CN110880174B - Method for judging material taking boundary of bucket-wheel material taking machine - Google Patents
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Abstract
The invention provides a method for judging a material taking boundary of a bucket wheel type material taking machine. The invention comprises the following steps: after receiving the first signal, cutting the pictures acquired frame by the image acquisition device to acquire an interest region; binarization conversion is carried out on the region of interest image through a mask method, so that the enhancement of image characteristics is completed; optimizing the enhanced image through a median filtering template; performing contour recognition on the optimized image; judging whether the number of the outlines is larger than a set threshold value, if so, feeding back the first signal state; if not, the second signal state is changed to be fed back, and meanwhile, the picture cutting operation is stopped; the first signal is a bucket wheel coal carrying signal, and the second signal is a bucket wheel arrival boundary signal. The invention directly judges the running state of the bucket wheel of the reclaimer by utilizing a digital image processing technology, judges that the bucket wheel is empty to turn to a PLC controller to send a next turning instruction in the first time, and makes accurate judgment for the turning boundary of the bucket wheel.
Description
Technical Field
The invention relates to the technical field of bucket-wheel reclaimers, in particular to a method for judging a reclaiming boundary of a bucket-wheel reclaimer.
Background
Bucket wheel reclaimers are important devices in the thermal power field for taking a pile of coal onto a belt conveyor. The traditional reclaimer is mostly manually reclaiming, and the state of a coal pile is observed through eyes of a driver to control the bucket wheel reclaimer to advance. The traditional method is greatly influenced by weather and personal factors of drivers, and has low working efficiency. Based on this, the prior art has developed automated control's reclaimer, including utilizing the mathematical simulation modeling of radar and laser scanning modeling method to carry out automated material piling and taking centralized control, operating personnel all have verified and subtracted, and the remaining personnel shifts to centralized control room and carries out remote monitoring, has effectively promoted work efficiency.
In an unattended control system of the reclaimer, the most important link is to make accurate judgment on the end position of the bucket wheel on the working face, and the accurate judgment on the reclaiming boundary is beneficial to improving the working efficiency of the bucket wheel, reducing the idle time of the bucket wheel and saving the electricity of equipment; the automatic control technology has a method for judging the running boundary of the bucket wheel by using a short-wave range radar or a laser scanning head, but has the defects of higher technical implementation cost and lower judgment precision, so that the bucket wheel has overlong idle time and poor automatic running efficiency.
Disclosure of Invention
According to the technical problems set forth above, a method for determining a material taking boundary of a bucket wheel type material taking machine is provided. The invention mainly utilizes a digital image processing technology to directly judge the running state of the bucket wheel of the reclaimer, can judge the bucket wheel to idle at the first time and then send a next rotation instruction to the PLC, and accurately judges the rotation boundary of the bucket wheel in an unmanned system of the reclaimer. The invention adopts the following technical means:
a method for judging a material taking boundary of a bucket wheel type material taking machine comprises the following steps:
s31, after receiving the first signal, cutting pictures acquired frame by the image acquisition device to acquire an interest region;
s32, performing binarization conversion on the region of interest image through a mask method to complete enhancement of image characteristics;
s33, optimizing the enhanced image through a median filtering template;
s34, performing contour recognition on the optimized image;
s35, judging whether the number of the outlines is larger than a set threshold value, and if so, feeding back the first signal state; if not, the second signal state is changed to be fed back, and meanwhile, the picture cutting operation is stopped;
the first signal is a bucket wheel coal carrying signal, and the second signal is a bucket wheel arrival boundary signal.
