CN111687077B - High-precision material color sorting method - Google Patents
High-precision material color sorting method Download PDFInfo
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- CN111687077B CN111687077B CN202010654542.6A CN202010654542A CN111687077B CN 111687077 B CN111687077 B CN 111687077B CN 202010654542 A CN202010654542 A CN 202010654542A CN 111687077 B CN111687077 B CN 111687077B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/34—Sorting according to other particular properties
- B07C5/342—Sorting according to other particular properties according to optical properties, e.g. colour
- B07C5/3425—Sorting according to other particular properties according to optical properties, e.g. colour of granular material, e.g. ore particles, grain
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/02—Measures preceding sorting, e.g. arranging articles in a stream orientating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/36—Sorting apparatus characterised by the means used for distribution
- B07C5/363—Sorting apparatus characterised by the means used for distribution by means of air
- B07C5/365—Sorting apparatus characterised by the means used for distribution by means of air using a single separation means
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Abstract
The application relates to a high-precision material color sorting method, which comprises the following steps: driving a rotary feeder sleeved with a dispersion disc to rotate so as to throw materials out of a material outlet of the rotary feeder; the thrown materials fall on the rotary dispersion disc, collide with the baffle after being scattered and fall on the material conveying part; driving the material conveying component to move so as to enable the materials to move along the directions of the color detection component, the material sorting component and the material recovery component; identifying the relative position of the heterochromatic materials on the material plate; and driving the material sorting component to sort the different-color materials according to the relative position. This application embodiment utilizes mechanical force to overcome the material adhesion, is favorable to preventing that the material from compressing tightly and assembling and adhesion to effectual dispersing the material, and then effectively improving recovery purity and rate of recovery.
Description
Technical Field
The application relates to the technical field of mineral separation, in particular to a high-precision material color sorting method.
Background
The mineral powder particles have a size of between 40 mesh and 80 mesh, and the basic colors include white, yellow, green, red and black. Different types of mineral powders are generally sorted according to color. The traditional separation work is mainly completed manually, but the manual analysis efficiency is low. In order to replace manual ore sorting work, the prior CN110340037A discloses a color sorting device for sorting single minerals, which supplies materials by vibration and sorts by a sliding mineral collecting device; CN110614160A provides a method for separating single mineral garnet from durite, which is performed by a porous plate, a vibration device and a mineral collection device.
In the prior art, materials are easy to adhere to the surface of a sorting device, so that material loss is caused; the sieve plate is not easy to clean; the distribution speed of the porous plate is low; the material positioning and extracting structure is complex, and the precision is low; and high cost.
Based on this, in order to effectively solve the above problems, it is urgently needed to develop a novel ore powder color sorter, and the ore powder color sorter is required to count and recover all normal materials (i.e. qualified color materials) and heterochromatic materials, and cannot be lost, and the recovery purity and recovery rate of the normal materials are required to meet the technical index requirements.
Disclosure of Invention
In order to solve the technical problem or at least partially solve the technical problem, the application provides a high-precision material color sorting method.
In a first aspect, the application provides a high-precision material color sorting method, which uses a material color sorting device, wherein the material color sorting device comprises a material supply component, a material conveying component, a color detection component, a material sorting component and a material recovery component; the material supply component, the color detection component, the material sorting component and the material recovery component are sequentially arranged along the material conveying direction of the material conveying component; the material supply part comprises a rotary feeder, a dispersion disc and a baffle plate; the material color selection method comprises the following steps:
driving a rotary feeder sleeved with a dispersion disc to rotate so as to throw materials out of a material outlet of the rotary feeder; the thrown materials fall on the rotary dispersion disc, collide with the baffle after being scattered and fall on the material conveying part;
driving the material conveying component to move so as to enable the materials to move along the directions of the color detection component, the material sorting component and the material recovery component;
driving a color detection component to acquire an image of the material;
carrying out image recognition on the collected image, and recognizing the relative position of the different-color material meeting the preset abnormal color standard on the material tray;
driving the material sorting component to sort the different-color materials according to the relative position;
and the driving material recovery part is used for recovering the normal materials which are remained in the materials and meet the preset normal color standard.
Optionally, the material color sorting method further includes:
determining the number of the material outlets according to a preset material feeding speed;
and determining the distance between the material outlets according to the preset material scattering distance.
Optionally, the material conveying part is a disc-type tray;
the material color sorting method further comprises the following steps:
in the process of driving the color detection part to acquire the image of the material, taking the material tray as a background plate of the color detection part, wherein the color of the material tray is matched with the normal color;
and adjusting the angle between a light source in the color detection part and the material tray so as to adjust the intensity of photoelectric signals generated by the CCD camera assembly for collecting the different-color materials with preset different-color standards.
Optionally, the relative position includes a distance between the abnormal material and the center of the material tray and a rotation target angle of the abnormal material on the material tray to a position where the ball screw nut of the material sorting part is located;
the material sorting component is driven to sort the different-color materials according to the relative position; driving a material recovery part to recover the normal materials which are remained in the materials and meet the preset normal color standard; the method comprises the following steps:
determining the target position of the different-color material suction nozzle according to the distance between the abnormal material and the center of the material tray;
driving the ball screw nut to drive the different-color material suction nozzle of the material sorting component to reach the target position;
when the heterochromatic materials are detected to reach the rotating target angle, the electromagnetic valve is driven to switch a gas path to the first exhaust port, and the vacuum pump is driven to suck gas so as to recover the heterochromatic materials;
and after the recovery of the heterochromatic materials is finished, driving the electromagnetic valve to switch the gas path to the second gas outlet so as to recover normal materials.
Optionally, the material color sorting method further includes:
and a first encoder arranged on the material tray is driven to detect the rotation angle of the material tray relative to a preset initial angle so as to determine the rotation target angle of the material.
