CN111813030B - Intelligent safety motion controller and control system - Google Patents
Intelligent safety motion controller and control system Download PDFInfo
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- CN111813030B CN111813030B CN202010925477.6A CN202010925477A CN111813030B CN 111813030 B CN111813030 B CN 111813030B CN 202010925477 A CN202010925477 A CN 202010925477A CN 111813030 B CN111813030 B CN 111813030B
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/042—Programme control other than numerical control, i.e. in sequence controllers or logic controllers using digital processors
- G05B19/0423—Input/output
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/20—Pc systems
- G05B2219/24—Pc safety
- G05B2219/24215—Scada supervisory control and data acquisition
Abstract
The invention relates to an intelligent safe motion controller and a control system, which comprise a motion control unit, a CPU, a video interface module, an I/O interface module, a clock, a data synchronous matching module, a storage unit, a communication interface module, a servo drive module and a power supply module. The invention utilizes the video interface module to receive an external video collector, and can monitor the motion action of the mechanical execution part in real time; the video data and the motion trail data can be subjected to clock synchronization, and whether the motion trail is consistent with the motion action of the mechanical execution part or not is monitored and analyzed; the video synchronization data can be stored, so that the fault tracing is facilitated; the intelligent analysis and diagnosis system has a video comparison function, monitors the motion of the mechanical execution part in real time, compares the motion with the motion video data of the motion of the normal mechanical execution part recorded in advance, intelligently analyzes and diagnoses whether the mechanical execution part is abraded, faulted and invaded by other foreign matters, and realizes intelligent analysis, diagnosis and safe motion control.
Description
Technical Field
The invention relates to an intelligent safety motion controller and a control system, and belongs to the technical field of motion control.
Background
In some motion control application occasions, because of the closed and semi-closed arrangement of the mechanical execution component, the motion action of the mechanical execution component cannot be observed through human eyes, and a debugging person can only deduce whether the mechanical execution component and the motion action thereof are normal according to the final result of the motion action of the mechanical execution component in the debugging process, so that the debugging efficiency is low. Meanwhile, when the mechanical execution component fails, the internal scene of the failed mechanical execution component cannot be restored, and the failure reason is difficult to trace. In addition, when the mechanical execution part is worn, has faults and other foreign matters invade to cause faults, the faults cannot be found in time, and larger production accidents are caused.
For the safety protection of a motion control system, at present, an external safety component is generally added to the motion control system, such as a safety light curtain, a safety pedal, a safety pull rope, and the like, when an external person or foreign matter abnormally invades an operating mechanical execution component, the external safety component sends a safety signal to the control system to drive the mechanical execution component to stop operating emergently, and such a safety protection measure is generally arranged at the periphery of the mechanical execution component, and cannot effectively protect the abrasion and the fault inside the mechanical execution component and the invasion of the foreign matter dropped from production materials.
The patent with publication number CN204154570U discloses a motion control system and a control method thereof; the patent with publication number CN101794139A discloses a method and a device for constructing a motion controller and the motion controller; the publication No. CN101256407A discloses an integrated motion control system of laser, vibrating mirror and motor; the publication number is CN102411353A discloses a driving and controlling integrated controller; the publication number CN204557101U discloses a PCI motion control card; publication No. CN204374700U discloses a motion controller; publication No. CN206848778U discloses a motion control card and control system; the motion controller and control system disclosed in the above patents do not have a video interface module and an intelligent security function.
Therefore, there is an urgent need for a motion control device and a corresponding control system capable of realizing intelligent analysis, diagnosis, tracing and safety functions, so as to improve debugging efficiency and ensure safe production.
Disclosure of Invention
Aiming at the defects in the prior art, the invention provides an intelligent safe motion controller and a control system, and the specific technical scheme is as follows:
a smart security motion controller comprising:
the motion control unit is used for generating motion track data;
CPU, is used for data operation, program control;
the video interface module is used for receiving the video data of the external video collector and transmitting the video data to the CPU;
the I/O interface module is used for receiving the safety data of the external safety component and transmitting the safety data to the CPU;
a clock for generating clock data;
the data synchronization matching module generates video synchronization data by matching the motion track data, the video data and the clock data transmitted by the CPU in a clock synchronization manner;
the storage unit is used for storing video synchronization data generated by the data synchronization matching module and receiving action video data of normal external mechanical execution part movement, which is recorded in advance by an external video collector, by the CPU through the video interface module;
the communication interface module is used for transmitting the video synchronous data to an external video display terminal;
the servo driving module drives an external servo motor according to the motion track data generated by the motion control unit;
and the power supply module is used for supplying power.
