CN110793451A - Sintering trolley walking monitoring method and system based on laser ranging and image processing - Google Patents
Sintering trolley walking monitoring method and system based on laser ranging and image processing Download PDFInfo
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Abstract
A sintering trolley walking monitoring method and system based on laser ranging and image processing are characterized in that 10 laser range finders are installed in the two side areas of a track behind an igniter of an upper platform: 1) 4 laser range finders are respectively installed on two sides of the trolley and used for measuring the distance from the range finders to wheels of the trolley, 2 laser range finders are arranged on each wheel, each wheel measures an upper point and a lower point, and the distance mark on one side is LFront upper、LFront lower part、LRear upper part、LAt the back lower partAnd the distance on the other side is marked as LFront upper’、LFront lower part’、LRear upper part’、LAt the back lower part'; distance L of front and rear laser range finders on same sideDistance between range findersIs the distance L between the front wheel and the rear wheel of the trolleyWheel spacing(ii) a 2) Two laser range finders are respectively arranged on two sides of the trolley and used for measuring the distance L from the range finders to the side plate of the table board of the trolleySide plate、LSide plate'; solves the problems of deviation and rapid fault diagnosis of the sintering trolley, effectively pre-judges and pre-warns in time when the trolley is abnormal,the operation rate of the sintering production line is improved.
Description
Technical Field
The invention relates to the technical field of sintering control systems, in particular to a method and a system for monitoring the running of a sintering trolley based on laser ranging and image processing.
Background
The sintering trolley is a main operation part of the sintering machine, the purpose of conveying sintering materials is achieved, and the stability of the operation of the sintering trolley is an important precondition for ensuring the operation rate of a sintering production line. In the whole production operation process, the trolley bearing is subjected to severe working conditions such as high temperature, heavy load, impact vibration, dust, air current scouring and water showering, fine materials and other impurities frequently enter a bearing roller, bearing abrasion is aggravated, the trolley wheel frequently suffers from faults such as loosening and falling, blocking and wheel cover breaking, the trolley needs to be shut down for replacement, meanwhile, the trolley deviation problem easily exists, the blockage is turned over at the tail bend of the sintering machine, and the trolley needs to be shut down for treatment. Meanwhile, when the sintering trolley enters the lower part from the upper bent lane, shoulders are formed to cause arching of different degrees, and when the sintering trolley returns to the head wheel in a return process, the head star wheel is easy to block due to misalignment of the trolley, and the star wheel needs to be reversely rotated. The wheel looseness of the trolley is judged early, the head and tail blocking faults are diagnosed quickly, and the gravity center of the sintering trolley shape-walking research is always the center of gravity.
At present, in the domestic ferrous metallurgy process, the sintering equipment is characterized by large scale, extensive and general automation level. The sintering trolley has a severe operating environment, so that wheels are easy to damage, the trolley is expensive and large in quantity, most of the traditional fault diagnosis methods are methods of listening abnormal sound, seeing the appearance, measuring the wheel temperature, measuring the wheel abrasion, rotating a bearing and the like and researching by depending on experience, obviously, the faults can not be accurately and effectively judged and can not be predicted in advance to be judged in advance, the operation rate of a sintering machine can not be fundamentally improved, and the continuous and stable sintering production can be ensured.
Disclosure of Invention
In order to solve the technical problems in the background art, the invention provides a sintering trolley traveling monitoring method and a system based on laser ranging and image processing, which solve the problems of deviation and rapid fault diagnosis of a sintering trolley. The method realizes the online monitoring of the trolley, and effectively and timely pre-judges and pre-warns; when the trolley is abnormal, the early warning is effectively and timely pre-judged, the fault part is quickly diagnosed, the fault downtime is reduced, the stable operation of the sintering trolley is realized, and the operation rate of a sintering production line is improved.