Optionally, the driving the ball screw nut drives the different-color material suction nozzle of the material sorting component to reach the target position, including:
driving the ball screw nut to drive the heterochromatic material suction nozzle to axially move along the ball screw nut;
driving a second encoder arranged on the ball screw nut to detect the displacement of the heterochromatic material suction nozzle moving along the axial direction of the ball screw nut;
and driving the ball screw nut according to the target position and the displacement so as to drive the different-color material suction nozzle of the material sorting component to reach the target position.
Optionally, the acquired image is one-dimensional image data;
carry out image recognition to the image of gathering, it is in to discern that the heterochrosis material that accords with preset unusual colour standard is in relative position on the charging tray includes:
reading the one-dimensional image data from a preset second memory;
carrying out image recognition on the one-dimensional image data to recognize different color pixel points corresponding to the different color materials;
determining initial coordinates and initial angles of the heterochromatic materials on the charging tray according to a coordinate system established in advance based on the center of the charging tray and the heterochromatic pixel points;
determining the distance between the heterochromatic materials and the center of the material tray according to the initial coordinates;
determining the target position of the different color material suction nozzle according to the distance between the different color material and the center of the material tray;
and determining a rotating target angle of the heterochromatic material required to rotate according to the initial angle and the position of the ball screw nut.
Optionally, the performing image recognition on the one-dimensional image data to recognize the heterochromatic pixel points corresponding to the heterochromatic material includes:
performing color space conversion on the one-dimensional image data;
combining the one-dimensional image data obtained by color space conversion into a two-dimensional image;
separating the material image from the two-dimensional image data;
and identifying each pixel point of the separated material image to identify the heterochromatic pixel point corresponding to the heterochromatic material.
Optionally, the determining, according to a coordinate system established in advance based on the center of the tray and the heterochromatic pixel points, an initial coordinate and an initial angle of the heterochromatic material on the tray includes:
carrying out image segmentation on the separated material image;
and determining the initial coordinates and the initial angles of the heterochromatic materials on the charging tray from the segmented images according to a coordinate system and the heterochromatic pixel points which are established in advance based on the center of the charging tray, and determining the initial coordinates of the heterochromatic materials in the identified heterochromatic pixel points.
Optionally, the material color sorting method further includes:
the surface of the rotary feeder, the dispersion disc, the material disc, the heterochromatic material separator of the material sorting part and the normal material separator of the material recovery part, which is contacted with the material, are provided with the ultrahigh molecular weight polyethylene.
The method of the invention can be used for the separation of ore material, such as sulphide ore, for example pyrite, which is the most widely distributed mineral in the crust, and pyrite monominerals can be used for the separation of ore material40Ar/39In the law of Ar year, S isotope analysis, inclusion component analysis and other geological fields, therefore, how to simply and rapidly sort out the single mineral pyrite is very important.
The experiment takes the pyrite and chalcopyrite symbiotic sulphide ore as an example, and the sulphide ore also contains nonmetallic minerals of calcite, quartz and feldspar. The traditional sorting method comprises the following steps: on one hand, the process is complex and takes long time; on the other hand, the flotation is realized by adding a chemical reagent, so that the surface physical and chemical properties of the pyrite monomineral are changed, and the later analysis of the pyrite monomineral is not facilitated. The method comprises the following steps: compared with the traditional separation method, the method is easy to operate and does not change the physicochemical properties of minerals; compared with a color sorting method, the invention provides a solution that materials are easy to adhere to the surface of a machine, reduces the loss of the materials and improves the recovery rate; the dispersing device consisting of the rotary feeder, the dispersing disc and the baffle and the disc are provided to disperse materials, so that the problems that a sieve plate is not easy to clean and the porous plate is slow in material distribution speed are solved; the air suction pipe is fixed on the nut of the movable ball screw to position and extract materials, and the defects of complex system and high cost of a precision mechanical device are overcome.
Compared with the prior art, the technical scheme provided by the embodiment of the application has the following advantages:
the material color sorting method provided by the embodiment of the application overcomes material adhesion by utilizing mechanical force, is favorable for preventing materials from being compressed, concentrated and adhered, effectively disperses the materials and further effectively improves the recovery purity and the recovery rate.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the invention and together with the description, serve to explain the principles of the invention.
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, and it is obvious for those skilled in the art that other drawings can be obtained according to the drawings without inventive exercise.
Fig. 1 is a functional block diagram of a material color sorting apparatus provided in various embodiments of the present application;
fig. 2 is a schematic structural diagram of a material color sorting apparatus according to various embodiments of the present application;
fig. 3 is a schematic structural view of a rotary feeder according to various embodiments of the present application;
fig. 4 is a schematic structural diagram of a dispersion tray according to various embodiments of the present application;
FIG. 5 is a schematic diagram of a separator according to various embodiments of the present application;
FIG. 6 is a schematic control diagram of a tray according to various embodiments of the present application;
FIG. 7 is a schematic control diagram of a lead screw nut according to various embodiments of the present application;
FIG. 8 is a functional block diagram of a software system based on FPGA phenomenon according to various embodiments of the present application;
fig. 9 is a flowchart of a signal detection and processing system according to various embodiments of the present application.
Detailed Description
It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
In the following description, suffixes such as "module", "component", or "unit" used to denote elements are used only for facilitating the explanation of the present invention, and have no specific meaning in itself. Thus, "module", "component" or "unit" may be used mixedly.
Example 1
As shown in fig. 1, the material color sorting device in the embodiment of the present invention mainly includes modules for material supply, material conveyance, color detection, material sorting, material recovery, human-computer interface, communication, and the like. In the embodiment of the invention, in order to improve the subsequent dispersion effect, the material supply module pre-disperses the materials, so that the color detection module and the material sorting module are favorable for detecting and sorting the different-color materials. The material conveying module conveys materials to the material recovery device. The color detection module detects the color of the material and sends the detection result to the material sorting module. The material sorting module separates the different-color materials from the normal materials according to the positions of the different-color materials detected by the color detection module. The man-machine interface module is used for interaction between the color selector and a user, and can receive user input and set parameters. The human-computer interface displays the working information and the parameter information. The communication module is used for communicating with external equipment.
