CN111591716A - Photoelectric integrated intelligent detection device for belt damage condition of conveyor - Google Patents
Photoelectric integrated intelligent detection device for belt damage condition of conveyor Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G43/00—Control devices, e.g. for safety, warning or fault-correcting
- B65G43/02—Control devices, e.g. for safety, warning or fault-correcting detecting dangerous physical condition of load carriers, e.g. for interrupting the drive in the event of overheating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G2203/00—Indexing code relating to control or detection of the articles or the load carriers during conveying
- B65G2203/02—Control or detection
- B65G2203/0266—Control or detection relating to the load carrier(s)
- B65G2203/0275—Damage on the load carrier
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G2203/00—Indexing code relating to control or detection of the articles or the load carriers during conveying
- B65G2203/04—Detection means
- B65G2203/041—Camera
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Abstract
The invention discloses a photoelectric integrated intelligent detection device for the belt damage condition of a conveyor, which mainly solves the problem that the prior art can not monitor the tearing damage condition in real time in the running process of the belt of the conveyor, and comprises a linear laser generator (1), a high-speed industrial camera (2) and a test box (3)), wherein the linear laser generator is placed below the belt to be detected, and linear laser emitted by the laser transversely irradiates the belt; the high-speed industrial camera is positioned obliquely below the belt and used for capturing the real-time change condition of the linear laser on the belt; the test box controls the camera and obtains real-time video images, and processes the shot images through a special image processing module in the test box to detect the tearing damage condition of the belt in the running process of the conveyor. The device has the advantages of simple structure, high detection efficiency, low cost, convenient maintenance and easy industrial realization, and can be used for real-time detection of the transmission belt in the metallurgy, high-smelting and coal mine industries.
Description
Technical Field
The invention belongs to the technical field of detecting instruments, and particularly relates to a photoelectric integrated intelligent detecting device which can be used for detecting the belt damage condition in the mechanical transmission process.
Background
In many metallurgical, high-end and coal-mine industrial plants, belt transport is undoubtedly a relatively common and heavily used means of transporting goods, and the long transport distances and the heavy weight of the goods carried subject the belts to a greater risk of breakage and tearing. Once the conveying belt is torn, a large amount of materials can be damaged, and serious economic loss is brought, so that safety detection and related maintenance of the damaged belt are necessary. The traditional damage condition detection method is too single and mechanical, and has obvious defects and careless mistakes in aspects of cost, detection time, detection accuracy, instantaneity, adjustability and the like. At present, domestic belt detection and monitoring systems are mainly divided into the following three types:
the first type is manual inspection in a long-distance and large-size transportation system, which has high labor intensity and the problem of missing inspection;
the second type is that the control part of the detection system is a man-machine interaction mode which is mainly controlled by man, so that the whole system is easy to have overload operation, thereby bringing potential safety hazards;
the third type is to use mechanical contact type detecting devices, such as magnetic sensors, pressure testing devices, etc., which have the most fatal disadvantages that the detection of the devices occurs after an accident, the operation condition of the belt cannot be predicted in advance, the real-time performance is poor, the maintenance task of the detecting device is heavy, the related parameter components are difficult to replace, and the work of the maintainer is difficult.
On the basis of the prior art, on the basis of computer vision, a target image is acquired through a high-speed industrial camera to complete digital conversion of a real target, information in the image is detected by adopting an effective detection algorithm, and further the actual running condition and trend of the belt are reflected to realize the work of the target function to be achieved by the whole device, and attempts are made by many people in China. Chengyu et al propose a visual auxiliary detection method in "visual detection of belt tearing" ("mechanical engineering and automation" 3 years 2018) to determine whether the belt has cracks or tears, so that the system gives an alarm or stops running. The idea of the method is as follows: in order to obtain a high-quality belt working surface image, the belt working surface is illuminated by a special illuminating light source, so that light rays in a camera view field range are uniform. After the intelligent camera collects the belt image, the surface condition of the belt is identified through image processing, feature extraction and BP network judgment. When the suspected cracks are found, an alarm is given in time to remind workers to further confirm and process; when the belt is torn, the alarm is given and the working power supply of the belt conveyor is cut off, so that further expansion of accidents is avoided. In this document, the author uses a Canny edge detection operator to detect the crack edge of the belt, sends the detection result to a BP neural network, and analyzes the crack characteristics by the network, thereby judging the damage condition of the belt. The method adopts visual assistance and has intellectualization. However, this method still has two disadvantages: firstly, the dependence of the BP network on the acquired image is too high, and if the light source irradiation is not uniform or the whole system shakes in the image acquisition process, the adverse effect on the network evaluation is brought; secondly, when the running speed of the belt is too fast or too slow, the detection accuracy is not very high.