Further, the step S34 specifically includes the following steps:
s341, performing 4-neighborhood contour recognition and counting statistics on the optimized image, wherein the method specifically comprises the following steps:
s3411, recording a sequence of continuous white pixels in each row, named a cluster, and recording information including a start point, an end point and a row number;
s3412, judging whether the clusters except the first row and all clusters in the previous row have overlapping areas one by one, and if not, giving new marks to the clusters; if it has a region of overlap with only one blob in the previous row, then the blob in the previous row is given its label; if it has an overlapping region with more than 2 clusters of the previous row, assigning a minimal number of contiguous sequences to the clusters and writing the labels of the clusters of the previous row into equivalent pairs, indicating that they belong to one class;
s3413, converting the equivalent pairs into equivalent sequences, wherein each sequence needs to be given the same reference numeral, and starting from 1, each equivalent sequence is given the same reference numeral;
s3414, traversing marks of the start groups, searching equivalent sequences, and giving new marks to the equivalent sequences;
s3415, filling the label of each cluster into the marked image, thereby completing the statistics of the number of connected domains in the image;
s342, determining the current bucket wheel operation state, specifically,
s3421, set array A n And B n The A is n For storing the counted number of connected domains in the current frame, B n The connected domain statistics method is used for storing the connected domain statistics conditions of the last 30 frames;
s3422, determining array index by means of an integer variable count, wherein count is used for determining which frame of image is currently, initialization is required to be 0, +1 is required after each picture is received and detected, and array A is used for determining the number of frames of images n The expression is:
index_1＝mod(count,30) (2)
wherein the shaping variable index_1 represents array A n Mod is a remainder arithmetic operation, taking the remainder of count/30 as A n Indexing of the array;
B n belongs to a BOOL type variable, and the values of elements in the array are determined according to an expression (3):
in B of i The value of (2) is the number of connected domains of the current nearest 30 frames of pictures, the sum is more than or equal to 500, and is assigned with 1, and if the sum is less than 499, is assigned with 0;
s3423, determining the working state of the bucket wheel is performed according to expression (4):
wherein State represents the current State of the bucket wheel, 1 represents that the bucket wheel with coal does not reach the boundary, 0 represents that the bucket wheel idles and reaches the material taking boundary, and rate represents B n Elements with the ratio greater than the ratio in the array are in the coal-carrying working state, and the whole returns to the coal-carrying state.
Further, the method also comprises the following steps:
s1, judging the coal taking condition of the gear teeth of the bucket wheel in the bucket wheel idling process based on a video image detection result, and if the coal is taken, entering a step S2;
s2, judging the numerical relation between the bucket wheel current and the idle current detected at the moment, and if the bucket wheel current is larger than the idle current and the state is kept in a preset time, sending a first signal to a main processor;
s3, after receiving the first signal, the main processor executes boundary detection from S31 to S35;
s4, after receiving the second signal, judging the numerical relation between the bucket wheel current and the idle current detected at the moment, and if the bucket wheel current is smaller than the preset value and the state is kept in the preset time, sending a third signal to the main processor, wherein the third signal is the bucket wheel idle signal;
s5, the PLC system controls the bucket-wheel reclaimer to step a preset step length towards the direction of the coal pile, and the rotation direction is changed to take the material for the next round.
The invention directly judges the running state of the bucket wheel of the reclaimer by utilizing a digital image processing technology, can judge the bucket wheel to idle at the first time and then send a next rotation instruction to the PLC, and accurately judges the rotation boundary of the bucket wheel in an unmanned system of the reclaimer. According to the conclusion obtained by the on-site actual detection data, the invention reduces the idling time caused by the bucket wheel when the bucket wheel is driven out of the material taking boundary to 5-10 seconds, thereby playing a role in high-efficiency energy-saving control.
Based on the reasons, the invention can be widely popularized in the technical field of bucket-wheel reclaimers.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described, and it is obvious that the drawings in the following description are some embodiments of the present invention, and other drawings may be obtained according to the drawings without inventive effort to a person skilled in the art.
Fig. 1 is a flowchart of a method for determining a material taking boundary of a bucket wheel type material taking machine according to an embodiment of the present invention.
Fig. 2 is a flowchart illustrating a continuous operation of the bucket wheel reclaimer in accordance with an embodiment of the present invention.
Fig. 3 is a system diagram of an implementation method in an embodiment of the present invention.
Fig. 4 is a diagram of the original image data after being cut in the embodiment of the present invention.
Fig. 5 is a diagram of cut image data after mask binarization and median filtering processing in an embodiment of the present invention.
