CN111427302B - Wheel rotating speed monitoring system and method for trolley of annular cooler - Google Patents
Wheel rotating speed monitoring system and method for trolley of annular cooler Download PDFInfo
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- CN111427302B CN111427302B CN201910023167.2A CN201910023167A CN111427302B CN 111427302 B CN111427302 B CN 111427302B CN 201910023167 A CN201910023167 A CN 201910023167A CN 111427302 B CN111427302 B CN 111427302B
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/05—Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
- G05B19/058—Safety, monitoring
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/10—Plc systems
- G05B2219/14—Plc safety
- G05B2219/14005—Alarm
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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- Automation & Control Theory (AREA)
- Arrangements For Transmission Of Measured Signals (AREA)
- Length Measuring Devices By Optical Means (AREA)
Abstract
The invention discloses a wheel rotating speed monitoring system and a monitoring method for a trolley of an annular cooler, wherein the system comprises the following steps: the system comprises a monitoring module, a signal transmission relay station module, a central processing control module and a marker module. The monitoring module is used for realizing in-place detection and monitoring shooting of the trolley wheels; the signal transmission relay station module is used for realizing remote signal transmission of the monitoring module and the central processing control module, input of trolley speed signals and output of alarm signals; the central processing control module is used for realizing processing calculation and control decision of the whole system; the marker module is used for realizing the marking of the trolley wheels, facilitating the extraction of the image characteristics of the wheels and the coding of the wheels. The invention monitors the wheel rotation speed by utilizing machine vision, can find problems before the wheel is damaged and stops rotating, and alarms, thereby reducing the loss to the minimum.
Description
Technical Field
The invention relates to a system and a method for monitoring equipment states, in particular to a system and a method for monitoring the rotating speed of wheels of a trolley of a circular cooler.
Background
The annular cooler wheels usually adopt a periodic maintenance and overhaul mode, the replacement period is generally 2 years, but the state of the wheels is often deteriorated when the wheels do not reach the period, the annular cooler trolley is large in installed quantity, large in size, heavy in load, large in contact stress of the end parts of the wheels on two sides, bad in running environment of the wheels, easy to damage and jam the wheel bearings of the trolley, the wheels do not rotate, the trolley deflects, the wheels clamp a bent rail, an inner ring clamp sealing plate, a connecting plate break and other faults, the overhaul process wastes a large amount of manpower and material resources, and the production time is delayed.
The fault accident of the annular cooler trolley is frequent, and the production loss is directly caused: the cumulative production stopping time is more than 100 hours, the yield loss is about ten tons, and the economic loss reaches tens of kiloyuan. It is therefore highly desirable to discover or predict as early as possible the occurrence or possible failure of a trolley wheel during operation.
At present, the existing wheel rotation speed monitoring methods of the trolley of the annular cooler are as follows:
1) The working principle of the sensor type wheel speed monitoring method is that the distance from the wheel to the sensor is detected, and when the distance is changed, the wheel is damaged and loosened;
2) The working principle of the pound pressure type wheel rotating speed monitoring method is that the bearings of damaged wheels are damaged to generate gaps, when a trolley runs through a platform scale, the damaged wheels bear little force, the weight measured on the platform scale is small, and when the weight of a certain place of wheels is detected to be small, an alarm is given;
3) The moment type wheel rotation speed monitoring method adopts moment measuring equipment to measure wheel resistance moment, under normal conditions, a wheel bearing is not damaged, the wheel resistance moment is smaller, after the wheel bearing is damaged, the wheel resistance moment is larger, and when the wheel resistance moment is detected to be overlarge, an alarm is given.
However, when the system generates an alarm, the wheels of the annular cooling machine trolley are damaged, and the damaged wheels cannot be judged in advance and then are eliminated.
Disclosure of Invention
Aiming at the defects in the prior art, the invention aims to provide a wheel rotating speed monitoring system and a wheel rotating speed monitoring method for a trolley of an annular cooler, which utilize machine vision to monitor the wheel rotating speed, can find problems before the wheel is damaged and stops rotating, and can give an alarm so as to reduce the loss to the minimum.
In order to achieve the above purpose, the invention adopts the following technical scheme:
in one aspect, a wheel speed monitoring system for a trolley of a circular cooler comprises:
the monitoring module is used for detecting and monitoring the in-place condition of the trolley wheels;
the central processing control module is used for realizing the processing calculation and control decision of the whole system;
the signal transmission relay station module is used for realizing remote signal transmission between the monitoring module and the central processing control module, input of trolley speed signals and output of alarm signals;
the marker module is used for realizing the marking of the trolley wheels, and is convenient for the monitoring module to extract the image characteristics of the wheels and code the wheels.