As an improvement of the technical scheme, the CPU transmits the motion track data generated by the motion control unit, the video data acquired by the video interface module and the clock data generated by the clock to the data synchronization matching module in real time, generates the video synchronization data in a clock synchronization matching mode and transmits the video synchronization data to the storage unit for storage; meanwhile, the servo driving module drives an external servo motor according to the motion track data generated by the motion control unit, and the servo motor drives the mechanical execution part to perform corresponding action; reading the video synchronization data in the storage unit to a display terminal through a communication interface module;
the CPU receives the action video data of the normal external mechanical execution part movement recorded in advance by the external video collector through the video interface module and stores the action video data into the storage unit;
then, when the CPU receives real-time video data of real-time movement of the external mechanical execution part through the video interface module, the real-time video data is compared with pre-stored action video data of normal external mechanical execution part movement, wherein the real-time video data is obtained by recording the real-time movement of the external mechanical execution part through an external video collector;
when the comparison result is inconsistent, indicating that the safety information of mechanical abrasion, failure or foreign matter invasion exists;
meanwhile, the CPU reads the safety data of the external safety component through the I/O interface module, the CPU transmits the safety data to the motion control unit, and the motion control unit drives the servo driving module to stop working emergently.
As an improvement of the above technical solution, the control flow of the video synchronization data includes the following steps:
step S101: reading video data
The CPU receives video data through the video interface module and transmits the video data to the data synchronization matching module, and then step S102 is executed;
step S102: reading motion track data
The CPU reads the motion track data generated by the motion control unit and transmits the motion track data to the data synchronization matching module, and then step S103 is executed;
step S103: reading clock data
The CPU reads the clock data generated by the clock and transmits the clock data to the data synchronization matching module, and then step S104 is executed;
step S104: generating video synchronization data
The data synchronization matching module synchronizes and matches the video data, the motion trail data and the clock data in a clock synchronization mode to generate video synchronization data, synchronizes the video data and the motion trail data under the same clock, and then executes the step S105;
step S105: storing video synchronization data
The data synchronization matching module transmits the video synchronization data to the storage unit and stores the video synchronization data, and then step S106 is executed;
step S106: transmitting video synchronization data
The CPU reads the video synchronization data in the storage unit, transmits the video synchronization data to the communication interface module, and the external display terminal reads and displays the video synchronization data through the communication interface module, and then returns to the step S101 for execution.
As an improvement of the above technical solution, the flow of the intelligent security motion controller for intelligent security control includes the following steps:
step S201: reading the video data, and then executing step S202;
step S202: judging whether the motion video of the normal external mechanical execution part motion is stored or not, and if the judgment result is yes, executing the step S203; if the determination result is negative, executing step S204;
step S203: storing the motion video of the normal external mechanical execution part motion, and then returning to the step S201 for execution;
step S204: judging whether the read video data are consistent with the stored motion video of the normal external mechanical execution component, if so, executing the step S205; if the determination result is negative, go to step S207;
step S205: reading the security data of the external security component, and then performing step S206;
step S206: judging whether an external safety component sends out a safety signal or not, and if so, executing the step S207; if the judgment result is no, returning to the step S201 for execution;
step S207: and (4) emergency stopping.
As an improvement of the above technical solution, the method for monitoring mechanical wear comprises the following steps:
the CPU reads the motion track data of the motion control unit and judges whether the motion state is switched;
when the previous motion state is switched to the next motion state, sending an instruction to a video interface module, capturing static image data in the current motion state from video stream data, and performing size measurement and surface defect detection on the static image data in different motion states;
when the size error exceeds a preset threshold value or surface defect abrasion occurs, sending alarm information of a corresponding level;
the CPU acquires alarm information, if mechanical abrasion is found, the safety information of the mechanical abrasion is transmitted to the motion control unit, and the motion control unit drives the servo driving module to stop working emergently.
