bin floor is not horizontal, for example, the bin floor is conical with the cone top of the conical bin facing downward.
Preferably, the surface of the wall body is a plane or a curved surface perpendicular to the floor of the bin. When the surface of the wall body is a plane, the bin is a hexahedron. When the surface of the wall body is a curved surface, the chamber can be a cylinder. The surfaces of the walls of the bin are symmetrical relative to the central point of the ground of the bin, so that the image acquisition device can be conveniently arranged and can be used for sampling.
The scale arranged on the ground of the bin is a horizontal scale, and the scale arranged on the surface of the wall is a vertical scale. Since the object of the present invention is to measure the height of the material, the scale must be the above two cases, even if the chamber is not the above-mentioned cylinder or hexahedron, it is still necessary that the scale is a horizontal scale and the scale on the wall surface is a vertical scale.
Preferably, the surface of the scale is marked differently in colour from the scale and numerical values of the scale. Even if the brightness of the bin is not very high, the scales and the numerical values of the scale can be made to be obviously different from the objects of the surrounding environment. This setting is mainly in order to make scale and the numerical value of scale can be clearly discerned by the CCD camera easily.
Preferably, the scale surface is coated with a luminescent material, and the luminescent brightness and color of the luminescent material change with changes in the ambient light source. The purpose of coating the luminescent material is also to make the scale and the numerical value of the ruler more easily clearly recognizable by the CCD camera.
According to one embodiment, the number of image acquisition devices is two, and the two image acquisition devices are mutually symmetrical relative to the center point of the ground of the chamber. The purpose of arranging the image acquisition means opposite to each other is for the convenience of the subsequent industrial computer calculating the height of the material. If the number of the image acquisition devices is more than two, the height of the material can be calculated, particularly when the upper part of the bin is a non-cylindrical body and a non-hexahedral body, the number of the image acquisition devices is more than two, and the arrangement positions of the image acquisition devices are not symmetrical relative to the center point of the ground of the bin.
The device consists of a CCD camera, a scale, an industrial computer and the like. The materials produced by the material production line are conveyed to a background bin through a belt conveyor to be stacked. In each chamber, a wall body and the ground are respectively provided with a scale which is composed of scale marks and numerical values. According to one embodiment, in the case of a common light source, the bottom color of the scale surface is set to be white, and the numerical value and the scale are marked with a prominent yellow (or a scale capable of emitting light and changing color according to the change of the ambient light source is selected, so as to display the scale and the corresponding dimensional numerical value more clearly). The CCD camera is installed above the vertical scale.
In a second aspect of the present invention, there is also provided a material height measuring method for measuring a stacking height of a material in a bin, wherein a bin floor of the bin and two opposite wall surfaces in the bin are provided with a scale, and fig. 2 is a flowchart illustrating steps of the material height measuring method provided by the present invention, the measuring method comprising the following steps:
the two opposite wall surfaces of the bin are respectively provided with an image acquisition device, wherein the shooting range of each image acquisition device can cover all scales and numerical information of a scale on the ground of the bin when the bin is not stacked with materials, and all scales and numerical information of a scale on the wall surface below the image acquisition device opposite to the scale;
shooting and sampling the interior of the bin in which the materials are stacked by adopting the image acquisition device, and sending sampling image information to an image processing device remotely connected with the image acquisition device;
and performing image processing on the sampling image information by adopting the image processing device, identifying partial scale marks and numerical information on the surfaces of the bin ground and the wall body after being shielded by the material, and calculating the stacking height of the material according to the identified scale marks and numerical information.
According to the scheme of the invention, the image acquisition device can shoot the change of the height of the material in real time in the material stacking process in the bin. The image acquisition device sends the sampled pictures to an industrial computer for processing, and calculates the height of the material in real time.
The ground of the bin is a horizontal plane, and the wall of the bin is a plane or a curved surface vertical to the horizontal plane, namely when the bin is a cylinder or a hexahedron, and the height of the material changes from low to high, the algorithm for calculating the height of the material by the industrial computer is different. The different nature of the algorithms is due to the different size of the material volume relative to the bin volume.