The monitoring module comprises:
the proximity switch is arranged on the trolley travelling route and used for detecting whether the trolley wheels reach the monitoring range or not;
the industrial monitoring camera is used for monitoring and shooting the trolley wheels;
and the light supplementing lamp is used for supplementing light when the industrial monitoring camera shoots.
The signal transmission relay station module comprises:
PLC module includes: the device comprises a programmable controller and an analog input unit, wherein the programmable controller is used for reading a switch signal of a proximity switch and outputting an alarm signal, and the analog input unit is used for reading an analog speed signal of the trolley;
the serial port/network converter is used for converting serial port signals of the PLC module into network signals capable of being remotely communicated;
the optical fiber transceiver is used for converting network signals of the PLC module and the industrial monitoring camera into photoelectric signals;
the optical fiber terminal box is used for connecting the single-mode optical fiber into the optical cable;
the switching power supply is used for supplying power to the serial port/network converter and the optical fiber transceiver.
The central processing control module comprises:
the image processing calculator is communicated with the PLC module and the monitoring module, and the image processing and the feature extraction are carried out on the video image transmitted by the monitoring module, so that the rotating speed of the trolley wheel is calculated, the rotating speed is compared with the rotating speed of the trolley wheel read by the PLC module in real time, a rotating speed difference value is obtained, and an alarm mechanism is started when the difference value exceeds the error allowable range;
the display is used for displaying the running condition of the whole system in real time;
the optical fiber transceiver is used for converting the photoelectric signals transmitted from the signal transmission relay station module into network signals which can be directly processed by the image processing calculator;
the optical fiber terminal box is used for connecting the single-mode optical fiber into the optical cable;
USB, HDMI extender, in order to image processing calculator and remote operation display between the display.
The marker module comprises:
the number plate is used for coding the trolley wheels;
the wheel marker is used for assisting the industrial monitoring camera to capture the characteristics of the wheel.
The proximity switch has four, is diffusion reflection type infrared photoelectric sensor, the power of light filling lamp be 30w, light filling distance is 1m.
The programmable controller is ohm dragon CP1E, the analog input unit is CP1W, the serial port/network converter is ZLAN5103, RS232 is converted into a network cable, the optical fiber transceiver is TL-FC311A, the optical fiber transceiver is four-light electricity, and the switching power supply is DC12V5A.
The image processing calculator is a PC, and the USB and HDMI extender is an EKL-USB and EKL-HDMI extender.
The number plate is made of frosted materials, and the wheel marker is a rubidium magnet.
On the other hand, when the trolley wheel enters the range of the proximity switch, the industrial monitoring camera starts to shoot video of the trolley wheel, the image processing calculator reads in video signals by calling an interface of the SDK development kit, processes video files, extracts the characteristics of the wheel and the number of the wheel, calculates the rotating speed, calculates a rotating speed average value by multiple groups of calculation, compares the rotating speed average value with the actual rotating speed of the trolley read by the PLC module in real time, calculates errors, triggers an alarm mechanism when the rotating speed error exceeds the allowable range, is provided with three types of slow speed, no rotation and wheel dropping, and correspondingly processes the trolley wheel by staff according to the alarm mechanism.
According to the system and the method for monitoring the rotating speed of the trolley wheels of the annular cooler, provided by the invention, the trolley wheels are monitored by using a machine vision method, so that the failure of the trolley wheels in operation is predicted in advance, the maintenance cost is reduced, the abnormal degradation trend of the rotating speed of the trolley wheels of the annular cooler can be found in time, the influence of the failure of the trolley wheels of the annular cooler on production is greatly reduced, and the scientific and intelligent equipment management is performed by adopting a periodic maintenance and overhaul mode.
Drawings
FIG. 1 is a schematic system diagram of an embodiment of the present invention;
FIG. 2 is a system wiring diagram of an embodiment of the present invention;
FIG. 3 is a fiber optic transceiver patch diagram of an embodiment of the present invention;
FIG. 4 is a wiring diagram of a PLC module according to an embodiment of the present invention;
FIG. 5 is a flow chart of the system operation of an embodiment of the present invention.
Detailed Description
The technical scheme of the invention is further described below with reference to the accompanying drawings and examples.
Referring to fig. 1 to 4, the present invention provides a wheel rotation speed monitoring system for a trolley of a circular cooler, comprising:
the monitoring module 1 is used for detecting and monitoring the in-place condition of the trolley wheels 2.
The central processing control module 2 is used for realizing the processing calculation and control decision of the whole system.
The signal transmission relay station module 3 is used for realizing remote signal transmission between the monitoring module 1 and the central processing control module 2, input of trolley speed signals and output of alarm signals.