As an improvement of the above technical solution, the method for measuring the dimension and detecting the surface defect comprises the following steps:
step S301: collecting different motion states
、
、...、
Lower corresponding static good image
、
、...、
Taking the static good product image as a good product comparison template; static good image is marked in advance by adopting manual method
，
，...，
Dividing the region of interest to obtain a corresponding region of interest set
，
，...，
(ii) a Wherein n is a positive integer;
step S302: capturing the current motion state
In real time
Calculating a static image
And static good image
，
，...，
Similarity between still images, the still image having the greatest similarity
Corresponding motion state
The current motion state is obtained; at the same time, the static image of the current motion state is takenCorresponding region of interest
Delivery to images
；
Wherein the content of the first and second substances,
different motion states are represented, and the value range is a positive integer;
a motion state representing a current position;
in order to be the maximum value of the similarity,
a solution of maximum similarity for motion states;
is a similarity function;
is a function of taking the minimum value;
step S303: in the image
Traversing all the regions of interest, extracting features by adopting a row gradient difference value and a column gradient difference value to obtain a discrete point set of a straight line and an oblique line, and extracting features by adopting a radial gradient difference value to obtain a discrete point set of a circular arc;
carrying out interference point elimination on the discrete point set by using open and close operation, and carrying out least square fitting on the discrete point set after the interference points are eliminated to obtain a curve equation; solving the vertical distance, the arc radius or the center point coordinate between the curve equations, namely measuring the corresponding dimension value;
step S304: performing difference on the direct matrix, and calculating a characteristic map of the image
，
Wherein the content of the first and second substances,
calculating absolute value;
obtaining a feature map of an image
Then, carrying out convolution operation by using a small convolution kernel, and extracting local features; then, carrying out similarity judgment on Euclidean distance on the local features, and if the Euclidean distance similarity judgment exceeds a set threshold, taking the local covered by the convolution kernel as a whole to carry out defect position identification recording; identifying all locations marked as defects to an image
And finally obtaining a detection effect graph.
As an improvement of the above technical solution, the method for monitoring the fault or the intrusion of the foreign object includes:
receiving video data through a video interface module, carrying out real-time video online monitoring on faults or foreign matter invasion through a template comparison algorithm, and acquiring a monitoring result by a CPU (central processing unit); if the safety information of the fault or the intrusion of the foreign matters is found, the safety information of the fault or the intrusion of the foreign matters is transmitted to the motion control unit, and the motion control unit drives the servo driving module to emergently stop working;
step S401: collecting action video clips of normal movement of an external mechanical execution part in a complete movement period as a positive template;
step S402: reading the factTime video synchronization data
Time of day
Conversion to time within a cycle
Acquiring the positive template data frame at the same time in the same period
；
Step S403: real-time video synchronization data
And the positive template data frame of the time in the same period
Comparing the templates to obtain a characteristic diagram
(ii) a In the feature diagram
Performing sliding convolution operation to obtain a local characteristic diagram; and (4) sending the local feature map into an SVM classifier for classification and prediction, judging whether a fault or foreign matter invasion condition exists at the position corresponding to the convolution kernel, and identifying the detection result.
An intelligent safety control system comprises the intelligent safety motion controller.
As an improvement of the technical scheme, the safety component is a safety light curtain, a safety pedal or a safety pull rope, and the intelligent safety motion controller records and stores motion video data of normal motion of the external mechanical execution component through the video collector; then, the intelligent safety motion controller acquires real-time motion video data of the external mechanical execution component through the video collector, and compares the real-time motion video data with stored motion video data of the normal external mechanical execution component; when the comparison result is inconsistent, indicating that the safety information of mechanical abrasion, failure or foreign matter invasion exists; simultaneously, the intelligent safety motion controller reads the safety data of the safety light curtain, the safety pedal and the safety pull rope; when the safety light curtain, the safety pedal or the safety pull rope sends out a safety signal, the intelligent safety motion controller drives the servo motor to stop working emergently, and intelligent safety motion control is achieved.