Fig. 6 is a diagram of an example of a binary image marked by a connected domain in an embodiment of the present invention.
Fig. 7 is a schematic diagram of variable setting for threshold judgment in the embodiment of the present invention.
Fig. 8 is a diagram illustrating an example of boundary effect detection in an embodiment of the present invention.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the embodiments of the present invention more apparent, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is apparent that the described embodiments are some embodiments of the present invention, but not all embodiments of the present invention. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
As shown in fig. 2, a control flow chart of the bucket wheel reclaimer of the present invention specifically includes:
and after receiving the signal transmitted by the control room, automatically taking coal, and rotating the bucket wheel type material taking machine according to the initialization direction to take the coal fuel onto the conveying belt by the bucket wheel.
S1, judging the coal taking condition of the gear teeth of the bucket wheel in the bucket wheel idling process based on a video image detection result, and if the coal is taken, entering a step S2;
s2, judging the numerical relation between the detected bucket wheel current and the idle current, if the bucket wheel current is larger than the idle current and the state is kept in a preset time, sending a first signal to a main processor, and detecting the current of a bucket wheel motor through a current transformer in the embodiment, wherein the preset time is kept for 2 seconds;
s3, after receiving the first signal, the main processor executes boundary detection from S31 to S35;
s4, after receiving the second signal, judging the numerical relation between the bucket wheel current and the idle current detected at the moment, and if the bucket wheel current is smaller than the preset value and the state is kept in the preset time, sending a third signal to the main processor, wherein the third signal is the bucket wheel idle signal;
s5, the PLC system controls the bucket-wheel reclaimer to step a preset step length towards the direction of the coal pile and change the rotation direction to conduct next round reclaiming, in the embodiment, the bucket-wheel reclaimer steps 0.6 m towards the direction of the coal pile and rotates, and then the steps are continuously executed, so that the strategy is repeated to complete the continuous automatic reclaiming process, and the process flow can ensure the continuity of control and detection.
Fig. 3 shows a hardware architecture diagram for meeting the above requirements, where S6 is a camera for image acquisition at the bucket wheel, and the type is a network high-definition electric zoom gun type camera: pixel 800 ten thousand, protection level: IP67, maximum image size: 4096x 2160. S7 is a digital video recorder for storing video image data acquired by a camera, and the embodiment selects a 16-channel and 4T storage space Haikang Wei video DS-7716N-K4 type digital video recorder. And S8, a PC computer is used for communicating with a hard disk video recorder and processing the acquired video image to complete algorithm processing of boundary detection, communicating with an S9 PLC controller, and transmitting the processing result of the image to the PLC in real time by utilizing an OPC interface mode to complete boundary judgment of the bucket wheel position of the reclaimer and execution of automatic action logic.
In this embodiment, the camera mounting position is at the end of the cantilever of the reclaimer, and the rear side of the coal dropping hopper of the bucket wheel is 7.3 meters away from the bucket wheel teeth, so that the back transmission image is required to be able to clearly see the bucket wheel teeth, and the picture area occupied by the bucket wheel teeth in the video picture cannot be less than 1/3 of the whole picture.
As shown in fig. 1, S3 specifically includes: s31, after receiving the first signal, cutting the pictures acquired frame by the image acquisition device as shown in FIG. 4 to acquire an interest region;
s32, performing binarization conversion on the region-of-interest image through a mask method as shown in FIG. 5, and completing enhancement of image features; in this embodiment, the average value of three color channels is performed on the original RGB image, the pixel average value of the three color channels is [14,9,11], two channels of the pixel upper limit [49,44,46] and the pixel lower limit [9,4,6] are set, lower refers to a value lower than the lower limit in the image, the image value becomes 0, upper refers to a value higher than the upper value in the image, the image value becomes 0, and a value between lower and upper becomes 255, so that the RBG color image conversion binarization image operation is completed.