The marker module is used for marking the trolley wheels 2, and is convenient for the monitoring module 1 to extract the image characteristics of the trolley wheels 2 and code the wheels.
Preferably, the monitoring module 1 has an inner ring and an outer ring, and each set of monitoring module 1 includes:
the proximity switches 11 are arranged on the trolley travelling route and are used for detecting whether the trolley wheels 2 reach the monitoring range, the four proximity switches 11 are all diffuse reflection type infrared photoelectric sensors, and the detection distance can be adjusted within 300-1000 mm.
The industrial monitoring camera 12 is used for monitoring and shooting the trolley wheel 2, the industrial monitoring camera 12 is an outdoor sea-health-vision monitoring camera, and the waterproof and dustproof grade is IP67.
The light supplementing lamp 13 is used for supplementing light when the industrial monitoring camera 12 shoots, the light supplementing lamp 13 is normally on, the power is 30w, and the light supplementing distance is 1m.
Preferably, the signal transmission relay station module 3 includes:
The serial/network converter 32 is configured to convert serial signals of the PLC module 31 into network signals capable of remote communication; the serial/network converter is ZLAN5103, and RS232 is converted into a network cable.
The optical fiber transceiver 33 is used for converting the network signals of the PLC module 31 and the industrial monitoring camera 12 into photoelectric signals; the fiber optic transceiver is TL-FC 311A-optical-four-electrical.
The optical fiber terminal box is used for connecting the single-mode optical fiber into the optical cable.
The switching power supply is used for supplying power to the serial port/network converter 32 and the optical fiber transceiver 33; the switching power supply is DC12V5A.
Preferably, the central processing control module 2 includes:
the image processing calculator is communicated with the PLC module 31 and the monitoring module 1, and calculates the rotating speed of the trolley wheel 2 by carrying out image processing and feature extraction on the video image transmitted by the monitoring module 1, and compares the rotating speed with the rotating speed of the trolley wheel 1 read by the PLC module 32 in real time to obtain a rotating speed difference value, and an alarm mechanism is started when the rotating speed difference value exceeds an error allowable range; the image processing calculator is a PC.
And the display is used for displaying the running condition of the whole system in real time.
The optical fiber transceiver is used for converting the photoelectric signal transmitted from the signal transmission relay station module 3 into a network signal which can be directly processed by the image processing calculator.
The optical fiber terminal box is used for connecting the single-mode optical fiber into the optical cable.
USB, HDMI extender, in order to process the remote operation display between display and the calculator; the USB and HDMI extender is an EKL-USB and EKL-HDMI extender.
Preferably, the marker module includes:
number plate 4, in order to encode the wheel 2 of the trolley; the number plate is made of frosted materials and does not generate specular reflection.
A wheel marker 5 to assist the industrial monitoring camera in capturing the wheel characteristics; the wheel marker is rubidium magnet (40 x 20 x 3), the color should have a large contrast with the color of the wheel 2, the capturing of the wheel marker 5 by the industrial monitoring camera 12 is facilitated, and the installation is convenient.
Referring to fig. 5, the present invention further provides a method for monitoring the rotation speed of the trolley of the ring cooling machine, when the method is applied, firstly, starting a system, starting the rotation speed monitoring software of the trolley of the ring cooling machine, starting the rotation speed monitoring, when the trolley wheel 2 enters the proximity switch range, the industrial monitoring camera 12 starts to perform video shooting on the trolley wheel 2, the image processing calculator reads video signals by calling the interface of the existing hakuwei SDK development packet, processes video files, extracts the wheel characteristics and the wheel numbers in the video signals, performs rotation speed calculation, calculates a plurality of groups of calculation to obtain the rotation speed average value, then compares the rotation speed average value with the actual rotation speed of the trolley read by the PLC module 31 in real time, calculates errors, and when the rotation speed error exceeds the allowable range, triggers an alarm mechanism, the alarm mechanism is provided with three types of slow speed, no rotation and wheel dropping, and the staff performs corresponding processing on the trolley wheel according to the alarm mechanism.
In summary, the invention utilizes machine vision to monitor the wheel rotation speed, can find problems before the wheel is damaged and stops rotating, and gives an alarm so as to realize the early prediction of faults of the wheel of the trolley in operation.
It will be appreciated by persons skilled in the art that the above embodiments are provided for illustration only and not for limitation of the invention, and that variations and modifications of the above described embodiments are intended to fall within the scope of the claims of the invention as long as they fall within the true spirit of the invention.