The invention has the beneficial effects that:
1) the invention utilizes the video interface module to receive the external video collector, and can monitor the motion action of the mechanical execution part in real time.
2) The invention can perform clock synchronization on the video data and the motion track data by utilizing the data synchronization matching module, and monitors and analyzes whether the motion track is consistent with the motion action of the mechanical execution part.
3) By arranging the storage unit, the video synchronization data can be stored, and the fault tracing is facilitated.
4) The intelligent safety motion controller has a video comparison function, can record action video data of the motion of a normal mechanical execution component in advance, monitors the motion of the mechanical execution component in real time later, compares the action video data with the action video data of the motion of the normal mechanical execution component recorded in advance, intelligently analyzes and diagnoses whether the mechanical execution component is abraded, faulted and invaded by other foreign matters, and realizes intelligent analysis, diagnosis and safe motion control.
Drawings
FIG. 1 is a schematic diagram of an intelligent safety motion controller according to the present invention;
FIG. 2 is a schematic structural diagram of the intelligent security control system according to the present invention;
FIG. 3 is a control flow diagram of video synchronization data according to the present invention;
FIG. 4 is a diagram of a storage format of video synchronization data according to the present invention;
FIG. 5 is a schematic diagram illustrating the display effect of the video synchronization data according to the present invention;
FIG. 6 is a control flow diagram of the intelligent safety motion controller according to the present invention;
FIG. 7 is a block diagram of a method of dimensional measurement and surface defect detection in accordance with the present invention;
FIG. 8 is a block diagram of the template comparison algorithm of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
Example 1
As shown in fig. 1 and 2, the intelligent security motion controller 100 includes:
and a motion control unit 108 for generating motion trajectory data.
The video interface module 102 is used for receiving video data of the external video collector 1 and transmitting the video data to the CPU 109; wherein, the CPU109 is the reference numeral 109 of the CPU.
And the I/O interface module 103 is used for receiving the safety data of the external safety component and transmitting the safety data to the CPU 109.
A clock 110 for generating clock data.
The data synchronization matching module 104 generates video synchronization data by matching the motion trajectory data, the video data and the clock data transmitted from the CPU109 in a clock synchronization manner.
And the storage unit 105 is used for storing the video synchronization data generated by the data synchronization matching module and the action video data of the normal external mechanical execution part movement, which is recorded in advance by the external video collector 1, received by the CPU109 through the video interface module 102.
And the communication interface module 106 is used for transmitting the video synchronization data to an external video display terminal.
The servo drive module 107 drives the external servo motor 5 according to the motion trajectory data generated by the motion control unit 108.
The CPU109 is used for data arithmetic and program control.
And the power supply module 101 is used for supplying power.
The intelligent security motion controller 100 is implemented as follows:
the CPU109 transmits the motion trajectory data generated by the motion control unit 108, the video data acquired through the video interface module 102, and the clock data generated by the clock 110 to the data synchronization matching module 104 in real time, generates video synchronization data in a clock synchronization matching manner, and transmits the video synchronization data to the storage unit 105 for storage; meanwhile, the servo driving module 107 drives the external servo motor 5 according to the motion trajectory data generated by the motion control unit 108, and the servo motor 5 drives the mechanical executing component to perform corresponding actions; the video synchronization data in the storage unit 105 is read to the display terminal through the communication interface module 106, and finally intelligent analysis, diagnosis and retroactive motion control are realized.
The video synchronization data is only used for driving the external servo motor 5 to perform corresponding actions according to the generated motion track data, and is used for monitoring and analyzing whether the motion track is consistent with the motion actions of the execution component, so that the purposes of intelligent analysis, diagnosis and tracing are achieved.
CPU109 receives the action video data of normal external mechanical execution component movement recorded in advance by external video collector 1 through video interface module 102, and stores the action video data into storage unit 105; then, when the CPU109 receives real-time video data of real-time movement of the external mechanical execution component through the video interface module 102, the real-time video data is compared with pre-stored motion video data of normal motion of the external mechanical execution component, where the real-time video data is obtained by recording real-time movement of the external mechanical execution component through an external video collector;
when the comparison result is inconsistent, indicating that the safety information of mechanical abrasion, failure or foreign matter invasion exists;
meanwhile, the CPU109 reads the safety data of the external safety component through the I/O interface module 103, the CPU109 transmits the safety data to the motion control unit 108, and the motion control unit 108 drives the servo driving module 107 to stop working emergently, so that intelligent and safe motion control is realized.