In order to achieve the purpose, the invention adopts the following technical scheme:
a sintering trolley walking monitoring method based on laser ranging and image processing comprises the following steps:
step 101, installing 10 laser range finders in the two side areas of the track after sintering the igniter of the upper platform:
1) 4 laser range finders are respectively installed on two sides of the trolley and used for measuring the distance from the range finders to wheels of the trolley, 2 laser range finders are arranged on each wheel, each wheel measures an upper point and a lower point, and the distance mark on one side is LFront upper、LFront lower part、LRear upper part、LAt the back lower partAnd the distance on the other side is marked as LFront upper’、LFront lower part’、LRear upper part’、LAt the back lower part'; distance L of front and rear laser range finders on same sideDistance between range findersIs the distance L between the front wheel and the rear wheel of the trolleyWheel spacing；
2) Two laser range finders are respectively arranged on two sides of the trolley and used for measuring the distance L from the range finders to the side plate of the table board of the trolleySide plate、LSide plate’；
102, configuring a set of data acquisition subsystems on two sides of the sintering upper platform respectively, and acquiring 4-20ma signals output by the laser range finders on the corresponding sides and uploading the signals to a system server of a central control room through a field bus;
103, respectively installing a laser range finder on two sides of the track from the return of the lower track to the head star wheel for measuring the distance L from the range finder to the side plate strip of the trolleyReturn side plate、LReturn side plate’；
104, configuring a set of data acquisition subsystems in the head star wheel on the return of the lower track, wherein the data acquisition subsystems are used for acquiring 4-20ma signals output by the laser range finder and uploading the signals to a system server of a central control room through a field bus;
step 105, judging that the wheels shake and loosen and the contact area between the wheels and the track is too small:
1) collecting the distance from each point to the wheels of the trolley by adopting laser range finders which are distributed on two sides of an upper-layer track and are distributed on the same side with a distance of the length of a front axle and a rear axle of the trolley; when the wheel is normal, the two distance measurements above and below the wheel should be equal, i.e. LFront upper＝LFront lower part、LRear upper part＝LAt the back lower part、LFront upper’＝LFront lower part’、LRear upper part’＝LAt the back lower part'; when the wheel shakes, the upper distance measurement value and the lower distance measurement value of the wheel have deviation, and when the wheel exceeds the limit, the system gives an early warning prompt;
2) meanwhile, when the wheels are normal, the distance L between the two front wheels of the trolleyDistance between front wheelsAnd the distance L between the two rear wheelsRear wheel spacingStrain is not changed; when the wheels are loosened, the distance between two front wheels or the distance between two rear wheels of the trolley should be changed; calculating the real-time wheel distance L of the front wheels of the trolley by combining the installation distances of the front two laser range finders and the rear two laser range findersDistance on front wheel、LLower spacing of front wheels(upper and lower sets), real-time track L of rear wheelsUpper spacing of rear wheels、LLower spacing of rear wheels(upper and lower groups) and the deviation from the standard wheel track, when the deviation is out of limit, judging that the wheel is loose, uploading the picture of the corresponding vehicle number and giving an early warning;
3) when the distance between the collected same-side point and the trolley wheel is larger than the alarm limit value when the contact area between the wheel and the rail is too small, the distance between the wheel and the trolley wheel detected in opposite directions is combined, and the contact area between the wheel and the rail is too small; when the vehicle is abnormal, uploading a picture of a corresponding vehicle number and early warning;
step 106, judging running deviation of trolley
The distance L from the distance meter to the side plate strip of the trolley is acquired by adopting the laser distance meters fixedly arranged on the two sides of the upper-layer trackSide plate、LSide plate'; when the deviation exceeds the limit and lasts for a certain time or is asynchronous, judging that the trolley deviates, uploading a picture of a corresponding car number and early warning;
step 107, judging whether the front trolley of the star wheel of the head of the lower track is not aligned
The distance L from the distance measuring instrument to the side plate strip of the trolley is acquired and measured by adopting the laser distance measuring instruments arranged on the two sides of the lower part rail in the return stroke to the front of the head star wheelReturn side plate、LReturn side plate' when the distance deviation exceeds the limit and lasts for a certain time, judging that the trolley is not centered, and simultaneously shooting and uploading the picture of the corresponding car number and giving an early warning.
Also comprises the following steps:
step 201, installing industrial video network cameras on two sides of a track behind an igniter of an upper platform in a sintering mode, and accessing video signals to a corresponding image processing and identifying computer located in a central control room through an optical fiber network;
step 202, installing an industrial video camera on each of two sides of a track from the return of the lower track to the head star wheel, and accessing a video signal to a corresponding image processing and identifying computer;
step 203, in order to realize automatic image recognition, feature extraction is carried out on the images of the trolley, and for accurate judgment, feature identification is made on the four wheels of the trolley and the central position of the side part of the trolley: paint is adopted for spraying, and the marks of the front wheel and the rear wheel are different;
step 204, image recognition of trolley number
Establishing a car number characteristic image library of each trolley, when the trolley runs to the position of a camera, adopting a fixed-point industrial video recorder to pick up a picture, acquiring and processing a frame of image, performing gray level difference preprocessing on the image and characteristic extraction of the car number, comparing the image with a prestored trolley car number characteristic image, and automatically identifying the car number of the trolley;
step 205, image recognition of trolley wheel non-rotation
Shooting by adopting a fixed-point industrial video recorder, acquiring and processing a frame of image, performing gray level difference preprocessing and feature extraction on the image, acquiring and processing a frame of image after an acquisition period, and identifying the feature identification position of the trolley according to the running speed of the trolley of the sintering machine in the acquisition period; judging whether the wheels of the trolley rotate or not by changing the position angle of the trolley characteristic marks of two adjacent images; when the two images are abnormal, early warning is carried out, and the two images are uploaded to the monitoring client;
step 206, judging wheel loss of front trolley of star wheel at head of lower track
Shooting by adopting a fixed-point industrial video recorder arranged on the two sides of the track from the return of the lower track to the front track of the head star wheel, collecting and processing a frame of image, performing gray level difference preprocessing and characteristic extraction on the image, identifying the state of the wheels of the trolley, alarming when the wheels are lost, and uploading pictures;
step 207, wheel repair and replacement recording and wheel life tracking
The system provides a wheel repair and replacement subsystem; the maintenance and replacement of each trolley and each wheel can be recorded; on the basis, maintenance and replacement history and service life management and control of each trolley and each wheel can be realized, wheel maintenance and replacement records of the whole production line can be checked according to the month, the year and a certain time period, and the maintenance and replacement frequency can be counted.