S33, optimizing the enhanced image through a median filtering template; optimizing the image by adopting a 3*3 median filtering template, sequencing all pixel values in the template to generate a monotonically ascending or monotonically descending two-dimensional data sequence, and outputting the two-dimensional median filtering as shown in the expression (1):
g(x,y)＝medf{f(x-k,y-1),(k,l∈w)} (1)
where f (x, y) and g (x, y) are the original image and the processed image, respectively, and w is the input two-dimensional template, capable of sliding over the entire image. In addition, the outer frame of the original image is subjected to '0' filling processing before median filtering in order to not lose generality.
S34, performing contour recognition on the optimized image;
s35, judging whether the number of the outlines is larger than a set threshold value, and if so, feeding back the first signal state; if not, the second signal state is changed to be fed back, and meanwhile, the picture cutting operation is stopped;
the first signal is a bucket wheel coal carrying signal, and the second signal is a bucket wheel arrival boundary signal.
The step S34 specifically includes the following steps:
s341, as shown in FIG. 6, performing 4-neighborhood contour recognition and counting statistics on the optimized image, wherein the method specifically comprises the following steps:
s3411, recording a sequence of continuous white pixels in each row, named as a group (run), wherein the recorded information comprises a start point, an end point and a row number;
s3412, judging whether the clusters except the first row and all clusters in the previous row have overlapping areas one by one, and if not, giving new marks to the clusters; if it has a region of overlap with only one blob in the previous row, then the blob in the previous row is given its label; if it has an overlapping region with more than 2 clusters of the previous row, assigning a minimal number of contiguous sequences to the clusters and writing the labels of the clusters of the previous row into equivalent pairs, indicating that they belong to one class;
s3413, converting the equivalent pairs into equivalent sequences, wherein each sequence needs to be given the same reference numeral, and starting from 1, each equivalent sequence is given the same reference numeral;
s3414, traversing marks of the start groups, searching equivalent sequences, and giving new marks to the equivalent sequences;
s3415, filling the label of each cluster into the marked image, thereby completing the statistics of the number of connected domains in the image;
s342, determining the current bucket wheel operation state, specifically,
as shown in FIG. 7, S3421 sets array A n And B n The A is n For storing the counted number of connected domains in the current frame, B n The connected domain statistics method is used for storing the connected domain statistics conditions of the last 30 frames;
s3422, determining array index by means of an integer variable count, wherein count is used for determining which frame of image is currently, initialization is required to be 0, +1 is required after each picture is received and detected, and array A is used for determining the number of frames of images n The expression is:
index_1＝mod(count,30) (2)
wherein the shaping variable index_1 represents array A n Mod is a remainder arithmetic operation, taking the remainder of count/30 as A n Indexing of the array;
B n belongs to a BOOL type variable, and the values of elements in the array are determined according to an expression (3):
in B of i The value of (2) is the number of connected domains of the current nearest 30 frames of pictures, the sum is more than or equal to 500, and is assigned with 1, and if the sum is less than 499, is assigned with 0;
s3423, determining the working state of the bucket wheel is performed according to expression (4):
wherein State represents the current State of the bucket wheel, 1 represents that the bucket wheel with coal does not reach the boundary, 0 represents that the bucket wheel idles and reaches the material taking boundary, and rate represents B n Elements with the ratio greater than the ratio in the array are in the coal-carrying working state, and the whole returns to the coal-carrying state. In this embodiment, the value of rate is 0.75. Fig. 8 shows an example of the boundary detection effect.
Finally, it should be noted that: the above embodiments are only for illustrating the technical solution of the present invention, and not for limiting the same; although the invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some or all of the technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit of the invention.