Example 2
As shown in fig. 2, the intelligent security control system includes a video collector 1, a security light curtain 2, a security pedal 3, a security rope 4, a servo motor 5, and an intelligent security motion controller 100, wherein the video collector 1, the security light curtain 2, the security pedal 3, the security rope 4, and the servo motor 5 are all located outside the intelligent security motion controller 100, and the security light curtain 2, the security pedal 3, and the security rope 4 all belong to an external security component.
The intelligent safety motion controller 100 records and stores the motion video data of the normal motion of the external mechanical execution part through the video collector 1; then, the intelligent safety motion controller 100 acquires real-time motion video data of the motion of the external mechanical execution component through the video collector 1, and compares the real-time motion video data with the stored motion video data of the motion of the normal external mechanical execution component; when the comparison result is inconsistent, indicating that the safety information of mechanical abrasion, failure or foreign matter invasion exists; meanwhile, the intelligent safety motion controller 100 reads the safety data of the safety light curtain 2, the safety pedal 3 and the safety pull rope 4; when the safety light curtain 2, the safety pedal 3 or the safety pull rope 4 sends out a safety signal, the intelligent safety motion controller 100 drives the servo motor 5 to stop working emergently, so that intelligent safety motion control is realized.
Example 3
As shown in fig. 3, the control flow of video synchronization data monitoring, storing and tracing includes the following steps:
step S101: reading video data
The CPU109 receives the video data through the video interface module 102 and transmits the video data to the data synchronization matching module 104, and then executes step S102; the video data here is video data recorded by the external video collector 1.
Step S102: reading motion track data
The CPU109 reads the motion trajectory data generated by the motion control unit 108 and transmits to the data synchronization matching module 104, after which step S103 is executed.
Step S103: reading clock data
The CPU109 reads the clock data generated by the clock 110 and transmits to the data synchronization matching module 104, after which step S104 is executed.
Step S104: generating video synchronization data
The data synchronization matching module 104 synchronizes and matches the video data, the motion trajectory data, and the clock data in a clock synchronization manner to generate video synchronization data, specifically, the synchronization manner is to generate video synchronization data according to the video synchronization data format of fig. 4, synchronize the video data and the motion trajectory data at the same clock, and then execute step S105.
Step S105: storing video synchronization data
The data sync matching module 104 transmits and stores the video sync data to the storage unit 105, and then performs step S106.
Step S106: transmitting video synchronization data
The CPU109 reads the video synchronization data in the storage unit 105, transfers the video synchronization data to the communication interface module 106, and the external display terminal reads and displays the video synchronization data through the communication interface module 106, with the display effect shown in fig. 5, and then returns to step S101 for execution.
Example 4
As shown in fig. 6, the flow of the intelligent security motion controller 100 for intelligent security control includes the following steps:
step S201: the video data is read, and then step S202 is performed.
Step S202: judging whether the motion video of the normal external mechanical execution part motion is stored or not, and if the judgment result is yes, executing the step S203; if the determination result is negative, executing step S204;
step S203: storing the motion video of the normal external mechanical execution part motion, and then returning to the step S201 for execution;
step S204: judging whether the read video data are consistent with the stored motion video of the normal external mechanical execution component, if so, executing the step S205; if the determination result is negative, go to step S207;
step S205: reading the security data of the external security component, and then performing step S206;
step S206: judging whether an external safety component sends out a safety signal or not, and if so, executing the step S207; if the judgment result is no, returning to the step S201 for execution;
step S207: and (4) emergency stopping.
Example 5
The monitoring method of the mechanical wear comprises the following steps:
the CPU109 reads the motion trajectory data of the motion control unit 108, and determines whether the motion state is switched;
when the previous motion state is switched to the next motion state, an instruction is sent to the video interface module 102, the still image data in the current motion state is captured from the video stream data, and the size measurement and the surface defect detection are performed on the still image data in different motion states.