Further, in order to ensure that the laser ranging object of the trolley wheel is the trolley wheel, a fixed-point industrial video recorder is adopted for shooting, one frame of image is collected and processed, gray level difference preprocessing and characteristic extraction are carried out on the image, the image is compared with a prestored trolley characteristic image, namely a trolley center characteristic mark, in this state, the front wheel and the rear wheel of the trolley travel to the position of the laser range finder, and meanwhile, when the central mark position of the trolley is identified to be in the image center position, namely the front wheel and the rear wheel of the trolley travel to the position of the laser range finder, the image processing server sends out a wheel in-place signal, and the measurement data of the laser range finder on the side at the moment are stored and used as distinguished actual original data.
A sintering trolley walking monitoring system based on laser ranging and image processing comprises a first laser range finder, a second laser range finder, a third laser range finder, a fourth laser range finder, a fifth laser range finder, a sixth laser range finder, a seventh laser range finder, an eighth laser range finder, a ninth laser range finder, a tenth laser range finder, a data collector, a switch and an upper computer; the first laser range finder to the tenth laser range finder are connected with the input end of a data acquisition unit, and the output end of the data acquisition unit is connected with an upper computer system through a switch;
the first laser range finder to the eighth laser range finder are arranged in the areas on two sides of the track behind the igniter of the sintering upper platform;
the first laser range finder to the fourth laser range finder respectively align to the upper edge point and the lower edge point of the front wheel on the left side of the sintering trolley and the upper edge point and the lower edge point of the rear wheel on the left side of the sintering trolley, and distance values of the first laser range finder and the fourth laser range finder are measured;
respectively aligning the upper edge point and the lower edge point of the front wheel on the right side of the sintering trolley and the upper edge point and the lower edge point of the rear wheel on the right side by the fifth laser range finder to the eighth laser range finder, and measuring the distance values of the upper edge point and the lower edge point;
and the ninth laser range finder and the tenth laser range finder are respectively arranged at two sides of the sintering trolley and used for measuring the distance from the range finders to the side plate of the table board of the trolley.
Furthermore, the device also comprises an eleventh laser range finder and a twelfth laser range finder; the eleventh laser range finder and the twelfth laser range finder are both connected to the data collector and are connected to the upper computer system through the data collector; and the eleventh laser range finder and the twelfth laser range finder are respectively arranged at two sides of the track from the lower track of the sintering trolley to the head star wheel in a return way and are used for measuring the distance from the range finders to the side plate strips of the trolley.
The first industrial video network cameras and the second industrial video network cameras are respectively arranged on two sides of a track behind an igniter of the sintering upper platform, and the second industrial video network cameras are respectively arranged on two sides of a track from the lower track back to the head star wheel; all be used for drawing the car number of sintering platform truck, first industry video network camera and second industry video network camera all connect to host computer system through the switch.
Compared with the prior art, the invention has the beneficial effects that:
according to the invention, a laser ranging technology, a data processing technology and a fixed-point industrial video camera image acquisition and processing identification technology are adopted to carry out gray level difference preprocessing and characteristic extraction on the image, so that the characteristic identification of the trolley is identified, the monitoring problems of faults and deviation of the sintering trolley are effectively solved, the faults of wheel looseness of the trolley are judged as early as possible, the faults of head and tail jamming and the like are quickly diagnosed, and the production operation rate of a sintering production line is improved. The shape monitoring system of the sintering trolley is high in applicability and transportability, and can be applied to different sintering production lines.
Drawings
FIG. 1 is a view of the upper traveling platform of the sintering carriage of the system configuration of the present invention;
FIG. 2 is a return portion of the sintering pallet of the system configuration of the present invention;
FIG. 3 is a front view of a measuring section diagram of the laser rangefinder of the sintering pallet of the present invention;
FIG. 4 is a top view of a measuring portion diagram of the laser rangefinder of the sintering pallet of the present invention;
FIG. 5 is a view showing the overall configuration of a system for monitoring the traveling of a sintering carriage according to the present invention.