In the embodiment of the invention, corresponding components are constructed corresponding to each module, and as shown in fig. 2-5, the material color selection device comprises a material supply component, a material conveying component, a color detection component, a material sorting component and a material recovery component; the material supply component, the color detection component, the material sorting component and the material recovery component are sequentially arranged along the material conveying direction of the material conveying component; the material supply component is arranged above the material conveying component; the material supply part comprises a rotary feeder 11, a dispersion disc 12, a baffle 13 and a feeder motor 14; the material conveying part can be a chute or a conveyor belt, and preferably consists of a disc type tray 21 and a tray motor 22 in the embodiment of the invention; the color detection part comprises a CCD camera component 31, a light source 32 and a background plate, wherein the background plate can be composed of a material tray; the material sorting part comprises a different-color material suction nozzle 41, a different-color material bin 42, a different-color material separator 43, a ball screw nut (comprising a ball screw and a nut) 44, a screw nut motor 45 and a vacuum pump 47 provided with an electromagnetic valve 46; the material recovery part comprises a normal material suction nozzle 51, a normal material bin 52 and a normal material separator 53; the material recovery unit and the material sorting unit share an electromagnetic valve 46 and a vacuum pump 47.
Based on the above material color sorting device, an embodiment of the present invention provides a material color sorting method for a material color sorting device, where the material color sorting method includes:
driving a rotary feeder sleeved with a dispersion disc to rotate so as to throw materials out of a material outlet of the rotary feeder; the thrown materials fall on the rotary dispersion disc, collide with the baffle after being scattered and fall on the material conveying part;
driving the material conveying component to move so as to enable the materials to move along the directions of the color detection component, the material sorting component and the material recovery component;
driving a color detection component to acquire an image of the material;
carrying out image recognition on the collected image, and recognizing the relative position of the different-color material meeting the preset abnormal color standard on the material tray;
driving the material sorting component to sort the different-color materials according to the relative position;
and the driving material recovery part is used for recovering the normal materials which are remained in the materials and meet the preset normal color standard.
In the prior art, the material is small in size, is 80 meshes (0.18mm) at the minimum, and is easy to adhere to the surface of a machine or stay in gaps and corners of the machine. The materials processed by the common color sorter have larger sizes, the adhesion problem of fine materials is not considered, and the recovery rate of 99 percent is difficult to ensure. Based on this, one of the solutions adopted in the embodiments of the present invention is to solve the problem by material dispersion, so as to sufficiently disperse the materials, thereby improving the recovery purity and the recovery rate. In detail, at present, the material supply part mainly has three modes, namely a storage bin, a vibration feeding machine and a vibration screen. However, these feeders do not consider the adhesion and complete recycling of fine particles, and the embodiments of the present invention are based on the above method, in which the feeder, the dispersion plate, the baffle plate, and the material outlet are rotated to feed the material through the small hole (i.e., the material outlet) of the housing of the rotary feeder, the material is continuously agitated by the friction force, the gravity force, and the centrifugal force, the mechanical force is used to overcome the adhesion of the material, which is advantageous to prevent the material from being compacted and aggregated and adhered, to effectively disperse the material, and to count and recycle all normal materials (materials meeting the predetermined normal color standard) and abnormal materials (materials meeting the predetermined abnormal color standard).
The first end of the dispersion tray 12 is sleeved on the rotary feeder 11, the first end of the rotary feeder 11 is located between the first end of the dispersion tray 12 and the second end of the dispersion tray 12, a material outlet 15 is arranged on a shell of the rotary feeder between the first end of the rotary feeder 11 and the first end of the dispersion tray 12, and the baffle 13 is arranged at the second end of the dispersion tray; and a preset gap is reserved between the baffle and the other end of the dispersion disc.
Optionally, the rotary feeder is a hollow circular table; a radius of a first end of the rotary feeder is smaller than a radius of a second end of the rotary feeder; the dispersion disc is an annular round table; the radius of the first end of the dispersion impeller is smaller than the radius of the second end of the dispersion impeller.
In some embodiments, the method for color sorting a material further comprises: determining the number of the material outlets according to a preset material feeding speed; and determining the distance between the material outlets according to the preset material scattering distance. Furthermore, the number of the material outlets is at least 2; the number of the material outlets is in direct proportion to the material feeding speed; the distance between the material flow outlets is used for adjusting the scattering distance between the materials; the aperture of the material outlet is matched with the diameter of the material. That is, the shape of the rotary feeder is a hollow circular table, and the inner wall of the rotary feeder is provided with an ultrahigh molecular weight polyethylene lining. The rotary feeder feeds through a small hole (material outlet) in the housing. Selecting proper aperture according to the size of the material to enable the material to be basically single-grained; the proper number of the small holes is selected to obtain the proper material feeding speed, so that the accumulation caused by too fast material feeding is prevented; the hole pitch is reasonably designed, so that single-particle material flows are fully separated, and the subsequent dispersion has better effect. During feeding, the feeder motor 14 drives the rotary feeder to rotate, the rotating shaft is parallel to the material plate, and the material is thrown out of the small hole under the action of centrifugal force and falls onto the dispersion plate. The dispersion disc is an annular round table, and the inner wall of the dispersion disc is also provided with an ultrahigh molecular weight polyethylene lining and uniformly distributed convex ribs 16. The dispersion impeller rotates along with the rotary feeder, and the materials falling on the dispersion impeller collide with the baffle after being scattered and then fall on the material tray.
The adhesion of the material to the machine surface is mainly due to intermolecular forces, electrostatic forces and liquid bridge forces between the material and the machine surface. In some embodiments, material adhesion is reduced as follows.