The patent of Chengyong wave et al, "Belt tear detection device based on image processing" (publication No. CN 205151047U, publication No. 2016.04.13, application No. 2015.08.26) discloses a belt tear detection device based on image processing, which adopts an area-array camera and a rotary encoder to collect complete belt picture data, an image processing platform accesses the area-array camera through an IP address to read pictures, and performs a series of analyses such as preprocessing, defect detection, feature calculation and the like on the pictures, and finally judges whether the belt has tear or other defects. Although the device is convenient to maintain and avoids the problems of high detection error rate of the traditional sensor, the complexity of the system structure is undoubtedly increased if the scanning of the camera is completely matched with the running speed of the belt; meanwhile, the device has no particularly outstanding optimization on the detection algorithm, so that the improvement of the detection speed and the precision is influenced.
Disclosure of Invention
The invention aims to provide a photoelectric integrated intelligent detection device for the belt damage condition of a conveyor, which combines laser irradiation and vision-based image processing to realize real-time monitoring and detection of the belt damage condition in operation and improve the detection speed and precision.
In order to achieve the above object, the present invention provides a photoelectric integrated intelligent detection device for belt damage of a conveyor, comprising: a linear laser generator, a high-speed industrial camera and a test box.
The linear laser generator is loaded below the belt to be detected and used for generating green laser beams which are uniformly irradiated on the belt to be detected and used as a mark line for system detection;
the high-speed industrial camera is mounted at a position convenient for shooting a green laser beam so as to acquire continuous image frames and obtain real-time video display;
and the test box is connected with the high-speed industrial camera and the linear laser generator and is used for respectively controlling the high-speed industrial camera and the linear laser generator in real time, reading a video stream in the high-speed industrial camera, processing and detecting an image sample displayed in the video stream and feeding back the belt state to a user in real time.
Further, the line-shaped laser generator includes: the laser source, the switch control circuit and the working state feedback circuit; the laser source generates a linear green laser beam; the switch control circuit controls the laser switch through the test box; the working state feedback circuit detects the working state of the laser in real time and feeds the working state of the laser back to the test box.
Further, the high-speed industrial camera includes: the device comprises a USB3.0 high-speed transmission interface, a high-quality 1/4-inch image sensor and a protective cover shell, wherein the pixels of the USB3.0 high-speed transmission interface are not less than 100 ten thousand, and the frame frequency is not less than 30 frames per second; the high-quality 1/4-inch image sensor adopts a global shutter capable of performing precise snapshot; the shell of the protective cover is designed to be IP 67-level industrial protection, can prevent water and dust, and is provided with a windshield wiper system for clearing accumulated dust.
Further, a video stream processing system is arranged in the test box, and the system comprises:
the control module is used for controlling the working states of the linear laser generator 1 and the high-speed industrial camera 2 and has a parameter setting function;
the communication module is used for feeding back the working state and the detection result of the current belt to the remote main control server in real time and receiving the control instruction of the server;
and the image processing module is used for processing and detecting the acquired picture sample in real time and judging the damage condition of the belt according to the change condition of the laser beam in the acquired image.
The invention has the following advantages:
firstly, the laser is used as the reference target line, so that the defect of single detection mode in the current belt detection field is overcome, the belt damage detection is simplified, and the real-time rapid detection is facilitated.
Secondly, the novel belt damage feedback device is simple in overall structure and convenient to install, can feed back the belt damage condition in real time, and has a preliminary internet of things prototype;
thirdly, the detection result is accurate.
Most of the detection means in the field of belt detection at present are common alarm signal detection or manual overhaul, and the realization process is time-consuming and complex; the belt running condition can be rapidly detected in real time by adopting the detection device, and the detection result is accurate.
Drawings
FIG. 1 is a schematic diagram of the principles of the present invention;
FIG. 2 is a structural view of the detecting unit of the present invention.
Detailed Description
The embodiments of the present invention will be described in detail below with reference to the accompanying drawings:
referring to fig. 1 and 2, the inspection apparatus of the present embodiment includes a line-shaped laser generator 1, a high-speed industrial camera 2, and a test box 3. The test box 3 is respectively connected with the high-speed industrial camera 2 and the linear laser generator 1 and is used for respectively controlling the high-speed industrial camera 2 and the linear laser generator 1 in real time, reading the video stream in the high-speed industrial camera 2, processing and detecting image samples displayed in the video stream and feeding back the belt state to a user in real time.
