CN110744557B - Two-dimensional cableway inspection robot for mining belt conveyor - Google Patents
Two-dimensional cableway inspection robot for mining belt conveyor Download PDFInfo
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- CN110744557B CN110744557B CN201910983064.0A CN201910983064A CN110744557B CN 110744557 B CN110744557 B CN 110744557B CN 201910983064 A CN201910983064 A CN 201910983064A CN 110744557 B CN110744557 B CN 110744557B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J11/00—Manipulators not otherwise provided for
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J9/00—Programme-controlled manipulators
- B25J9/16—Programme controls
- B25J9/1602—Programme controls characterised by the control system, structure, architecture
Abstract
The invention discloses a two-dimensional cableway inspection robot for a belt conveyor, and relates to the technical field of inspection robots. The inspection robot comprises a cableway trolley, a flexible cable traction device and a ground control device; the aerial cableway trolley comprises a cableway trolley main body, a camera module, an environment monitoring module and a data processing module, wherein the camera module, the environment monitoring module and the data processing module are carried on the cableway trolley main body; the cableway trolley main body moves on the cableway under the driving of the flexible cable traction equipment, and various data information of the belt conveyor in the running process is collected in real time. The two-dimensional cableway inspection robot for the belt conveyor can acquire various data information in the running process of the belt conveyor in real time and feed back the data information in time, and monitoring personnel can find problems generated in the working process of the belt conveyor in time. Meanwhile, the pose level of the inspection robot can be guaranteed through the camera pose correction unit, so that a more stable picture is shot, and the monitoring effect is improved.
Description
Technical Field
The invention relates to the technical field of inspection robots, in particular to a two-dimensional cableway inspection robot for a mining belt conveyor.
Background
In the coal production process, a belt conveyor is important coal conveying equipment, but accidents such as belt breakage, deviation, slippage, carrier roller damage and the like frequently occur in the working process of the conveyor, so that property loss and casualties are caused. There is a need for a belt conveyor that can detect and resolve problems in a timely manner to prevent more serious consequences.
Therefore, people have proposed the inspection robot to help people monitor the working condition of the conveyor in real time. However, the traditional inspection robot needs to erect an I-shaped steel track above the belt conveyor for the robot to move, which is difficult to realize in a coal mine mining area with complex terrain, and the construction cost is high. Moreover, the movement range of the inspection robot on the track is relatively fixed, inspection can only be performed along the laid fixed track route, and the visual field is narrow.
Aiming at the problem, a cableway inspection robot is provided, the cableway inspection robot enables a camera to be capable of shooting remotely without dead angles, is not influenced by terrain any more, and can control the camera to move on the cableway to complete a shooting task only by erecting the cableway.
However, the existing cableway inspection robot is difficult to keep balance in pose due to operation on a flexible cableway, so that the motion stability is influenced, a camera cannot shoot a stable and clear picture, and data acquisition of a belt conveyor in the working process is influenced.
Disclosure of Invention
The invention provides a two-dimensional cableway inspection robot for a mining belt conveyor, which comprises a cableway trolley, a flexible cable traction device and a ground control device, wherein the flexible cable traction device is arranged on the cableway trolley; the aerial cableway trolley comprises a cableway trolley main body, a camera module, an environment monitoring module and a data processing module, wherein the camera module, the environment monitoring module and the data processing module are carried on the cableway trolley main body;
the cableway trolley main body moves on the cableway under the driving of a flexible cable traction device, and the flexible cable traction device comprises a traction flexible cable for drawing the cableway trolley main body, a first servo motor, a first servo driver and a communication module, wherein the first servo motor is arranged at two ends of the cableway and controls rollers to wind the flexible cable;
the camera module comprises a camera and a camera pose correction unit, the camera is used for acquiring image information of the belt conveyor, and the camera pose correction unit is used for sensing the inclination direction and the inclination amount of the camera and adjusting the pose of the camera;
the environment monitoring module is used for acquiring the environmental state information around the belt conveyor;
the data processing module is electrically connected with the flexible cable traction equipment, the camera module and the environment monitoring module respectively; the data processing module comprises a data acquisition module, a data compression module and a wireless transmission module, the data acquisition module acquires motion information, camera image information and environment state information of the cableway trolley, the motion information, the camera image information and the environment state information are compressed by the data compression module and then transmitted to the ground control equipment through the wireless transmission module for processing and analysis, and the ground control equipment returns a control instruction to the flexible cable traction equipment according to an analysis result to adjust the motion state of the cableway trolley.