1) Selecting materials with weak adhesion
The ultra-high molecular weight polyethylene is a non-metallic material with excellent comprehensive performance, can be applied to the transportation of powder and particle materials, and has been proved to be capable of effectively preventing the materials from adhering. The ultra-high molecular weight polyethylene is selected as the lining of key parts (a rotary feeder, a dispersion disc, a material tray material conveying pipe and a material separator), so that the adhesion of materials is reduced;
2) the roughness of the contact surface of the material is reduced, and the contact area between the machine surface and the material is reduced, so that the intermolecular acting force is reduced;
3) the metal component is grounded, so that the electrostatic force is reduced;
4) keeping the surfaces of the materials and the color sorting device dry, and reducing the liquid bridge force;
5) avoid being difficult to the structure of clearance material, like narrow and small space, gap, aperture etc..
In the existing structure, the material conveying mode has two types of chute type and crawler type. The chute type color sorter utilizes gravity to enable materials to slide along a chute, and certain materials cannot slide at a constant speed or jump up and down in the sliding process, so that the color sorting precision is low. The crawler-type color sorter conveys materials to a sorting area by means of conveying of the crawler. However, the track is easy to adhere materials and is difficult to install the ultra-high molecular weight polyethylene lining plate, so that a special disc type material transmission mechanism, namely a material disc, is adopted in the embodiment of the invention. The charging tray motor drives the charging tray to rotate, and the materials are conveyed to the color detection part, the material sorting part and the material recovery part, so that the materials are further prevented from being compressed, concentrated and adhered.
Embodiments of the present invention are particularly suitable for materials with particle sizes between 40 mesh and 80 mesh, and the basic colors include white, yellow, green, red and black. The material may be mineral powder, mainly including sulfide ore, quartz, feldspar, amphibole, pyroxene, garnet, etc.
The method for the color separation of the materials of the device for the color separation of the materials is used for the color separation and recovery of the 40-80-mesh sulfide ores, the purity of the recovered pyrite is more than 99.2%, and the recovery rate is more than 98.6%.
Example 2
On the basis of the embodiment 1, the embodiment of the invention further improves the material image detection in order to further improve the purity and the recovery rate of the recovered normal material. The color detection component in the embodiment of the invention comprises a light source, a light path and a photoelectric signal detection assembly. Wherein, the light source can be selected from halogen lamp, fluorescent lamp, LED lamp, xenon lamp, and electron luminescent tube. And an LED lamp with better performance is selected as an illumination light source.
The photoelectric signal detection element is a CCD camera component. The CCD camera assembly has a wider spectral response range, faster response speed and longer lifetime. As the ores with different colors are sorted, the color linear array CCD camera assembly is selected as a detection element, and the scanning detection of the materials is completed by utilizing the movement of the material tray.
In the embodiment of the invention, the method adopts a suction mode to extract materials, and in order to realize the extraction of the materials with the minimum size of 80 meshes (0.18mm), the suction holes at least cover half of the area of the materials. And a CCD camera component is adopted for detection, and the size of a CCD pixel is selected to be less than 0.02mm, so that the requirement that the detection error of the position of the material is not more than 0.02mm is met.
In detail, the CCD camera component detects the material with the width of 180mm, the minimum size of a single-grain material is 0.18mm, and a line of material contains 1000 single-grain materials. The number of the selected CCD camera component pixels is at least 2000. If the movement speed of the material during detection is 100mm/s at most, the time for passing a single particle of the material is 1.8ms, and in the time, the CCD needs to finish line scanning, namely the line scanning frequency is not lower than 0.56 KHz. In the color CCD camera assembly, the number of ILX524K pixels of Sony corporation is 2700, the size of the pixels is 8um multiplied by 8um, and the highest transfer clock frequency is 5MHz, so that the requirements can be met.
The optical lens in the CCD camera component is a fixed focus lens. The width is detected for 180mm for the material, detects CCD camera subassembly TCD2564DG pixel size and is 8um, and the pixel number is 2700, and effective photosurface length is 2700 x 8um equals 21.6mm, and then the magnification is 0.12, if the camera lens is placed 300mm department above the material, then focal length f is 0.12/(1+0.12) × 300 equals 32.14 mm. Thus a lens with a focal length of 35mm is chosen.
In order to reduce background noise, the method for selecting the color of the material in the embodiment of the invention further comprises the following steps: in the process of driving the color detection part to acquire the image of the material, taking the material tray as a background plate of the color detection part, wherein the color of the material tray is matched with the normal color; and adjusting the angle between a light source in the color detection part and the material tray so as to adjust the intensity of photoelectric signals generated by the CCD camera assembly for collecting the different-color materials with preset different-color standards.
That is to say, regard charging tray surface as the background board, the colour of charging tray and the material colour matching of predetermineeing normal colour standard, that is to say that the background board colour sets up as far as possible and is close with normal material colour, and the CCD signal voltage that normal material produced like this is close with background board signal voltage, and the signal voltage that heterochromous material produced and background board signal voltage difference is great, can elect heterochromous material from this. Because its angle is not adjustable when using the charging tray as the background board, the light source with adjustment angle between the charging tray can be used for adjusting CCD camera subassembly gathers the intensity of the photoelectric signal that the heterochrosis material of predetermineeing the heterochrosis standard produced, can be based on adjustment LED light source angle in order to obtain the maximum signal to reduce background noise, and then improved the discernment of heterochrosis material, guaranteed the normal material purity and the rate of recovery of retrieving.
In some embodiments, in order to improve the detection accuracy, a double-sided detection mode may also be adopted, that is, two sets of CCD camera assemblies and light sources are provided to detect the material from two sides.
The material color separation method of the material color separation device in the embodiment 2 is used for carrying out color separation recovery on the 40-80-mesh sulfide ore, the purity of the recovered pyrite is more than 99.5%, and the recovery rate is more than 99.4%.