In the figure: 1. 2 parts of sintering machine, 3 parts of trolley, 3 parts of network cameras (3-1 left first industrial video network camera, 3-2 right first industrial video network camera, 3-3 left second industrial video network camera, 3-4 right second industrial video network camera), 4 parts of laser range finder (4-1 first laser range finder, 4-2 second laser range finder, 4-3 third laser range finder, 4-4 fourth laser range finder, 4-5 fifth laser range finder, 4-6 sixth laser range finder, 4-7 seventh laser range finder, 4-8 eighth laser range finder, 4-9 ninth laser range finder, 4-10 tenth laser range finder, 4-11 eleventh laser range finder and 4-12 twelfth laser range finder), 5. Data collector, 6, exchanger 7, data server 8, image processing computer 9, video hard disk recorder 10, client.
Detailed Description
The following detailed description of the present invention will be made with reference to the accompanying drawings.
As shown in fig. 1 to 5, a method for monitoring the traveling of a sintering pallet based on laser ranging and image processing includes the following steps:
step 101, as shown in figure 1, installing 10 laser range finders 4-1 to 4-10 in the two side areas of the track after sintering the igniter on the upper platform 1:
1) 4 laser range finders 4-1 to 4-8 are respectively arranged on two sides of the trolley 2 and used for measuring the distance from the range finders to the wheels of the trolley 2, 2 laser range finders are arranged on each wheel, each wheel measures an upper point and a lower point, and the distance mark on one side is LFront upper、LFront lower part、LRear upper part、LAt the back lower partAnd the distance on the other side is marked as LFront upper’、LFront lower part’、LRear upper part’、LAt the back lower part'; distance L of front and rear laser range finders on same sideDistance between range findersIs the distance L between the front wheel and the rear wheel of the trolley 2Wheel spacing；
2) Two sides of the trolley 2 are respectively provided with a laser range finder 4-9 and a laser range finder 4-10 for measuring the distance L from the range finders to the table board side plate of the trolley 2Side plate、LSide plate’；
102, configuring a set of data acquisition subsystems on two sides of the sintering upper platform respectively, and acquiring 4-20ma signals output by the laser range finders on the corresponding sides and uploading the signals to a system server of a central control room through a field bus;
step 103, as shown in fig. 2, mounting a laser range finder 4-11 and a laser range finder 4-12 on each of two sides of the track from the lower track back to the head star wheel for measuring the distance L from the range finders to the table side plate strip of the trolley 2Return side plate、LReturn side plate’；
104, configuring a set of data acquisition subsystems in the head star wheel on the return of the lower track, wherein the data acquisition subsystems are used for acquiring 4-20ma signals output by the laser range finder and uploading the signals to a system server of a central control room through a field bus;
step 105, judging that the wheels shake and loosen and the contact area between the wheels and the track is too small:
1) collecting the distance from each point to the wheels of the trolley 2 by adopting laser range finders which are distributed on two sides of the upper-layer track and are distributed on the same side with a distance of the length of the front axle and the rear axle of the trolley 2; when the wheel is normal, the two distance measurements above and below the wheel should be equal, i.e. LFront upper＝LFront lower part、LRear upper part＝LAt the back lower part、LFront upper’＝LFront lower part’、LRear upper part’＝LAt the back lower part'; when the wheel shakes, the upper distance measurement value and the lower distance measurement value of the wheel have deviation, and when the wheel exceeds the limit, the system gives an early warning prompt;
2) meanwhile, when the wheels are normal, the distance L between the two front wheels of the trolley 2Distance between front wheelsAnd the distance L between the two rear wheelsRear wheel spacingStrain is not changed; when the wheels are loose, the distance between the two front wheels or the distance between the two rear wheels of the trolley 2 should be changed; the real-time wheel distance L of the front wheels of the trolley 2 is calculated by combining the installation distances of the front two laser range finders and the rear two laser range findersDistance on front wheel、LLower spacing of front wheels(upper and lower sets), real-time track L of rear wheelsUpper spacing of rear wheels、LLower spacing of rear wheels(upper and lower groups) and the deviation from the standard wheel track, when the deviation is out of limit, judging that the wheel is loose, uploading the picture of the corresponding vehicle number and giving an early warning;
3) when the distance between the collected same-side point and the wheels of the trolley 2 is larger than the alarm limit value when the contact area between the wheels and the track is too small, the distance between the wheels and the track is comprehensively judged by combining the distance between the wheels of the trolley 2 detected in opposite directions; when the vehicle is abnormal, uploading a picture of a corresponding vehicle number and early warning;
step 106, judging running deviation of trolley 2
Collecting the distance L from the distance meter to the side plate strip of the trolley 2 by adopting laser distance meters 4-9 and 4-10 fixedly arranged on the two sides of the upper trackSide plate、LSide plate'; when the deviation exceeds the limit and lasts for a certain time or is asynchronous, judging that the trolley 2 deviates, uploading a picture of a corresponding car number and early warning;
step 107, judgment of misalignment of front trolley 2 of star wheel of lower rail head
The laser range finders 4-11 and 4-12 arranged on the two sides of the lower rail back to the front of the head star wheel are adopted to collect and measure the distance L from the range finders to the side plate strips of the trolleyReturn side plate、LReturn side plateIf the distance deviation exceeds the limit and continues for a certain time, it is judged that the carriage 2 is not centered and simultaneously the image is takenAnd uploading pictures of corresponding car numbers and giving an early warning.