As shown in fig. 3, when the volume of the material is larger than the volume of the bin, and the height of the material is higher, so that the image acquisition device recognizes the vertical scale on the wall surface through the highest point of the material, but the image acquisition device cannot acquire the scale and the numerical value of the horizontal scale through the highest point of the material, the method of the industrial computer is as follows:
since the mounting positions of the two image capturing devices, the width of the chamber are determined, a fixed amount a is assumed0c0＝LR，d0f0＝LL，c0f0＝dB(ii) a Wherein, c0f0Is the length of the bin horizontal scale, a0c0Is the length of a vertical scale on the left wall of the bin, d0f0The length of the vertical scale is the length of the wall body on the right side of the bin.
Numerical image with scale being identifiable by two image acquisition devicesAnd (3) measuring the following values: e.g. of the type0f0＝Lh_m_L，b0c0＝Lh_m_R(ii) a Wherein e is0f0B, the length from the scale mark of the lowest point of the vertical scale which can be shot by the CCD camera on the wall body on the left side of the bin through the highest point of the material to the horizontal plane, b0c0The CCD camera on the wall body on the right side of the bin is calibrated to the length from the ruler at the lowest point of the vertical ruler, which can be shot by the highest point of the material, to the horizontal plane.
G is obtained by the fixed value and the measured value and combining with a mathematical method and an industrial computer0h0I.e. the height of the material, the steps are as follows:
1、Δa0b0g0～Δd0e0g0，
2、Δm0b0c0～Δm0d0f0，
3、Δm0h0g0～Δm0f0d0，
as shown in fig. 4, when the volume of the material is smaller than the volume of the bin, and the height of the material is lower, so that the image capturing device recognizes the vertical scale of the wall surface through the highest point of the material, and can also recognize the horizontal scale of the bin level, the method calculated by the industrial computer is as follows:
since the mounting positions of the two image capturing devices, the width of the chamber are determined, a fixed amount a is assumed1b1＝LR，d1e1＝LL，b1e1＝c1f1＝dB(ii) a Wherein, a1b1Is the length of a vertical scale on the left wall of the bin, d1e1Is the length of a vertical scale on the right wall of the bin, b1e1And c1f1The length of the bin horizontal scale.
The numerical image of scale can be discerned through two image acquisition device, the measured value: b1k1＝dl_m_L1，b1n1＝dl_m_L2，b1m1＝dl_m_R1，b1l1＝dl_m_R2(ii) a Wherein, b1k1The length of the leftmost point at the bottom of the material pile from the left wall body of the chamber, b1n1The length from the scale of the horizontal scale shot by the CCD camera at the left side through the highest point of the material to the wall body at the leftmost side of the chamber, b1m1The length from the scale of the horizontal scale shot by the CCD camera at the right side through the highest point of the material to the wall body at the leftmost side of the chamber, b1l1The length from the rightmost point of the bottom of the material to the leftmost wall of the bin.
G is obtained by the fixed value and the measured value and combining with a mathematical method and an industrial computer1h1I.e. the value of the height of the material, the procedure is as follows:
1、Δc1b1m1～Δd1e1m1，
Δe1n1f1～Δb1n1a1，
2、Δa1c1g1～Δd1f1g1，
3、Δb1c1m1～Δh1g1m1，
the scale numerical value image is influenced by various interference noises inside and outside the system and adverse working conditions in the processes of imaging, transmission, conversion or storage, so that the acquired image has the defects of characteristic inundation, rough picture, character inclination and the like. In order to reduce image noise, restore a real image, highlight a character area, and perform preprocessing on an acquired image. Extracting the interested character region after preprocessing, and then completing the classification and identification of the feature extraction after segmenting, feature screening and morphological optimization of the character region. Graphics preprocessing methods are well known to those skilled in the art and will not be described herein.