Example 3
In the embodiment of the invention, the material color sorting method adopts an air suction sorting mode, and on the basis of the embodiment 1 and the embodiment 2, the material sorting component is driven to sort the different-color materials according to the relative position; the method comprises the following steps that a material recovery part is driven to recover normal materials which accord with a preset normal color standard and are left in the materials, wherein the relative position comprises the distance between the abnormal materials and the center of a material tray and the rotating target angle of the abnormal materials on the material tray to the position of a ball screw nut of a material sorting part; this step may include:
determining the target position of the different-color material suction nozzle according to the distance between the abnormal material and the center of the material tray; driving the ball screw nut to drive the different-color material suction nozzle of the material sorting component to reach the target position; when the heterochromatic materials are detected to reach the rotating target angle, the electromagnetic valve is driven to switch a gas path to the first exhaust port, and the vacuum pump is driven to suck gas so as to recover the heterochromatic materials; and after the recovery of the heterochromatic materials is finished, driving the electromagnetic valve to switch the gas path to the second gas outlet so as to recover normal materials.
The material sorting component comprises a different-color material suction nozzle 41, a different-color material bin 42, a different-color material separator 43, a ball screw nut 44, a screw nut motor 45 and a vacuum pump 47 provided with an electromagnetic valve 46; the different color material separator 43 is arranged above the different color material bin 42, the first exhaust port 48 is arranged above the different color material separator 43, the side wall of the different color material separator is provided with a first air suction port 49, the first air suction port is communicated with the different color material suction nozzle 41, the different color material suction nozzle 41 is also fixedly connected with the ball screw nut 44, and the ball screw nut 44 is used for positioning the different color material; the screw nut motor 45 is used for driving the ball screw nut 44, so that the ball screw nut 44 drives the different-color material suction nozzle 41 to move, and the different-color material is positioned.
In the embodiment of the invention, the vacuum pump 47 generates vacuum negative pressure, and the different-color materials are sucked away from the normal materials through the different-color material suction nozzle. The diameter of the suction nozzle for the different-color materials is slightly larger than the size of the materials, so that the materials near the target materials can not be sucked. The heterochromatic material suction nozzle is driven by a mechanical device formed by a ball screw, the heterochromatic material suction nozzle is fixed on the ball screw nut and moves together with the ball screw nut to drive, the heterochromatic materials at different positions are accurately sorted, the positioning precision of the heterochromatic materials is ensured, the purity of the recovered normal materials is ensured to be more than 99%, and the recovery rate is more than 99%.
In the embodiment of the invention, the positioning error of the ball screw nut is not more than 0.02mm in consideration of the material position detection error and the size error of an optical system and a mechanism. The ball screw nut is driven by a direct current servo motor. In actual implementation, the pitch of ball screw nut is d, and the accumulative lead error in material detection width 250mm within range is s, and servo motor encoder angle error is phi, then should:
a ball screw nut having a pitch of 5mm, C3 grade accuracy, with a lead error of 0.012mm/315mm, may be selected. The encoder angle error should be selected to be less than 0.5 °.
In some embodiments, a heterochromatic material separator is used to separate material and gas. In order to ensure the recovery rate, a special separator is preliminarily designed, and the separator is the same as a normal material separator in shape and only different in size. The gas that carries the material gets into from the intake pipe, and the material is along the spiral downwardly rotating of inner wall, and the material is got rid of to the separator wall under the effect of centrifugal force to fall into the feed bin under the action of gravity, gas is discharged by the blast pipe. The separator inner wall is installed with ultra high molecular weight polyethylene to prevent sticking. The material sorting component and the material recovery component share one vacuum pump, and the electromagnetic valve is used for switching gas paths of the two components.
The material recovery part comprises a normal material suction nozzle 51, a normal material bin 52 and a normal material separator 53; the normal material separator is arranged above the normal material bin, the second air outlet is arranged above the heterochromatic material separator, and the normal material suction nozzle is arranged on the side wall of the normal material separator; the first exhaust port and the second exhaust port are communicated with a suction port of the vacuum pump through the electromagnetic valve. The material recovery unit and the material sorting unit share a solenoid valve 46 and a vacuum pump 47. The materials on the material tray are sucked from the normal material suction nozzle and are conveyed into the normal material separator through the conveying pipe. The materials and the air are separated in the normal material separator, the materials are recycled to the normal material bin, and the air is discharged from the air outlet. The normal material separator 53 is similar in structure to the abnormal material separator, and differs only in size.
In each embodiment of the invention, the material color selection device is of a disc-air suction structure, and the working process is as follows: the material falls onto the charging tray after passing through the rotary feeder, the dispersion disc and the baffle. The charging tray is driven by a charging tray motor to rotate. And a CCD camera assembly and a lead screw nut are arranged above the material tray. In the process that materials rotate along with a material tray, after the FPGA detects the position of abnormal materials through some detection parts, the FPGA drives a screw nut motor to enable a nut to move to the detection position, a suction pipe fixed with the nut falls down, meanwhile, an electromagnetic valve is switched to a material sorting gas path, a vacuum pump sucks gas, the different-color materials are sucked into a different-color material separator to realize material and gas separation, and the different-color materials fall into a material bin. After all the heterochromatic materials are sorted, the electromagnetic valve is switched to a material recovery gas circuit, the vacuum pump sucks gas, normal materials are sucked into the normal separator to realize material and gas separation, and the normal materials fall into the storage bin. The disc-air suction structure is compact, and the material tray is directly driven by the material tray motor, so that accurate positioning can be easily realized.
The material color separation method of the material color separation device in the embodiment 3 is used for carrying out color separation recovery on the 40-80-mesh sulfide ore, the purity of the recovered pyrite is more than 99.7%, and the recovery rate is more than 99.9%.
Example 4
The material color sorting device in the embodiment of the invention can also comprise a hardware system and a control part consisting of a software system, wherein the control part mainly consists of a Field Programmable Gate Array (FPGA), a first memory, a second memory and a computer program stored on the first memory, and the computer program comprises a control system program and a signal detection and processing system program. The hardware system mainly comprises a plurality of motors, encoders, motor controllers, driving circuits and the like. The FPGA mainly loads programs so as to input control signals and the like to a hardware system. The second memory may be an EPROM.
Wherein, rotatory feeder and dispersion impeller are mainly thrown away after breaking up the material through rotary motion, and is not high to speed and position control accuracy requirement, can adopt ordinary direct current motor drive. The DC motor driver adopts a commercial driver, and generally needs an FPGA to input a control signal and a PWM speed regulation signal.