Claims (2)
1. The method for judging the material taking boundary of the bucket wheel type material taking machine is characterized by comprising the following steps of:
s31, after receiving the first signal, cutting pictures acquired frame by the image acquisition device to acquire an interest region;
s32, performing binarization conversion on the region of interest image through a mask method to complete enhancement of image characteristics;
s33, optimizing the enhanced image through a median filtering template;
s34, performing contour recognition on the optimized image;
s35, judging whether the number of the outlines is larger than a set threshold value, and if so, feeding back the first signal state; if not, the second signal state is changed to be fed back, and meanwhile, the picture cutting operation is stopped;
the first signal is a bucket wheel coal carrying signal, and the second signal is a bucket wheel arrival boundary signal;
the bucket wheel gear teeth can be clearly seen in the acquired pictures, and the picture area occupied by the bucket wheel gear teeth is not less than 1/3 of the whole picture;
the steps S34 and S35 specifically include the following steps:
s341, performing 4-neighborhood contour recognition and counting statistics on the optimized image, wherein the method specifically comprises the following steps:
s3411, recording a sequence of continuous white pixels in each row, named a cluster, and recording information including a start point, an end point and a row number;
s3412, judging whether the clusters except the first row and all clusters in the previous row have overlapping areas one by one, and if not, giving new marks to the clusters; if it has a region of overlap with only one blob in the previous row, then the blob in the previous row is given its label; if it has an overlapping region with more than 2 clusters of the previous row, assigning a minimal number of contiguous sequences to the clusters and writing the labels of the clusters of the previous row into equivalent pairs, indicating that they belong to one class;
s3413, converting the equivalent pairs into equivalent sequences, wherein each sequence needs to be given the same reference numeral, and starting from 1, each equivalent sequence is given the same reference numeral;
s3414, traversing marks of the start groups, searching equivalent sequences, and giving new marks to the equivalent sequences;
s3415, filling the label of each cluster into the marked image, thereby completing the statistics of the number of connected domains in the image;
s342, determining the current bucket wheel operation state, specifically,
s3421, set array A n And B n The A is n For storing the counted number of connected domains in the current frame, B n The connected domain statistics method is used for storing the connected domain statistics conditions of the last 30 frames;
s3422, determining array index by means of an integer variable count, wherein count is used for determining which frame of image is currently, initialization is required to be 0, +1 is required after each picture is received and detected, and array A is used for determining the number of frames of images n The expression is:
index_1 ＝ mod(count, 30) (2)
wherein the shaping variable index_1 represents array A n Mod is a remainder arithmetic operation, taking the remainder of count/30 as A n Indexing of the array;
B n belongs to a BOOL type variable, and the values of elements in the array are determined according to an expression (3):
in B of i The value of (2) is the number of connected domains of the current nearest 30 frames of pictures, the sum is more than or equal to 500, and is assigned with 1, and if the sum is less than 499, is assigned with 0;
s3423, determining the working state of the bucket wheel is performed according to expression (4):
wherein State represents the current State of the bucket wheel, 1 represents that the bucket wheel with coal does not reach the boundary, 0 represents that the bucket wheel idles and reaches the material taking boundary, and rate represents B n Elements with the ratio greater than the ratio in the array are in the coal-carrying working state, and the whole returns to the coal-carrying state.
2. The method of determining a material take out boundary of a bucket wheel reclaimer of claim 1, further comprising the steps of:
s1, judging the coal taking condition of the gear teeth of the bucket wheel in the bucket wheel idling process based on a video image detection result, and if the coal is taken, entering a step S2;
s2, judging the numerical relation between the bucket wheel current and the idle current detected at the moment, and if the bucket wheel current is larger than the idle current and the state is kept in a preset time, sending a first signal to a main processor;
s3, after receiving the first signal, the main processor executes boundary detection from S31 to S35;
s4, after receiving the second signal, judging the numerical relation between the bucket wheel current and the idle current detected at the moment, and if the bucket wheel current is smaller than a preset value and the state is kept in a preset time, sending a third signal to the main processor, wherein the third signal is a bucket wheel idle signal;
s5, the PLC system controls the bucket-wheel reclaimer to step a preset step length towards the direction of the coal pile, and the rotation direction is changed to take the material for the next round.
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| CN113284114B (en) * | 2021-05-28 | 2022-12-16 | 华能聊城热电有限公司 | Bucket wheel machine rotation angle measurement and coal flow equalization method based on image processing |
| CN114803391B (en) * | 2022-05-12 | 2023-11-03 | 北京华能新锐控制技术有限公司 | Unmanned automatic material taking method for bucket wheel machine of intelligent fuel system |
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