Preferably, the camera pose correction unit comprises a horizontal sensor, a pose correction mechanism and a pose correction program processing module; the horizontal sensor is electrically connected with the data processing module and used for sensing the inclination direction and the inclination amount of the camera, compressing the sensed real-time data through the data processing module and then wirelessly transmitting the compressed real-time data to the pose correction program processing module in the ground control equipment, and determining the pose vector of the camera after the analysis and the processing of the pose correction program processing module; when the pose vector deviates from the set range, starting a computer vision processing program block in the pose correction program processing module, determining the inclination angle of the camera according to the image information of the camera, and sending a control instruction to the pose correction mechanism; the pose correction mechanism comprises a second servo motor, a second servo driver and an embedded PC (personal computer) arranged on the cableway trolley, the ground control equipment sends a control instruction to the embedded PC, the embedded PC controls the second servo driver to send a pulse signal to the second servo motor, and the second servo motor controls the camera to reversely rotate according to the pulse signal to calculate the deviation angle so as to correct the pose of the camera.
Preferably, the inspection robot further comprises a cableway tensioning device, wherein the cableway tensioning device comprises a tensioning mechanism and a motion controller, the tensioning mechanism is installed at one end of the cableway and connected with the cableway; the camera posture correction unit detects that the camera is inclined, calculates the specific inclination direction and the specific inclination amount, sends a control command to the motion controller through the ground control equipment, and the motion controller controls a tension wheel in the tension mechanism to work to perform tensioning adjustment on the ropeway.
Preferably, the ground control device comprises a computer which is responsible for carrying out centralized analysis and processing on all collected data; the ground control equipment comprises two working modes, namely an automatic operation mode and a manual operation mode; under the automatic operation mode, the cableway trolley automatically operates according to a set back-and-forth program and continuously transmits the image and the environmental state information back to the working process of the belt conveyor; under the manual operation mode, monitoring personnel can manually control the cableway trolley to move forwards, backwards, pause and adjust the state of the camera.
Preferably, the camera module further comprises a camera horizontal 360-degree rotation driving unit and a camera vertical lifting unit, and the two units are respectively and correspondingly provided with a servo motor and a servo driver; in the manual operation mode, monitoring personnel control the ground control equipment to send a control instruction to the embedded PC, the embedded PC controls the servo driver to send a pulse signal to the corresponding servo motor, and the servo motor controls the camera to move correspondingly according to the pulse signal.
Preferably, the environment monitoring module comprises an infrared temperature sensor and a smoke alarm, wherein the infrared temperature sensor is arranged on the cableway trolley main body and is used for detecting the temperature condition around the belt conveyor; the ground control equipment also comprises a smoke alarm switch and a temperature alarm switch which are electrically connected with the computer, and when the temperature data or the smoke concentration analyzed and processed by the computer reaches a system preset threshold value, the corresponding alarm switch is started to alarm.
Preferably, the cableway trolley is further provided with an intelligent charging module used for supplying power to the cableway trolley, the intelligent charging module comprises a battery and an electric quantity sensing system, the intelligent charging module is electrically connected with the data processing module, when the electric quantity sensing system senses that the electric quantity is lower than the preset minimum electric quantity, the intelligent charging module sends information to the ground control equipment through the data processing module, and sends an instruction to the flexible cable traction equipment through the ground control equipment to drive the cableway trolley to return to a power supply place for charging.
Preferably, the traction trolley further comprises a driving unit, the driving unit comprises a driving mechanism, a fifth servo motor, a third servo driver and an embedded PC, the driving mechanism, the fifth servo motor, the third servo driver and the embedded PC are mounted on the main body of the cableway trolley, the ground control device sends a control instruction to the embedded PC, the embedded PC controls the third servo driver to send a pulse signal to the fifth servo motor, and the fifth servo motor controls the driving mechanism according to the pulse signal.