Also comprises the following steps:
step 201, installing industrial video network cameras 3-1 and 3-2 on two sides of a track behind an igniter of an upper platform in a sintering mode, and accessing video signals to a corresponding image processing and identifying computer located in a central control room through an optical fiber network;
step 202, installing an industrial video camera 3-3 and an industrial video camera 3-4 on the two sides of the track from the return of the lower track to the head star wheel respectively, and accessing a video signal into a corresponding image processing and identifying computer;
step 203, in order to realize automatic image recognition, feature extraction is performed on the image of the trolley 2, and for accurate judgment, feature identification is made on the four wheels of the trolley 2 and the central position of the side part of the trolley 2: paint is adopted for spraying, and the marks of the front wheel and the rear wheel are different;
step 204, image recognition of trolley 2 number
Establishing a car number characteristic image library of each trolley 2, when the trolley 2 runs to the position of a camera, adopting a fixed-point industrial video recorder to pick up a picture, acquiring and processing a frame of image, performing gray level difference preprocessing on the image and characteristic extraction of the car number, comparing the image with the pre-stored trolley 2 car number characteristic image, and automatically identifying the car number of the trolley 2;
step 205, image recognition of non-rotation of wheels of trolley 2
Shooting by adopting a fixed-point industrial video recorder, acquiring and processing a frame of image, performing gray level difference preprocessing and feature extraction on the image, acquiring and processing a frame of image after an acquisition period, and identifying the feature identification position of the trolley 2 according to the running speed of the trolley 2 of the sintering machine in the acquisition period; judging whether wheels of the trolley 2 rotate or not by changing the position angle of the characteristic mark of the trolley 2 of two adjacent images; when the two images are abnormal, early warning is carried out, and the two images are uploaded to the monitoring client;
step 206, judging that the wheel of the front trolley 2 of the star wheel of the head of the lower track is lost
Shooting by adopting a fixed-point industrial video recorder arranged on the two sides of the track from the return of the lower track to the front track of the head star wheel, collecting and processing a frame of image, performing gray level difference preprocessing and characteristic extraction on the image, identifying the state of the wheels of the trolley 2, alarming when the wheels are lost, and uploading pictures;
step 207, wheel repair and replacement recording and wheel life tracking
The system provides a wheel repair and replacement subsystem; the maintenance and replacement of each trolley 2 and each wheel can be recorded; on the basis, maintenance and replacement history and service life management and control of each trolley 2 and each wheel can be realized, wheel maintenance and replacement records of the whole production line can be checked according to the month, the year and a certain time period, and the maintenance and replacement frequency can be counted.
In order to ensure that the laser ranging object of the wheels of the trolley 2 is the wheels of the trolley 2, a fixed-point industrial video recorder is adopted for shooting, one frame of image is collected and processed, gray level difference preprocessing and characteristic extraction are carried out on the image, the image is compared with the prestored characteristic image of the trolley 2, namely the central characteristic mark of the trolley 2 in the state, the front wheels and the rear wheels of the trolley 2 run to the positions of the laser range finders at the moment, when the central mark position of the trolley 2 is identified to be at the central position of the image, namely the front wheels and the rear wheels of the trolley 2 run to the positions of the laser range finders, an image processing server sends out wheel in-place signals, and the measurement data of the laser range finders at the side at the moment are stored and used as the actual original data.
The technical scheme of the invention is as follows:
1) after the igniter is sintered on the upper platform, the number of the walking trolley 2 on the track is identified by an image, and whether four wheels of the trolley 2 normally run or not is analyzed and judged; the distance between the side laths of the trolley 2 and the distances between the four wheels of the trolley 2 (the upper point and the lower point are measured by each wheel, and the total distance is 8 distance measurements) of the corresponding trolley number is collected, whether the trolley 2 deviates or not is intelligently analyzed, and whether the wheels loosen or rock up and down is judged by combining historical data.
2) Before the sintering trolley 2 returns to the head star wheel from the lower rail, whether the wheels of the walking trolley 2 on the rail are lost or not is identified by an image; gather 2 side laths distances of platform truck, whether this platform truck 2 of intelligent analysis is to centering unusual, upload the picture of this platform truck 2 when unusual, prevent that 2 blocks of platform truck.