Claims (7)
1. The utility model provides a ring cooler trolley wheel rotational speed monitoring system which characterized in that includes:
the monitoring module is used for detecting and monitoring the in-place condition of the trolley wheels;
the central processing control module is used for realizing the processing calculation and control decision of the whole system;
the signal transmission relay station module is used for realizing remote signal transmission between the monitoring module and the central processing control module, input of trolley speed signals and output of alarm signals;
the marker module is used for realizing the marking of the trolley wheels, facilitating the extraction of the image characteristics of the wheels and the coding of the wheels by the monitoring module,
the monitoring module comprises:
the proximity switch is arranged on the trolley travelling route and used for detecting whether the trolley wheels reach the monitoring range or not;
the industrial monitoring camera is used for monitoring and shooting the trolley wheels;
a light supplementing lamp for supplementing light when the industrial monitoring camera shoots,
the signal transmission relay station module comprises:
PLC module includes: the device comprises a programmable controller and an analog input unit, wherein the programmable controller is used for reading a switch signal of a proximity switch and outputting an alarm signal, and the analog input unit is used for reading an analog speed signal of the trolley;
the serial port/network converter is used for converting serial port signals of the PLC module into network signals capable of being remotely communicated;
the optical fiber transceiver is used for converting network signals of the PLC module and the industrial monitoring camera into photoelectric signals;
the optical fiber terminal box is used for connecting the single-mode optical fiber into the optical cable;
a switching power supply for supplying power to the serial port/network converter and the optical fiber transceiver,
the central processing control module comprises:
the image processing calculator is communicated with the PLC module and the monitoring module, and the image processing and the feature extraction are carried out on the video image transmitted by the monitoring module, so that the rotating speed of the trolley wheel is calculated, the rotating speed is compared with the rotating speed of the trolley wheel read by the PLC module in real time, a rotating speed difference value is obtained, and an alarm mechanism is started when the difference value exceeds the error allowable range;
the display is used for displaying the running condition of the whole system in real time;
the optical fiber transceiver is used for converting the photoelectric signals transmitted from the signal transmission relay station module into network signals which can be directly processed by the image processing calculator;
the optical fiber terminal box is used for connecting the single-mode optical fiber into the optical cable;
USB, HDMI extender, in order to image processing calculator and remote operation display between the display.
2. The wheel speed monitoring system of the annular cooler trolley, as claimed in claim 1, wherein: the marker module comprises:
the number plate is used for coding the trolley wheels;
the wheel marker is used for assisting the industrial monitoring camera to capture the characteristics of the wheel.
3. The wheel speed monitoring system of the annular cooler trolley, as claimed in claim 1, wherein: the proximity switch has four, is diffusion reflection type infrared photoelectric sensor, the power of light filling lamp be 30w, light filling distance is 1m.
4. The wheel speed monitoring system of the annular cooler trolley, as claimed in claim 1, wherein: the programmable controller is ohm dragon CP1E, the analog input unit is CP1W, the serial port/network converter is ZLAN5103, RS232 is converted into a network cable, the optical fiber transceiver is TL-FC311A, the optical fiber transceiver is four-light electricity, and the switching power supply is DC12V5A.
5. The wheel speed monitoring system of the annular cooler trolley, as claimed in claim 1, wherein: the image processing calculator is a PC, and the USB and HDMI extender is an EKL-USB and EKL-HDMI extender.
6. The wheel speed monitoring system of the annular cooler trolley, as claimed in claim 2, wherein: the number plate is made of frosted materials, and the wheel marker is a rubidium magnet.
7. A monitoring method for the wheel speed monitoring system of the annular cooler trolley according to any one of claims 1 to 6, characterized in that: when the trolley wheels enter the range of the proximity switch, the industrial monitoring camera starts to shoot the trolley wheels, the image processing calculator reads in video signals by calling an interface of the SDK development kit, processes video files, extracts wheel characteristics and wheel numbers in the video files, calculates rotating speed, calculates a plurality of groups of rotating speed average values, compares the rotating speed average values with the actual rotating speed of the trolley read by the PLC module in real time, calculates errors, triggers an alarm mechanism when the rotating speed errors exceed an allowable range, and is provided with three types of slow speed, no rotation and wheel dropping, and a worker carries out corresponding processing on the trolley wheels according to the alarm mechanism.
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| Application Number | Priority Date | Filing Date | Title |
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| CN201910023167.2A CN111427302B (en) | 2019-01-10 | 2019-01-10 | Wheel rotating speed monitoring system and method for trolley of annular cooler |
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| Application Number | Priority Date | Filing Date | Title |
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| CN201910023167.2A CN111427302B (en) | 2019-01-10 | 2019-01-10 | Wheel rotating speed monitoring system and method for trolley of annular cooler |
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| CN111427302A CN111427302A (en) | 2020-07-17 |
| CN111427302B true CN111427302B (en) | 2023-05-09 |
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