Compared with the prior art, the two-dimensional cableway inspection robot for the mining belt conveyor has the advantages that:
(1) the invention utilizes the belt conveyor inspection robot to collect various data information in the running process of the belt conveyor in real time and feed back the data information in time, thereby facilitating monitoring personnel to find problems generated in the working process of the belt conveyor in time.
(2) The invention can ensure the pose level of the inspection robot so as to shoot more stable pictures and improve the monitoring effect.
(3) The invention controls the inspection robot to finish the actions of moving, horizontally rotating and vertically lifting and the like through computer software, carefully observes the conditions around the belt conveyer and greatly increases the visual field range of the inspection robot.
(4) The flexible cable traction equipment is used for driving the cableway trolley, and the driving device is placed on the ground, so that the weight of the inspection robot is reduced, and the load of the cableway is reduced.
(5) The intelligent power supply system can intelligently sense the electric quantity of the inspection robot, and can automatically return to a ground charging place for charging in time when the electric quantity is too low.
(6) The invention can realize an automatic operation mode and a manual operation mode, and the two modes can be switched mutually. During ordinary monitoring, an automatic operation mode can be adopted, the inspection robot automatically operates according to a set program, and once an accident occurs, the manual mode can be immediately switched to control the camera to rotate and lift, so that specific field conditions can be observed.
Drawings
For a clearer explanation of the embodiments or technical solutions of the present invention, the drawings used in the description of the embodiments or the prior art will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for a person skilled in the art to obtain other drawings based on these drawings without creative efforts.
Fig. 1 is a schematic diagram of a control system of a two-dimensional cableway inspection robot of a belt conveyor disclosed by the invention.
Fig. 2 is a flowchart of a control procedure of the two-dimensional cableway inspection robot for the belt conveyor disclosed by the invention.
The part names represented by more numbers or letters in the figures are as follows:
1-cableway trolley; 11-a camera module; 12-an environmental monitoring module; 13-a data processing module; 14-a smart charging module; 2-a flexible cable traction device; 3-ground control equipment; 4-a cableway tensioning device.
Detailed Description
The following provides a brief description of embodiments of the present invention with reference to the accompanying drawings. It is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments, and all other embodiments obtained by those skilled in the art based on the embodiments of the present invention without any inventive work belong to the protection scope of the present invention.
The two-dimensional cableway inspection robot for the mining belt conveyor comprises a cableway trolley 1, a flexible cable traction device 2 and a ground control device 3. The cableway trolley 1 comprises a cableway trolley main body, a camera module 11, an environment monitoring module 12 and a data processing module 13, wherein the camera module 11 is carried on the cableway trolley main body.
The cableway trolley main body moves on the cableway under the driving of the flexible cable traction equipment 2. The flexible cable traction equipment 2 comprises a traction flexible cable for drawing a cableway trolley main body, a first servo motor, a first servo driver and an EtherCAT communication module, wherein the first servo motor is arranged at two ends of a cableway and used for controlling rollers to wind the flexible cable. The ground control equipment 3 sends a control instruction to the communication module, the communication module controls the first servo driver to send pulses to the first servo motor, and the first servo motor controls the corresponding roller to rotate according to the pulse signals. Specifically, the flexible cable traction equipment 2 controls the advancing and retreating of the cableway trolley 1 and the speed of the cableway trolley 1 through traction of the flexible cable. Flexible cables are led out from the front and the back of the cableway trolley main body respectively, and the flexible cables are wound by rollers controlled by servo motors at two ends of the cableway to control the movement of the cableway trolley 1. If the cableway trolley 1 needs to be braked, only one flexible cable which moves opposite to the flexible cable needs to be wound for braking. The TwinCAT software in the ground control equipment 3 controls the first servo driver to send out pulses to control the first servo motor through the EtherCAT communication module, and the first servo motor is electrically connected with the data processing module and feeds back information such as the running speed of the first servo motor to the ground control equipment 3. The design of separating the robot driving part from the inspection robot reduces the weight of the robot and is beneficial to the movement of the robot on the cableway without overlarge sag of the cableway.