3) A non-contact monitoring system is designed, and an industrial laser range finder 4 is adopted to monitor the trolley 2 in real time, measure the distance of a fixed object and measure the distance of a moving object. And the high measurement precision and the running stability can be still maintained under the severe working environment, so that the accuracy and the reliability of the measured data are ensured.
4) The data measured by the laser range finder 4 are collected for multiple times, then the data groups measured for multiple times are analyzed and processed, and because the field detection environment is complex, in order to ensure the stability and accuracy of the analysis data, the collected data with obvious difference or difference is removed from the data, so that the measurement data with serious distortion is prevented from causing deviation to influence the analysis conclusion and result. And (3) judging whether the measured data has large errors or not in a combined mode by adopting a Romanofsky criterion (t test criterion), a Grubbs criterion, a Dixon criterion and the like.
5) And systematically analyzing and processing a large amount of collected data, identifying the data, removing difference data, and analyzing effective data. The system adopts a linear or nonlinear fitting method for the measured data, thereby obtaining a function model which is close to the actual field condition as much as possible and reflects the data change rule.
6) The whole life process management of each wheel of each trolley 2 records the maintenance and replacement of each trolley 2 and each wheel, and forms maintenance and replacement history and service life tracking management.
As shown in fig. 1-5, a sintering pallet traveling monitoring system based on laser ranging and image processing comprises a first laser range finder 4-1, a second laser range finder 4-2, a third laser range finder 4-3, a fourth laser range finder 4-4, a fifth laser range finder 4-5, a sixth laser range finder 4-6, a seventh laser range finder 4-7, an eighth laser range finder 4-8, a ninth laser range finder 4-9, a tenth laser range finder 4-10, a data collector 5, a switch 6 and an upper computer 7-10; the first laser range finder 4-1 to the tenth laser range finder 4-10 are connected with the input end of the data acquisition unit 5, and the output end of the data acquisition unit 5 is connected with the upper computer 7-10 system through the switch 6;
the first laser range finder 4-1 to the eighth laser range finder 4-8 are arranged in the areas on two sides of the track behind the igniter of the platform on the upper part of the sintering machine 1;
as shown in fig. 1, 3 and 4, the first laser range finder 4-1 to the fourth laser range finder 4-4 are respectively aligned with the upper and lower edge points of the front wheel on the left side of the sintering pallet 2 and the upper and lower edge points of the rear wheel on the left side, and measure the distance values; the fifth laser range finder 4-5 to the eighth laser range finder 4-8 are respectively aligned with the upper and lower edge points of the front wheel on the right side of the sintering pallet 2 and the upper and lower edge points of the rear wheel on the right side, and the distance values thereof are measured. And the ninth laser range finder 4-9 and the tenth laser range finder 4-10 are respectively arranged at two sides of the sintering trolley 2 and used for measuring the distance from the range finders to the side plate of the table top of the trolley 2.
As shown in fig. 2, further comprises an eleventh laser range finder 4-11 and a twelfth laser range finder 4-12; and the eleventh laser range finder 4-11 and the twelfth laser range finder 4-12 are respectively arranged at two sides of the track from the lower track of the sintering trolley 2 to the head star wheel in a return way and are used for measuring the distance from the range finders to the table side plate strip of the trolley 2. The eleventh laser range finder 4-11 and the twelfth laser range finder 4-12 are connected to the data acquisition unit 5 and are connected to the upper computer 7-10 system through the data acquisition unit 5.
The first industrial video network camera comprises two 3-1 and two 3-2 which are respectively arranged at two sides of a track behind an igniter of the sintering upper platform, and the second industrial video network camera comprises two 3-3 and two 3-4 which are respectively arranged at two sides of a track from a lower track back to a head star wheel; the first industrial video network cameras 3-1 and 3-2 and the second industrial video network cameras 3-3 and 3-4 are connected to an upper computer 7-10 system through an exchanger 6.
The sintering trolley 2 monitoring system structure comprises a data acquisition layer, a data transmission layer and a monitoring client layer; the data acquisition layer realizes on-site laser ranging, image acquisition and data acquisition and transmits acquired data and data information to the monitoring client layer through the data transmission layer; the monitoring client layer is used for realizing data display, alarm and recording, processing each frame of image, preprocessing gray level difference and extracting characteristics, accurately judging, automatically identifying characteristic identification and analyzing data; and (4) analyzing and processing the ranging measurement data, eliminating distortion data and analyzing and processing effective data.
The above embodiments are implemented on the premise of the technical solution of the present invention, and detailed embodiments and specific operation procedures are given, but the scope of the present invention is not limited to the above embodiments. The methods used in the above examples are conventional methods unless otherwise specified.