The linear laser generator 1 is loaded below the belt to be detected and used for generating green laser beams which are uniformly irradiated on the belt to be detected and used as a mark line for system detection; the linear laser generator comprises a laser source 11, a switch control circuit 12 and a working state feedback circuit 13; the laser source 11 generates a linear green laser beam; the switch control circuit 12 controls the laser switch through the test box; the working state feedback circuit 13 detects the laser working state in real time and feeds the laser working state back to the test box 3
The high-speed industrial camera 2 is mounted at a position convenient for shooting green laser beams so as to acquire continuous image frames and obtain real-time video display; the high-speed industrial camera includes: the device comprises a USB3.0 high-speed transmission interface 21, a high-quality 1/4-inch image sensor 22 and a protective cover shell 23, wherein the pixels of the USB3.0 high-speed transmission interface are not less than 100 ten thousand, and the frame frequency is not less than 30 frames/second; the high-quality 1/4-inch image sensor adopts a global shutter capable of performing precise snapshot; the shell of the protective cover is designed to be IP 67-level industrial protection, can prevent water and dust, and is provided with a windshield wiper system for clearing accumulated dust.
And the test box 3 is connected with the high-speed industrial camera 2 and the linear laser generator 1, and is used for respectively controlling the high-speed industrial camera 2 and the linear laser generator 1 in real time, reading a video stream in the high-speed industrial camera 2, processing and detecting an image sample displayed in the video stream, and feeding back a belt state to a user in real time.
The test box 3 is provided with a video stream processing system, and the system comprises: a control module 31, a communication module 32 and an image processing module 33, wherein:
the control module 31 is used for controlling the working states of the linear laser generator and the high-speed industrial camera and has a parameter setting function;
the communication module 32 is used for feeding back the working state and the detection result of the current belt to the remote main control server in real time and receiving the control instruction of the server;
and the image processing module 33 is used for processing and detecting the acquired picture sample in real time, and judging the damage condition of the belt according to the change condition of the laser beam in the acquired image. The image processing module includes an image preprocessing sub-module 331, a detection target extraction module 332, and a detection module 333.
The image preprocessing submodule 331 is configured to crop an image to be suitable for detection, and perform basic preprocessing of denoising, filtering, sharpening, and enhancing on the acquired original image in sequence;
the detected target extracting module 332 is configured to remove an interference background of the preprocessed image, improve the contrast of the target region, and perform thinning processing on the detected target;
the detecting module 333 is configured to perform multi-stage detection to determine whether the belt is abnormal, and feed back the detection condition to the communication module in real time.
The working principle of the invention is as follows:
during operation, load the inside laser source 11 emission green laser beam of laser generator in the belt below that awaits measuring, evenly shine suitable position on the belt to make high-speed industry camera 2 can shoot the straight line that will detect, as the detection line of system, the inside on-off control circuit 12 control test box 3 of laser generator 1 controls the green laser beam of laser generator 1 transmission, operating condition feedback circuit 13 detects laser operating condition in real time, and feed back test box 3. The high speed industrial camera 2 captures successive image frames and acquires a real time video display. The control module 31 in the test box 3 sends the image shot by the high-speed industrial camera 2 to the image processing module 33 thereof, processes and detects the image by an algorithm, and judges the damage condition of the belt according to the change condition of the laser beam obtained in the image. Firstly, an image preprocessing submodule 331 of an image processing module 33 in the test box 3 is utilized to sequentially perform denoising, filtering, sharpening and enhanced basic preprocessing on an obtained original image; then, the detection target extraction module 332 of the image processing module 33 is used for removing the interference background of the preprocessed image, improving the contrast of the target area and performing thinning processing on the detection target; finally, the detection module 333 of the image processing module 33 adopts multi-stage detection to judge whether the belt is abnormal. The judging method comprises the following steps: calculating a corner response function R of each pixel in the image which is shot by the high-speed industrial camera 2 and is subjected to preprocessing and morphological thinning processing, performing local non-maximum value inhibition processing on the corner response function R, arranging the corner response function R from large to small, solving the slope between any two corners of N corner position coordinates, solving the difference S of the maximum value of the slope, comparing the S with a judgment threshold value K given by experiments, if the S is larger than the K, tearing occurs to the belt, otherwise, the belt is not torn. The image processing module 33 feeds back the detection condition to the communication module 32 in real time. The communication module 32 feeds back the working state and the detection result of the current belt to the remote main control server, and receives the next control instruction of the server.