The charging tray is driven by a charging tray motor to rotate, so that the materials are conveyed. Because the position of the material is determined according to the rotating target angle, the requirement on positioning accuracy is high, a direct current servo motor is needed to be adopted by the motor, and a photoelectric encoder is selected as a position detection element. As shown in fig. 6, the tray is driven by a first dc servo motor (i.e. a tray motor), and the tray is provided with a first encoder, wherein the first encoder is used for detecting a rotation target angle of the tray relative to a preset initial angle, so as to determine the rotation target angle of the material on the tray.
Because the lighting system of the material color selection device is required to have high reliability and the brightness can be adjusted according to the intensity of ambient light, the LED driving chip is adopted, the switching power supply is controlled in a constant current driving mode and a PWM mode, the stability and the adjustability of LED current are ensured, and different control requirements are met.
The vacuum pump control is used to control the vacuum pump to be powered on and off. When suction is required, the vacuum pump is powered on, otherwise, the vacuum pump is powered off. Optionally, a small DC-powered vacuum pump is used. The power-on and power-off are controlled by the MOS tube switch.
And a two-position three-way vacuum electromagnetic valve is selected to realize the gas circuit switching of the material sorting part and the material recovery part. The electromagnetic valve control module mainly controls the electrification and the outage of the electromagnetic valve. The electromagnetic valve is electrified, and the vacuum pump is connected with the air path of the material sorting component; the solenoid valve outage, vacuum pump connection material recovery part gas circuit, it is optional whether circular telegram as switch tube control solenoid valve with the MOS pipe.
The embodiment of the present invention is mainly to improve the step of driving the ball screw nut to drive the different-color material suction nozzle of the material sorting component to reach the target position in the above embodiments, and the step may include:
driving the ball screw nut to drive the heterochromatic material suction nozzle to axially move along the ball screw nut; driving a second encoder arranged on the ball screw nut to detect the displacement of the heterochromatic material suction nozzle moving along the axial direction of the ball screw nut; and driving the ball screw nut according to the target position and the displacement so as to drive the different-color material suction nozzle of the material sorting component to reach the target position.
In detail, as shown in fig. 7, a ball screw nut (referred to as a screw nut for short) is used for driving a suction pipe to complete the sorting of the different-color materials, and the requirement on the position precision is high, so a direct current servo motor is adopted. The ball screw nut is driven by a second direct-current servo motor, and the second direct-current servo motor is used for driving the ball screw nut to drive the heterochromatic material suction nozzle to axially move along the ball screw nut; the ball screw nut is provided with a second encoder, and the second encoder is used for detecting the displacement of the heterochromatic material suction nozzle along the axial movement of the ball screw nut.
The FPGA generates a CCD driving signal, reads image data output by the CCD and processes the image data. The CCD driving signal is generated by the FPGA. Because the IO port level of the FPGA is not consistent with the CCD driving level, the conversion is carried out through a level conversion circuit. The analog signal output by the CCD is converted into a digital signal by the ADC and is sent to the FPGA. The CCD outputs a large amount of data, the real-time requirement is high when the material image is processed and transmitted, but the capacity of a memory in the FPGA is too small to meet the requirement, so that the system adopts the SDRAM as the image cache. The output image data is stored in an SDRAM (second memory) first, and the data is directly read in the SDRAM at the time of image processing. When the external equipment needs the material image data, the material image data is also read from the SDRAM.
As shown in fig. 8, the software system runs on the FPGA and includes a control system program, a signal detection and processing system program, a human-computer interface, and a communication system. The control system program is used for reading the detection data of the detection element and the processing result of the signal detection and processing system, sending a control signal to the hardware system, sending system parameters and information to the human-computer interface, receiving and processing user input of the human-computer interface, and completing communication with external equipment by cooperating with the communication module. The signal detection and processing system program is mainly used for generating a driving waveform required by the CCD work, configuring ADC work parameters, reading CCD data converted by the ADC and processing the CCD data. The signal detection and processing system program in the software system is the core of the software system.
The FPGA loads the computer program to realize the following steps:
the acquired image is one-dimensional image data;
carry out image recognition to the image of gathering, it is in to discern that the heterochrosis material that accords with preset unusual colour standard is in relative position on the charging tray includes:
reading the one-dimensional image data from a preset second memory;
carrying out image recognition on the one-dimensional image data to recognize different color pixel points corresponding to the different color materials;
determining initial coordinates and initial angles of the heterochromatic materials on the charging tray according to a coordinate system established in advance based on the center of the charging tray and the heterochromatic pixel points;
determining the distance between the heterochromatic materials and the center of the material tray according to the initial coordinates;
determining the target position of the different color material suction nozzle according to the distance between the different color material and the center of the material tray;
and determining a rotating target angle of the heterochromatic material required to rotate according to the initial angle and the position of the ball screw nut.
In detail, as shown in fig. 9, the method includes:
step 1, reading one-dimensional image data: driving the CCD camera assembly to acquire one-dimensional image data, wherein the one-dimensional image data is stored in the second memory; reading the one-dimensional image data from the second memory.
Step 2, filtering:
since the one-dimensional image data contains a lot of noise, which causes the color and brightness of the material to deviate from the actual value, the read CCD original image data (one-dimensional image data) needs to be filtered before the image is identified and positioned. The noise in the image data is typically high frequency noise and may optionally be removed by a low pass filter. A median filtering algorithm is used. The algorithm sorts the color values of all pixels in a certain pixel neighborhood according to size, and selects the middle value of the sequence as the color value of the pixel.
Step 3, correcting
Due to the fact that the lengths of different light paths of the optical system are not consistent and the like, the LED light sources which are originally uniformly distributed enter the linear array CCD sensor through the imaging system, and then the phenomenon of nonuniform light energy distribution is generated, specifically, the original output is a straight line, but the straight line is changed into an upward convex curve with a high middle and low two ends, and after the LED light sources are combined into an image, the brightness of the image is obviously reduced from the middle to the two sides. This has just caused very big deviation in the material colour, even the same material, when different positions of spout are passed through to the colour that reflects will obviously be different to the discernment degree of difficulty has been increased. Therefore, correction of the original image data is required.