Further, the traction trolley 1 further comprises a driving unit, the driving unit comprises a driving mechanism, a fifth servo motor, a third servo driver and an embedded PC, the driving mechanism, the fifth servo motor, the third servo driver and the embedded PC are installed on the cableway trolley main body, the ground control device 3 sends a control instruction to the embedded PC, the embedded PC controls the third servo driver to send a pulse signal to the fifth servo motor, and the fifth servo motor controls the driving mechanism according to the pulse signal. The fifth servo motor is electrically connected with the data processing module 13, and wirelessly transmits information such as the rotating speed of the fifth servo motor to the ground control equipment to feed back the information in real time, so that the control is better. The arrangement of the driving unit improves the accuracy of the power control of the cableway trolley 1.
The camera module 11 includes a camera for acquiring image information of the belt conveyor. The environmental monitoring module 12 is used for collecting environmental status information around the belt conveyor. The data processing module 13 is electrically connected with the flexible cable traction device 2, the camera module 11 and the environment monitoring module 12. The data processing module 13 comprises a data acquisition module, a data compression module and a wireless transmission module which are connected in sequence. The data acquisition module acquires the motion information, the camera image information and the environmental state information of the cableway trolley 1, the compressed data is transmitted to the ground control equipment 3 through the wireless transmission module for processing and analysis after being compressed by the data compression module, and the ground control equipment 3 returns a control command to the flexible cable traction equipment 2 according to an analysis result to adjust the motion state of the cableway trolley 1. The data processing module 13 is an integrated chip and is composed of a data acquisition unit, a data compression chip and a wireless data transmission chip. The specific model is not limited, and the corresponding function can be realized.
Further, the camera module 11 further includes a camera pose correction unit. Because the rigid track of the inspection robot is changed into the flexible steel wire track, the stability of the camera becomes a vital part. The cableway inspection robot often generates a serious pose unbalance phenomenon in the working process and seriously influences the shooting work of the camera, so that the pose of the camera needs to be adjusted by a control system, and the camera can be kept horizontal as much as possible to shoot a stable picture.
The camera pose correction unit comprises a horizontal inductor, a pose correction mechanism and a pose correction program processing module. The horizontal sensor is electrically connected with the data processing module 13, senses the inclination direction and the inclination amount of the camera, compresses the sensed real-time data through the data processing module 13, wirelessly transmits the compressed real-time data to the pose correction program processing module in the ground control equipment 3, and determines the pose vector of the camera after the compressed real-time data is analyzed and processed by the pose correction program processing module. Specifically, for the inspection robot in the space, a single horizontal sensor cannot determine the specific pose state of the inspection robot, so that the scheme adopts a three-point non-collinear mode to arrange three horizontal sensors, senses three positions of the front end, the rear left end and the rear right end of the inspection robot to obtain the inclination direction and the inclination amount of the position, sends sensed real-time data to a pose correction program processing module in the ground control equipment 3, and analyzes three-point numerical values by MATLAB software in the pose correction program processing module to determine the pose vector of the inspection robot. And when the pose vector deviates from the set range, starting a computer vision processing program block in the pose correction program processing module, determining the inclination angle of the camera according to the image information of the camera, and sending a control instruction to the pose correction mechanism.
The computer vision processing program block is based on Python language and is a vision algorithm built on an OpenCV computer vision library, OpenCV provides a video Capture class to acquire a frame stream of a camera, an image display function is used for displaying images, frames in a window can be kept to be updated all the time, and a dynamic picture is formed, the core of the algorithm provided by the invention is that each captured video frame is converted by a rotation matrix and is converted into a set correct display position, the set correct display position is that a shot picture is aligned by an image processing class library in Python under an OpenCV frame and then is compared with a line cluster of a set normal picture, when the line clusters in two pictures are in a parallel state, the shot picture is considered to be in line with a normal observation visual angle of a human, an optimal rotation scheme principle is adopted, the normal picture is returned by a minimum rotation angle, and the rotation angle is prevented from exceeding 180 degrees, and outputting the absolute value of the rotation angle converted by the corresponding rotation matrix, judging that when the absolute value of the rotation angle is higher than a specified range, namely the inspection robot is seriously inclined at the moment, the picture shot by the camera rotates to influence the monitoring of the person, and starting the TwinCAT software to send a control command to the embedded PC.