Claims (6)
1. A sintering trolley walking monitoring method based on laser ranging and image processing is characterized by comprising the following steps:
step 101, installing 10 laser range finders in the two side areas of the track after sintering the igniter of the upper platform:
1) 4 laser range finders are respectively installed on two sides of the trolley and used for measuring the distance from the range finders to wheels of the trolley, 2 laser range finders are arranged on each wheel, each wheel measures an upper point and a lower point, and the distance mark on one side is LFront upper、LFront lower part、LRear upper part、LAt the back lower partAnd the distance on the other side is marked as LFront upper’、LFront lower part’、LRear upper part’、LAt the back lower part'; distance L of front and rear laser range finders on same sideDistance between range findersIs the distance L between the front wheel and the rear wheel of the trolleyWheel spacing；
2) Two laser range finders are respectively arranged on two sides of the trolley and used for measuring the distance L from the range finders to the side plate of the table board of the trolleySide plate、LSide plate’；
102, configuring a set of data acquisition subsystems on two sides of the sintering upper platform respectively, and acquiring 4-20ma signals output by the laser range finders on the corresponding sides and uploading the signals to a system server of a central control room through a field bus;
103, respectively installing a laser range finder on two sides of the track from the return of the lower track to the head star wheel for measuring the distance L from the range finder to the side plate strip of the trolleyReturn side plate、LReturn side plate’；
104, configuring a set of data acquisition subsystems in the head star wheel on the return of the lower track, wherein the data acquisition subsystems are used for acquiring 4-20ma signals output by the laser range finder and uploading the signals to a system server of a central control room through a field bus;
step 105, judging that the wheels shake and loosen and the contact area between the wheels and the track is too small:
1) collecting the distance from each point to the wheels of the trolley by adopting laser range finders which are distributed on two sides of an upper-layer track and are distributed on the same side with a distance of the length of a front axle and a rear axle of the trolley; when the wheel is normal, the two distance measurements above and below the wheel should be equal, i.e. LFront upper＝LFront lower part、LRear upper part＝LAt the back lower part、LFront upper’＝LFront lower part’、LRear upper part’＝LAt the back lower part'; when the wheel shakes, the upper distance measurement value and the lower distance measurement value of the wheel have deviation, and when the wheel exceeds the limit, the system gives an early warning prompt;
2) meanwhile, when the wheels are normal, the distance L between the two front wheels of the trolleyDistance between front wheelsAnd the distance L between the two rear wheelsRear wheel spacingStrain is not changed; when the wheels are loosened, the distance between two front wheels or the distance between two rear wheels of the trolley should be changed; calculating the real-time wheel distance L of the front wheels of the trolley by combining the installation distances of the front two laser range finders and the rear two laser range findersDistance on front wheel、LLower spacing of front wheels(upper and lower sets), real-time track L of rear wheelsUpper spacing of rear wheels、LLower spacing of rear wheels(upper and lower groups) and the deviation from the standard wheel track, when the deviation is out of limit, judging that the wheel is loose, uploading the picture of the corresponding vehicle number and giving an early warning;
3) when the distance between the collected same-side point and the trolley wheel is larger than the alarm limit value when the contact area between the wheel and the rail is too small, the distance between the wheel and the trolley wheel detected in opposite directions is combined, and the contact area between the wheel and the rail is too small; when the vehicle is abnormal, uploading a picture of a corresponding vehicle number and early warning;
step 106, judging running deviation of trolley
Adopts the laser range finders fixedly arranged on the two sides of the upper track to collect and rangeDistance L from instrument to trolley side plate stripSide plate、LSide plate'; when the deviation exceeds the limit and lasts for a certain time or is asynchronous, judging that the trolley deviates, uploading a picture of a corresponding car number and early warning;
step 107, judging whether the front trolley of the star wheel of the head of the lower track is not aligned
The distance L from the distance measuring instrument to the side plate strip of the trolley is acquired and measured by adopting the laser distance measuring instruments arranged on the two sides of the lower part rail in the return stroke to the front of the head star wheelReturn side plate、LReturn side plate' when the distance deviation exceeds the limit and lasts for a certain time, judging that the trolley is not centered, and simultaneously shooting and uploading the picture of the corresponding car number and giving an early warning.