The invention sets a scale in the bin for stacking materials, reads the scale and the numerical value on the scale through the image acquisition device, and finally sends the scale and the numerical value to the industrial computer to calculate the height of the materials. The device requires simply, setting that can be convenient for the height of material can be caught by the device in real time, and the device can be integrated into material transportation device, realizes when the material height surpasses expected value, stops the effect that the material is carried the bin again. The device realizes the digitization and the high-efficiency operation of material transportation. The measurement of the height of the material and the dynamic management thereof do not need to depend on manual measurement and estimation, and the continuity of production is not influenced.
While the embodiments of the present invention have been described in detail with reference to the accompanying drawings, the embodiments of the present invention are not limited to the details of the above embodiments, and various simple modifications can be made to the technical solution of the embodiments of the present invention within the technical idea of the embodiments of the present invention, and the simple modifications are within the scope of the embodiments of the present invention.
It should be noted that the various features described in the above embodiments may be combined in any suitable manner without departing from the scope of the invention. In order to avoid unnecessary repetition, the embodiments of the present invention will not be described separately for the various possible combinations.
In addition, any combination of the various embodiments of the present invention is also possible, and the same should be considered as disclosed in the embodiments of the present invention as long as it does not depart from the spirit of the embodiments of the present invention.
Claims (9)
1. A material height measuring device for measuring a stacking height of a material in a bin, the measuring device comprising:
the scale is arranged on the ground of the bin, and the scales are arranged on the surfaces of two opposite wall bodies in the bin;
the image acquisition devices are respectively arranged on the two opposite wall surfaces of the bin, and the shooting range of each image acquisition device can cover all scales and numerical value information of the scale on the ground of the bin when no materials are stacked in the bin and all scales and numerical value information of the scale on the wall surface below the image acquisition device opposite to the image acquisition device; the image acquisition device is used for shooting and sampling the interior of the bin in which the materials are stacked and sending sampling image information to the image processing device;
the image processing device is remotely connected with the image acquisition device and used for carrying out image processing on the sampling image information, identifying part of scale marks and numerical information on the surface of the bin ground and the wall body after the sampling image information is shielded by the material, and calculating the stacking height of the material according to the identified scale marks and the numerical information.
2. The height measuring device of claim 1, wherein the image acquisition device is a CCD camera and the image processing device is an industrial computer.
3. The height measuring device of claim 1, wherein the bin floor is a horizontal surface.
4. The height measuring device of claim 3, wherein the wall surface is a plane or a curved surface perpendicular to the floor of the chamber.
5. The height measuring device according to claim 1, wherein the scale provided on the floor of the chamber is a horizontal scale, and the scale provided on the wall surface is a vertical scale.
6. The height measuring device of claim 1, wherein the scale surface is marked differently in color from the scale markings and numerical values of the scale.
7. The height measuring device according to claim 1, wherein the scale surface is coated with a luminescent material, and a luminescent brightness and a color of the luminescent material change with a change in an ambient light source.
8. The height measuring device of claim 1, wherein there are two image capturing devices, and the two image capturing devices are symmetrical to each other with respect to a center point of the chamber floor.
9. A material height measuring method is used for measuring the stacking height of materials in a bin, and scales are arranged on the bin ground of the bin and two opposite wall surfaces in the bin, and is characterized by comprising the following steps of:
s1) arranging image acquisition devices on the two opposite wall surfaces of the bin respectively, wherein the shooting range of each image acquisition device can cover all scales and numerical value information of a scale on the ground of the bin when the bin is not stacked with materials, and all scales and numerical value information of a scale on the wall surface below the image acquisition device opposite to the scale;
s2) shooting and sampling the interior of the bin with the stacked materials by adopting the image acquisition device, and sending sampling image information to an image processing device remotely connected with the image acquisition device;
s3) image processing is carried out on the sampling image information by adopting the image processing device, part of scale marks and numerical information of the bin ground and the wall surface which are shielded by the material are identified, and the stacking height of the material is calculated according to the identified scale marks and numerical information.
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