When the video file is processed by the visual algorithm, a frame-by-frame analysis mode is adopted, a large amount of memory and a CPU are occupied, so that whether the pose of the inspection robot is inclined or not needs to be confirmed in one step by matching with the horizontal sensor system, then a computer visual processing program is used for identification and accurate calculation, a specific inclination angle is obtained, and after data are processed, TwinCAT software is used for controlling the camera to move, so that an intelligent pose automatic correction system is formed.
Specifically, the pose correction mechanism comprises a second servo motor, a second servo driver and an embedded PC (personal computer) arranged on the cableway trolley 1, the ground control equipment 3 sends a control instruction to the embedded PC, the embedded PC controls the second servo driver to send a pulse signal to the second servo motor, the second servo motor is driven by the second servo driver, the second servo motor drives a worm gear to move through a gear connected with the second servo motor, the cantilever is meshed with the worm gear through a gear set, a gear shaft at one end of the cantilever drives the whole cantilever to generate corresponding deflection motion under the driving of the gear set, and a camera is fixed at the other end of the cantilever, so that the camera also generates deflection motion, and the deflection direction is opposite to the image inclination direction calculated by the computer. The calculation of the deflection amount is based on the known modulus and tooth number of the worm and gear, the transmission ratio of the gear set and the length of the cantilever, and the obtained image deflection amount is combined, so that the rotation amount of the motor can be quickly calculated, and a camera can be controlled to shoot normal images. Meanwhile, the second servo motor is electrically connected with the data processing module, and wirelessly transmits information such as the rotating speed of the second servo motor to the ground control equipment 3 to feed back the information in real time.
Further, the inspection robot further comprises a cableway tensioning device 4, wherein the cableway tensioning device 4 comprises a tensioning mechanism and a motion controller, the tensioning mechanism is installed at one end of the cableway and connected with the cableway. The camera posture correction unit detects that the camera is inclined, calculates the specific inclination direction and the specific inclination amount, sends a control command to the motion controller through the ground control equipment 3, controls a tension wheel in the tension mechanism to work, and conducts tensioning adjustment on the ropeway. Specifically, the cableway tensioning device 4 is characterized in that a tensioning mechanism is arranged at one end of a cableway, is connected with the cableway and is controlled by a motion controller, the control principle is that based on the detected pose vector of the inspection robot, when the pose vector deflects, the specific inclination direction and the specific inclination amount are calculated, a plurality of connected parallel cableway tension values are input into an upper computer cableway tensioning control program, the motion controller is used for cooperatively controlling the tensioning degree of each cableway by combining the pose vector, and the motion controller controls the tensioning mechanism to tension the cableway and then further automatically adjusts through collected pose vector information to form an automatic feedback and adjustment tensioning system. The sag of the cableway is reduced through the cableway tensioning device 4, and then the inspection robot on the cableway is stabilized, so that the cableway is in a tensioning state in strong wind weather, excessive swing is not generated, and the stable operation of the inspection robot is guaranteed. After the ropeway is tensioned and adjusted, the position and pose of the inspection robot are balanced, a computer vision processing program block in the position and pose correction program processing module determines the inclination angle of the camera according to the image information acquired by the camera, and the camera is adjusted again to balance the position and pose of the camera.