2. The method for monitoring the running of the sintering trolley based on the laser ranging and image processing as claimed in claim 1, characterized by further comprising the following steps:
step 201, installing industrial video network cameras on two sides of a track behind an igniter of an upper platform in a sintering mode, and accessing video signals to a corresponding image processing and identifying computer located in a central control room through an optical fiber network;
step 202, installing an industrial video camera on each of two sides of a track from the return of the lower track to the head star wheel, and accessing a video signal to a corresponding image processing and identifying computer;
step 203, in order to realize automatic image recognition, feature extraction is carried out on the images of the trolley, and for accurate judgment, feature identification is made on the four wheels of the trolley and the central position of the side part of the trolley: paint is adopted for spraying, and the marks of the front wheel and the rear wheel are different;
step 204, image recognition of trolley number
Establishing a car number characteristic image library of each trolley, when the trolley runs to the position of a camera, adopting a fixed-point industrial video recorder to pick up a picture, acquiring and processing a frame of image, performing gray level difference preprocessing on the image and characteristic extraction of the car number, comparing the image with a prestored trolley car number characteristic image, and automatically identifying the car number of the trolley;
step 205, image recognition of trolley wheel non-rotation
Shooting by adopting a fixed-point industrial video recorder, acquiring and processing a frame of image, performing gray level difference preprocessing and feature extraction on the image, acquiring and processing a frame of image after an acquisition period, and identifying the feature identification position of the trolley according to the running speed of the trolley of the sintering machine in the acquisition period; judging whether the wheels of the trolley rotate or not by changing the position angle of the trolley characteristic marks of two adjacent images; when the two images are abnormal, early warning is carried out, and the two images are uploaded to the monitoring client;
step 206, judging wheel loss of front trolley of star wheel at head of lower track
Shooting by adopting a fixed-point industrial video recorder arranged on the two sides of the track from the return of the lower track to the front track of the head star wheel, collecting and processing a frame of image, performing gray level difference preprocessing and characteristic extraction on the image, identifying the state of the wheels of the trolley, alarming when the wheels are lost, and uploading pictures;
step 207, wheel repair and replacement recording and wheel life tracking
The system provides a wheel repair and replacement subsystem; the maintenance and replacement of each trolley and each wheel can be recorded; on the basis, maintenance and replacement history and service life management and control of each trolley and each wheel can be realized, wheel maintenance and replacement records of the whole production line can be checked according to the month, the year and a certain time period, and the maintenance and replacement frequency can be counted.
3. The method as claimed in claim 1, wherein in order to ensure that the laser ranging object of the trolley wheel is the trolley wheel, a fixed-point industrial video recorder is used for shooting, acquiring and processing a frame of image, preprocessing the gray level difference and extracting the characteristic, comparing the gray level difference with the prestored characteristic image of the trolley, namely the central characteristic mark of the trolley in the state, when the central characteristic mark of the trolley is in the central position of the image, namely the front wheel and the rear wheel of the trolley are moved to the position of the laser range finder, and when the central mark of the trolley is recognized to be in the central position of the image, namely the central mark of the trolley is moved to the position of the laser range finder, the image processing server sends a wheel in-place signal, and the measurement data of the laser range finder on the side at the moment are stored and used as the actual raw data for judgment.
4. A sintering trolley walking monitoring system based on laser ranging and image processing is characterized by comprising a first laser range finder, a second laser range finder, a third laser range finder, a fourth laser range finder, a fifth laser range finder, a sixth laser range finder, a seventh laser range finder, an eighth laser range finder, a ninth laser range finder, a tenth laser range finder, a data acquisition unit, a switch and an upper computer; the first laser range finder to the tenth laser range finder are connected with the input end of a data acquisition unit, and the output end of the data acquisition unit is connected with an upper computer system through a switch;
the first laser range finder to the eighth laser range finder are arranged in the areas on two sides of the track behind the igniter of the sintering upper platform;
the first laser range finder to the fourth laser range finder respectively align to the upper edge point and the lower edge point of the front wheel on the left side of the sintering trolley and the upper edge point and the lower edge point of the rear wheel on the left side of the sintering trolley, and distance values of the first laser range finder and the fourth laser range finder are measured;
respectively aligning the upper edge point and the lower edge point of the front wheel on the right side of the sintering trolley and the upper edge point and the lower edge point of the rear wheel on the right side by the fifth laser range finder to the eighth laser range finder, and measuring the distance values of the upper edge point and the lower edge point;
and the ninth laser range finder and the tenth laser range finder are respectively arranged at two sides of the sintering trolley and used for measuring the distance from the range finders to the side plate of the table board of the trolley.
5. The sintering trolley traveling monitoring system based on laser ranging and image processing is characterized by further comprising an eleventh laser range finder and a twelfth laser range finder; the eleventh laser range finder and the twelfth laser range finder are both connected to the data collector and are connected to the upper computer system through the data collector;
and the eleventh laser range finder and the twelfth laser range finder are respectively arranged at two sides of the track from the lower track of the sintering trolley to the head star wheel in a return way and are used for measuring the distance from the range finders to the side plate strips of the trolley.
6. The sintering trolley traveling monitoring system based on laser ranging and image processing is characterized by further comprising a first industrial video network camera and a second industrial video network camera, wherein the first industrial video network camera comprises two cameras and is respectively installed on two sides of a track behind an igniter of a sintering upper platform, and the second industrial video network camera comprises two cameras and is respectively installed on two sides of a track from a lower track back to a head star wheel; all be used for drawing the car number of sintering platform truck, first industry video network camera and second industry video network camera all connect to host computer system through the switch.
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