The photoelectric response outputs of the CCD pixels are generally linear and independent of each other, and their outputs can be expressed by the following formula:
Gi＝Ki·E+Ti
in the formula GiIs the output of the ith CCD pixel, KiIs the response parameter of the ith CCD pixel, E is the light intensity, TiIs the dark current output of the ith CCD pixel. For TiCan be detected by making the light intensity zero. All image data GiDark current T is reduced and removediThen multiply by the response parameter KiObtaining corrected image data Ge：
Correction parameter KiIs composed of
The method for identifying the different color pixel points corresponding to the different color materials by carrying out image identification on the one-dimensional image data comprises the following steps
And 4, color space conversion: and performing color space conversion on the corrected one-dimensional image data.
The image collected by the CCD is based on an RGB model of a color space. The RGB model is a hardware-oriented color space model, which is very different from human eye perception. In the RGB space, luminance values affect all color channels. If the surface roughness of the materials with the same color is different and the color selection environment is different, the color values of the obtained images are different, so that great difficulty is caused for color identification. Three color channels of the HSV color space model are respectively H (hue), S (saturation) and V (brightness), and the RGB model is more suitable for perception of human eyes on colors, and the three color channels are mutually independent, do not interfere with each other and are insensitive to conditions of an acquisition system. For the reflective points formed on the surface of the material, in the RGB space, the brightness value can affect all color channels, in the HSV space, the H channel can hardly be affected, and the brightness can be independently analyzed through the S channel or the V channel, so that the negative effect caused by material reflection is eliminated to the greatest extent. The system thus computationally analyzes by converting the RGB color space to the HSV color space by the color space conversion module.
And 5, judging whether the one-dimensional image data is read for the first time, if so, executing the step 6, and if not, executing the step 7.
And 6, judging whether n (preset) lines are accumulated or not. If yes, executing step 7, otherwise, executing step 1.
And 7, combining the one-dimensional image data obtained by color space conversion into a two-dimensional image.
Step 8, separating foreground from background: separating the material image from the two-dimensional image data.
Background separation is the process of extracting material from the background. Before the material is conveyed by the conveyor belt, reading multi-frame background image data, and calculating the average value of RGB or HSV three-channel data to be used as background color. And starting to convey the materials after obtaining the background color parameters. After the material image information is collected, the difference operation is carried out by using the value of each point of the image and the background color parameter, if the obtained difference value exceeds a certain threshold value, the point is considered as a material point, otherwise, the point is considered as a background point.
Step 9, identifying the different color points: and identifying each pixel point of the separated material image to identify the heterochromatic pixel point corresponding to the heterochromatic material.
And after the foreground and background are separated, identifying each pixel point, and judging whether the pixel points are heterochromatic pixel points or not. Firstly, carrying out difference operation on the value of each pixel point and a set normal material color parameter, and if the difference result is smaller than a certain set threshold value, determining the pixel point as a normal material pixel point; and if the difference result is larger than the threshold value, the material point is considered as a heterochromatic pixel point.
Step 10, image segmentation and positioning: and carrying out image segmentation on the separated material image, and determining the coordinates of the heterochromatic material in the identified heterochromatic pixel points.
And the image segmentation is used for finding out all CCD pixel units corresponding to the different-color materials. And scanning the image data points line by line from left to right and from top to bottom. The coordinates (Xi, Yi) of each metachromatic point are recorded. The dots (Xi-1, Yi), (Xi +1, Yi), (Xi, Yi-1), (Xi, Yi +1), (Xi-1, Yi-1), (Xi +1, Yi-1), (Xi-1, Yi +1), and (Xi +1, Yi +1) adjacent to the dots are checked for heterochromatic dots. If the adjacent points are still different color points, all the adjacent different color points form a different color material. And respectively adding the abscissa and the ordinate of all the pixel points of the different-color material, and obtaining an intermediate value to obtain an initial coordinate value of the different-color material.
And 11, outputting the positions of the different-color materials to finish the positioning of the different-color materials.
The embodiment of the invention can effectively identify and position the position of the heterochromatic material, thereby ensuring that the purity of the recovered normal material is more than 99 percent and the recovery rate is more than 99 percent.
It should be noted that, the above embodiments may be combined arbitrarily without logic errors. Above-mentioned each embodiment chooses ultra-high molecular weight polyethylene as key spare part lining for use, reduces the adhesion of material, utilizes mechanical device to disperse the material, adopts the sorting mode of breathing in to inhale the material pipe with inhaling when conveyer conveys the material and siphons away the heterochrosis material to material position accuracy detects, the accurate positioning of ball screw nut, thereby makes the normal material purity of retrieving more than 99%, and the rate of recovery is more than 99%.
It should be noted that, in this document, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising an … …" does not exclude the presence of other like elements in a process, method, article, or apparatus that comprises the element.
The above-mentioned serial numbers of the embodiments of the present invention are merely for description and do not represent the merits of the embodiments.
Through the above description of the embodiments, those skilled in the art will clearly understand that the method of the above embodiments can be implemented by software plus a necessary general hardware platform, and certainly can also be implemented by hardware, but in many cases, the former is a better implementation manner. Based on such understanding, the technical solutions of the present invention may be embodied in the form of a software product, which is stored in a storage medium (such as ROM/RAM, magnetic disk, optical disk) and includes instructions for enabling a terminal (such as a mobile phone, a computer, a server, an air conditioner, or a network device) to execute the method according to the embodiments of the present invention.
While the present invention has been described with reference to the embodiments shown in the drawings, the present invention is not limited to the embodiments, which are illustrative and not restrictive, and it will be apparent to those skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope of the invention as defined in the appended claims.