Furthermore, the ground control device 3 includes a computer, and is responsible for performing centralized analysis and processing on all the acquired data, and finally displaying the data on a human-computer interaction interface of the display, so as to facilitate monitoring of the pictures transmitted back by the camera and the data of each servo motor. The ground control equipment 3 comprises two working modes, namely an automatic operation mode and a manual operation mode; when any one mode is operated, the operation can be interrupted at any time and switched to the other mode, and the human-computer interaction interfaces of the two operation modes are kept unchanged. Under the automatic operation mode, the cableway trolley 1 automatically operates according to a set back-and-forth program and continuously transmits images and environmental state information back to the working process of the belt conveyor; under the manual operation mode, monitoring personnel can manually control the cableway trolley to advance, retreat and pause, and simultaneously operate the horizontal 360-degree rotation and vertical lifting functions of the camera to carefully observe the conditions around the belt conveyor, so that the visual field range is greatly enlarged. Under the automatic operation mode, the monitoring personnel only need observe the picture of gathering can, if need carry out the key observation to certain place, can switch manual mode immediately, through TwinCAT software control servo motor drive camera horizontal rotation and lift, obtain the picture of higher definition and wider visual angle.
The software responsible for controlling the drive unit on the cableway trolley 1 in the computer is TwinCAT software of Beckhoff company, the TwinCAT software is automatic system programming development software which is provided by Beckhoff company in Germany and integrates control, programming and visualization, and the TwinCAT software system can convert any one PC-based system into a real-time control system with a plurality of PLC, NC, CNC and robot real-time operating systems. Real-time data of each servo motor of the driving unit on the cableway trolley 1 can be obtained through TwinCAT software, so that monitoring by workers is facilitated. And the camera pose correction processing program module is responsible for processing the information and the video information sent by the horizontal sensor, comprises an MATLAB vector calculation program and a computer vision program, opens a communication channel with the TwinCAT after the data processing is finished, sends an instruction, and realizes the automatic correction function of the camera pose by using the TwinCAT control system. In addition, the control program responsible for the environmental monitoring module 12 analyzes the data in real time and displays the results in the interface. Therefore, the human-computer interaction interface consists of three parts, namely a camera picture monitoring part, an environment monitoring module 12 data display part and a servo motor data display part in a driving module.
Furthermore, the camera module 11 further includes a camera horizontal 360-degree rotation driving unit and a camera vertical lifting unit, the camera horizontal 360-degree rotation driving unit is correspondingly provided with a third servo motor, and the camera vertical lifting unit is correspondingly provided with a fourth servo motor. In a manual operation mode, monitoring personnel control the ground control equipment 3 to send a control instruction to the embedded PC according to operation requirements, the embedded PC controls a corresponding second servo driver to send a pulse signal to a third servo motor or a fourth servo motor, the corresponding servo motor controls the camera to move correspondingly according to the pulse signal, namely, the third servo motor in the camera horizontal 360-degree rotation driving unit drives a rotating disc to drive the camera to rotate, the fourth servo motor in the camera vertical lifting unit drives a telescopic rod to control the lifting of the camera, the third servo motor and the fourth servo motor are both connected with a data acquisition module, and the data are compressed and then sent to the ground computer through a wireless transmission module for real-time monitoring.
Further, the environmental monitoring module 12 includes an infrared temperature sensor disposed on the cableway cart body for detecting the ambient temperature condition of the belt conveyor and a smoke alarm for detecting the ambient smoke condition of the belt conveyor. The ground control equipment 3 further comprises a smoke alarm switch and a temperature alarm switch which are electrically connected with the computer, when the temperature data or smoke concentration analyzed and processed by the computer reaches a system preset threshold value, the corresponding alarm switch is started to give an alarm, meanwhile, the servo motor is controlled to stop polling the robot, the specific conditions of a scene are shot, and the specific position is determined, so that a worker can timely repair the robot. The ground control equipment 3 further comprises a PLC, the PLC is electrically connected with the computer and is simultaneously connected with the smoke alarm switch and the temperature alarm switch, each alarm switch is logically controlled, and the control progress and the real-time performance are better.
The infrared temperature sensor is responsible for collecting the temperature around the belt conveyor during operation to data transfer to data acquisition module 13, sends to ground controlgear through wireless transmission module after the warp compression, in case the temperature value appears unusually, ground controlgear 3 alright open the temperature alarm switch through software control PLC and send out the police dispatch newspaper.