So far, a detection process of the whole detection device is completed, and as can be seen from the above, three modules of the device are mutually associated and work together, but have an order relationship, namely, a laser generator firstly emits a laser beam, a high-speed industrial camera shoots a green laser beam, and the shot image is processed and detected and fed back by a test box to judge the damage condition of the belt.
The above is a specific example of the present invention, and is not to be construed as limiting the invention in any way, and it is apparent that modifications in various forms and parameters can be made without departing from the spirit and principle of the invention, which is set forth in the following claims.
Claims (5)
1. The utility model provides an integrative intellectual detection system device of photoelectricity of conveyer belt damage situation which characterized in that includes: the device comprises a linear laser generator (1), a high-speed industrial camera (2) and a test box (3);
the linear laser generator (1) is loaded below the belt to be detected and used for generating green laser beams which are uniformly irradiated on the belt to be detected and used as a mark line for system detection;
the high-speed industrial camera (2) is mounted at a position convenient for shooting green laser beams so as to acquire continuous image frames and obtain real-time video display;
and the test box (3) is connected with the high-speed industrial camera and the linear laser generator and is used for respectively controlling the high-speed industrial camera and the linear laser generator in real time, reading a video stream in the high-speed industrial camera, processing and detecting an image sample displayed in the video stream and feeding back the belt state to a user in real time.
2. The device according to claim 1, wherein the line-shaped laser generator (1) comprises: the laser control circuit comprises a laser source (11), a switch control circuit (12) and a working state feedback circuit (13); the laser source (11) generates a linear green laser beam; the switch control circuit (12) controls the laser switch through the test box; the working state feedback circuit (13) detects the working state of the laser in real time and feeds the working state of the laser back to the test box.
3. The device according to claim 1, characterized in that the high-speed industrial camera (2) comprises: the device comprises a USB3.0 high-speed transmission interface (21), a high-quality 1/4-inch image sensor (22) and a protective cover shell (23), wherein the pixels of the USB3.0 high-speed transmission interface (21) are not less than 100 ten thousand, and the frame frequency is not less than 30 frames/second; the high-quality 1/4-inch image sensor (22) employs a global shutter capable of precision snap shots; the shell of the protective cover (23) is designed to be IP 67-grade industrial protection, can prevent water and dust, and is provided with a windshield wiper system for clearing accumulated dust.
4. Device according to claim 1, characterized in that the test box (3) is provided with a video stream processing system comprising:
the control module (31) is used for controlling the working states of the linear laser generator and the high-speed industrial camera and has a parameter setting function;
the communication module (32) is used for feeding back the working state and the detection result of the current belt to the remote main control server in real time and receiving the control instruction of the server;
and the image processing module (33) is used for processing and detecting the acquired picture samples in real time and judging the damage condition of the belt according to the change condition of the laser beams in the acquired image.
5. The apparatus according to claim 4, wherein the image processing module (33) comprises:
the image preprocessing submodule (331) is used for cutting the image to be suitable for detection, and sequentially carrying out basic preprocessing of denoising, filtering, sharpening and enhancing on the obtained original image;
a detection target extraction module (332) for removing the interference background of the preprocessed image, improving the contrast of the target area, and thinning the detection target;
and the detection module (333) is used for carrying out multistage detection to judge whether the belt is abnormal or not and feeding back the detection condition to the communication module in real time.
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Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112945855A (en) * | 2021-02-04 | 2021-06-11 | 中冶东方工程技术有限公司 | Online intelligent inspection system and inspection method for material conveying belt |
| CN114476579A (en) * | 2022-03-07 | 2022-05-13 | 郑州职业技术学院 | Intelligent monitoring system and method for coal mine belt |
| CN115583475A (en) * | 2022-11-03 | 2023-01-10 | 武汉顶力康自动化有限公司 | Intelligent control device and control method for preventing tearing and deviation of conveying belt |
| CN115947066A (en) * | 2023-03-14 | 2023-04-11 | 合肥金星智控科技股份有限公司 | Belt tearing detection method, device and system |
| CN117228262A (en) * | 2023-11-16 | 2023-12-15 | 徐州众图智控通信科技有限公司 | Coal mine conveyor belt longitudinal tearing detection system and method based on laser detection |
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