Claims (10)
1. A material color selection method for a material color selection device is characterized in that the material color selection device comprises a material supply component, a material conveying component, a color detection component, a material sorting component and a material recovery component; the material supply component, the color detection component, the material sorting component and the material recovery component are sequentially arranged along the material conveying direction of the material conveying component; the material supply part comprises a rotary feeder, a dispersion disc and a baffle plate;
the material color selection method comprises the following steps:
driving a rotary feeder sleeved with a dispersion disc to rotate so as to throw materials out of a material outlet of the rotary feeder; the thrown materials fall on the rotary dispersion disc, collide with the baffle after being scattered and fall on the material conveying part;
driving the material conveying component to move so as to enable the materials to move along the directions of the color detection component, the material sorting component and the material recovery component;
driving a color detection component to acquire an image of the material;
carrying out image recognition on the collected image, and recognizing the relative position of the different-color material on the material tray, wherein the different-color material meets the preset abnormal color standard;
driving the material sorting component to sort the different-color materials according to the relative position;
driving a material recovery part to recover the normal materials which are remained in the materials and meet the preset normal color standard;
the first end of the dispersion plate is sleeved on the rotary feeder, the first end of the rotary feeder is positioned between the first end of the dispersion plate and the second end of the dispersion plate, a material outlet is formed in a shell of the rotary feeder between the first end of the rotary feeder and the first end of the dispersion plate, and the baffle is arranged at the second end of the dispersion plate; a preset gap is reserved between the baffle and the other end of the dispersion disc; a radius of a first end of the rotary feeder is smaller than a radius of a second end of the rotary feeder; the radius of the first end of the dispersion impeller is smaller than the radius of the second end of the dispersion impeller.
2. The material color sorting method according to claim 1, further comprising:
determining the number of the material outlets according to a preset material feeding speed;
and determining the distance between the material outlets according to the preset material scattering distance.
3. The method of color sorting a material according to claim 1, wherein the material conveying member is a disc-type tray;
the material color sorting method further comprises the following steps:
in the process of driving the color detection part to acquire the image of the material, taking the material tray as a background plate of the color detection part, wherein the color of the material tray is matched with the normal color;
and adjusting the angle between a light source in the color detection part and the material tray so as to adjust the intensity of photoelectric signals generated by the CCD camera assembly for collecting the different-color materials with preset different-color standards.
4. The material color sorting method according to claim 1, wherein the relative position includes a distance of the abnormal material with respect to a center of the tray and a rotation target angle of the abnormal material on the tray to a position where a ball screw nut of the material sorting part is located;
the material sorting component is driven to sort the different-color materials according to the relative position; driving a material recovery part to recover the normal materials which are remained in the materials and meet the preset normal color standard; the method comprises the following steps:
determining the target position of the suction nozzle of the different-color material according to the distance between the abnormal material and the center of the material tray;
driving the ball screw nut to drive the different-color material suction nozzle of the material sorting component to reach the target position;
when the heterochromatic materials are detected to reach the rotating target angle, the electromagnetic valve is driven to switch the gas path to the first exhaust port, and the vacuum pump is driven to suck gas so as to recover the heterochromatic materials;
and after the recovery of the heterochromatic materials is finished, the electromagnetic valve is driven to switch the gas path to a second gas outlet so as to recover normal materials.
5. The material color sorting method according to claim 4, further comprising:
and a first encoder arranged on the material tray is driven to detect the rotation angle of the material tray relative to a preset initial angle so as to determine the rotation target angle of the material.
6. The method for color sorting materials according to claim 4, wherein the driving the ball screw nut to drive the different color material suction nozzle of the material sorting component to reach the target position comprises:
driving the ball screw nut to drive the heterochromatic material suction nozzle to axially move along the ball screw nut;
driving a second encoder arranged on the ball screw nut to detect the displacement of the heterochromatic material suction nozzle moving along the axial direction of the ball screw nut;
and driving the ball screw nut according to the target position and the displacement so as to drive the different-color material suction nozzle of the material sorting component to reach the target position.
7. The material color sorting method according to claim 4, wherein the collected image is one-dimensional image data;
carry out image recognition to the image of gathering, it is in to discern that the heterochrosis material that accords with preset unusual colour standard is in relative position on the charging tray includes:
reading the one-dimensional image data from a preset second memory;
carrying out image recognition on the one-dimensional image data to recognize different color pixel points corresponding to the different color materials;
determining initial coordinates and initial angles of the heterochromatic materials on the charging tray according to a coordinate system established in advance based on the center of the charging tray and the heterochromatic pixel points;
determining the distance between the heterochromatic materials and the center of the material tray according to the initial coordinates;
determining the target position of the different color material suction nozzle according to the distance between the different color material and the center of the material tray;
and determining a rotating target angle of the heterochromatic material required to rotate according to the initial angle and the position of the ball screw nut.
8. The material color sorting method according to claim 7, wherein the image recognition of the one-dimensional image data to identify the heterochromatic pixel points corresponding to the heterochromatic material comprises:
performing color space conversion on the one-dimensional image data;
combining the one-dimensional image data obtained by color space conversion into a two-dimensional image;
separating the material image from the two-dimensional image data;
and identifying each pixel point of the separated material image to identify the heterochromatic pixel point corresponding to the heterochromatic material.
9. The material color sorting method according to claim 8, wherein the determining of the initial coordinates and the initial angles of the different color materials on the material tray according to a coordinate system established in advance based on the center of the material tray and the different color pixel points comprises:
carrying out image segmentation on the separated material image;
and determining the initial coordinates and the initial angles of the heterochromatic materials on the charging tray from the segmented images according to a coordinate system and the heterochromatic pixel points which are established in advance based on the center of the charging tray, and determining the initial coordinates of the heterochromatic materials in the identified heterochromatic pixel points.
10. The material color selection method according to any one of claims 1-9, further comprising:
the surface of the rotary feeder, the dispersion disc, the material disc, the heterochromatic material separator of the material sorting part and the normal material separator of the material recovery part, which is contacted with the material, are provided with the ultrahigh molecular weight polyethylene.
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