The smoke sensor is responsible for collecting the smoke condition around the belt conveyor when in work, and similarly, the data of the smoke sensor is finally transmitted to the ground control equipment 3 in the same way as the infrared temperature sensor, and the data is analyzed by the computer. The PLC in the ground control equipment 3 is connected with the computer and is simultaneously connected with the temperature alarm switch and the smoke alarm switch, the PLC is controlled by the program controlled by the environment monitoring module 12, and when the temperature data or the smoke concentration reaches the threshold value, the corresponding alarm is started.
Further, still be provided with the intelligent charging module 14 that is used for cableway dolly 1 power supply on the cableway dolly 1, intelligent charging module 14 includes battery and electric quantity perception system, intelligent charging module 14 is connected with data processing module 13 electricity, when electric quantity perception system senses that the electric quantity is less than the minimum electric quantity of predetermineeing, send information to ground controlgear 3 via data processing module 13, send the instruction to flexible cable haulage equipment 2 through ground controlgear 3, drive cableway dolly 1 and get back to the place of supplying power and charge, wait to dash and start again after the electricity, begin to patrol and examine the task.
In conclusion, the two-dimensional cableway inspection robot for the mining belt conveyor disclosed by the invention can acquire various data information in the running process of the belt conveyor in real time and feed back the data information in time, so that monitoring personnel can find problems generated in the working process of the belt conveyor in time. Meanwhile, the pose level of the inspection robot can be guaranteed through the camera pose correction unit, so that a more stable picture is shot, and the monitoring effect is improved.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims (7)
1. A two-dimensional cableway inspection robot for a mining belt conveyor is characterized by comprising a cableway trolley (1), a flexible cable traction device (2) and a ground control device (3); the cableway trolley (1) comprises a cableway trolley main body, a camera module (11) carried on the cableway trolley main body, an environment monitoring module (12) and a data processing module (13);
the cableway trolley main body moves on the cableway under the driving of the flexible cable traction equipment (2), and the flexible cable traction equipment (2) comprises a traction flexible cable for dragging the cableway trolley main body, a first servo motor, a first servo driver and a communication module, wherein the first servo motor is arranged at two ends of the cableway and controls rollers to wind the flexible cable;
the camera module (11) comprises a camera and a camera pose correction unit, the camera is used for acquiring image information of the belt conveyor, and the camera pose correction unit is used for sensing the inclination direction and the inclination amount of the camera and adjusting the pose of the camera; the camera pose correction unit comprises a horizontal inductor, a pose correction mechanism and a pose correction program processing module; the horizontal sensor is electrically connected with the data processing module (13) and used for sensing the inclination direction and the inclination amount of the camera, compressing the sensed real-time data through the data processing module (13), wirelessly transmitting the compressed real-time data to a pose correction program processing module in the ground control equipment (3), and determining a pose vector of the camera after the compressed real-time data is analyzed and processed through the pose correction program processing module; when the pose vector deviates from the set range, starting a computer vision processing program block in the pose correction program processing module, determining the inclination angle of the camera according to the image information of the camera, and sending a control instruction to the pose correction mechanism; the pose correction mechanism comprises a second servo motor, a second servo driver and an embedded PC (personal computer) arranged on the cableway trolley (1), the ground control equipment (3) sends a control instruction to the embedded PC, the embedded PC controls the second servo driver to send a pulse signal to the second servo motor, and the second servo motor controls the camera to reversely rotate according to the pulse signal to calculate a deviation angle so as to correct the pose of the camera;
the environment monitoring module (12) is used for acquiring the environmental state information around the belt conveyor;
the data processing module (13) is respectively and electrically connected with the flexible cable traction equipment (2), the camera module (11) and the environment monitoring module (12); the data processing module (13) comprises a data acquisition module, a data compression module and a wireless transmission module, the data acquisition module acquires motion information, camera image information and environment state information of the cableway trolley, the motion information, the camera image information and the environment state information are compressed by the data compression module and then transmitted to the ground control equipment through the wireless transmission module for processing and analysis, and the ground control equipment (3) returns a control instruction to the flexible cable traction equipment (2) according to an analysis result to adjust the motion state of the cableway trolley (1).
2. The mining belt conveyor two-dimensional cableway inspection robot according to claim 1, characterized in that the inspection robot further comprises a cableway tensioning device (4), wherein the cableway tensioning device (4) comprises a tensioning mechanism and a motion controller, the tensioning mechanism is installed at one end of the cableway and connected with the cableway; the camera posture correction unit detects that the camera is inclined, calculates the specific inclination direction and the specific inclination amount, sends a control command to the motion controller through the ground control equipment (3), and the motion controller controls a tension wheel in the tension mechanism to work to perform tensioning adjustment on the ropeway.
3. The mining belt conveyor two-dimensional cableway inspection robot according to claim 1, characterized in that the ground control device (3) comprises a computer responsible for the centralized analysis and processing of all the acquired data; the ground control equipment (3) comprises two working modes, namely an automatic operation mode and a manual operation mode; in the automatic operation mode, the cableway trolley (1) automatically operates according to a set back-and-forth program and continuously transmits images and environmental state information back to the working process of the belt conveyor; under the manual operation mode, monitoring personnel can manually control the cableway trolley to move forwards, backwards, pause and adjust the state of the camera.
4. The mining belt conveyor two-dimensional cableway inspection robot according to claim 3, characterized in that the camera module (11) further comprises a camera horizontal 360-degree rotation driving unit and a camera vertical lifting unit, and the two units are respectively and correspondingly provided with a third servo motor and a fourth servo motor; in a manual operation mode, monitoring personnel control the ground control equipment (3) to send a control instruction to the embedded PC, the embedded PC controls the second servo driver to send a pulse signal to the corresponding servo motor, and the servo motor controls the camera to move correspondingly according to the pulse signal.
5. The mining belt conveyor two-dimensional cableway inspection robot according to claim 1, characterized in that the environment monitoring module (12) comprises an infrared temperature sensor and a smoke alarm, wherein the infrared temperature sensor is arranged on a cableway trolley main body and used for detecting the temperature condition around the belt conveyor, and the smoke alarm is used for detecting the smoke condition around the belt conveyor; the ground control equipment (3) further comprises a smoke alarm switch and a temperature alarm switch which are electrically connected with the computer, and when the temperature data or the smoke concentration which are analyzed and processed by the computer reach a system preset threshold value, the corresponding alarm switch is started to alarm.
6. The mining belt conveyor two-dimensional cableway inspection robot according to claim 1, characterized in that the cableway trolley (1) is further provided with an intelligent charging module (14) for supplying power to the cableway trolley, the intelligent charging module (14) comprises a battery and an electric quantity sensing system, the intelligent charging module (14) is electrically connected with the data processing module (13), when the electric quantity sensing system senses that the electric quantity is lower than a preset minimum electric quantity, the intelligent charging module sends information to the ground control device (3) through the data processing module (13), and sends an instruction to the flexible cable traction device (2) through the ground control device (3), so that the cableway trolley (1) is driven to return to a power supply place for charging.
7. The mining belt conveyor two-dimensional cableway inspection robot according to claim 1, characterized in that the cableway trolley (1) further comprises a driving unit, the driving unit comprises a driving mechanism, a fifth servo motor, a third servo driver and an embedded PC, the driving mechanism is installed on the cableway trolley main body, the ground control device (3) sends a control instruction to the embedded PC, the embedded PC controls the third servo driver to send a pulse signal to the fifth servo motor, and the fifth servo motor controls the driving mechanism according to the pulse signal.
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| CN111633660A (en) * | 2020-06-15 | 2020-09-08 | 吴洪婷 | Intelligent inspection robot |
| CN113021305B (en) * | 2021-03-19 | 2022-11-11 | 太原理工大学 | Inspection robot system |
| CN113334374A (en) * | 2021-05-14 | 2021-09-03 | 广西电网有限责任公司电力科学研究院 | Indoor automatic inspection robot system of transformer substation |
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