And when the size error exceeds a preset threshold value or surface defect abrasion occurs, sending alarm information of a corresponding level.
The CPU109 acquires the alarm information, and if mechanical wear is found, transmits the safety information of the occurrence of mechanical wear to the motion control unit 108, and the motion control unit 108 drives the servo drive module 107 to perform emergency stop operation, thereby implementing intelligent and safe motion control.
Example 6
As shown in fig. 7, the method of dimension measurement and surface defect detection is as follows:
step S301: collecting different motion states
、
、...、
Lower corresponding static good product diagramImage
、
、...、
Taking the static good product image as a good product comparison template; static good image is marked in advance by adopting manual method
，
，...，
Dividing the region of interest to obtain a corresponding region of interest set
，
，...，
(ii) a Wherein n is a positive integer.
Wherein the movement state is collected
Lower static good image
Collecting the motion state
Lower static good image
Collecting the motion state
Lower static good image
(ii) a Static good image is marked in advance by adopting manual method
Dividing the region of interest to obtain a corresponding region of interest set
(ii) a Static good image is marked in advance by adopting manual method
Dividing the region of interest to obtain a corresponding region of interest set
(ii) a Static good image is marked in advance by adopting manual method
Dividing the region of interest to obtain a corresponding region of interest set
。
Step S302: capturing the current motion state
In real time
Separately calculating static images
And static stateGood product image
，
，...，
Similarity between still images, the still image having the greatest similarity
Corresponding motion state
The current motion state is obtained; at the same time, the static image of the current motion state is taken
Corresponding region of interest
Delivery to images
；
Wherein the content of the first and second substances,
different motion states are represented, and the value range is a positive integer;
a motion state representing a current position;
the value is the maximum similarity value, and the smaller the value is, the higher the similarity is;
a solution of maximum similarity for motion states;
is a similarity function, such as Euclidean distance;
is a function of taking the minimum value.
Step S303: in the image
Traversing all the regions of interest, extracting features by adopting a row gradient difference value and a column gradient difference value to obtain a discrete point set of a straight line and an oblique line, and extracting features by adopting a radial gradient difference value to obtain a discrete point set of a circular arc;
carrying out interference point elimination on the discrete point set by using open and close operation, and carrying out least square fitting on the discrete point set after the interference points are eliminated to obtain a curve equation; and solving the vertical distance, the arc radius or the central point coordinate between the curve equations, and measuring the corresponding dimension value.
Step S304: performing difference on the direct matrix, and calculating a characteristic map of the image
，
Wherein the content of the first and second substances,
the absolute value is taken for operation.
Obtaining a feature map of an image
Then, carrying out convolution operation by using a small convolution kernel, and extracting local features; then, carrying out similarity judgment on Euclidean distance on the local features, and if the Euclidean distance similarity judgment exceeds a set threshold, taking the local covered by the convolution kernel as a whole to carry out defect position identification recording; identifying all locations marked as defects to an image
And finally obtaining a detection effect graph.
Before size measurement, the detection method firstly compares the similarity of a static image and a static good image to determine the current motion state and avoid size detection errors in motion; meanwhile, the method divides the static image into a plurality of interested areas, compares the interested areas with the static good image, and overcomes the defects of high calculation complexity and large memory space compared with the common method for searching the shape curve by edge detection, reduces the calculation amount, can obtain the detection result in a short time, has high real-time performance, and is suitable for the video monitoring of the action of the mechanical execution part running at high speed.
Example 7
The fault and foreign matter invasion monitoring method comprises the following implementation processes: video data is received through the video interface module 102. And carrying out real-time video online monitoring on faults and foreign matter invasion through a template comparison algorithm. The CPU109 acquires the detection result, and if the safety information of the failure or the intrusion of the foreign object is found, transmits the safety information to the motion control unit 108, and the motion control unit 108 drives the servo drive module 107 to stop the operation in an emergency, thereby realizing the motion control of the intelligent security.
As shown in fig. 8, the template alignment algorithm includes the following steps:
step S401: and collecting the action video clips of the normal movement of the external mechanical execution part in the complete movement period as a positive template.
Step S402: reading real-time video synchronization data
Time of day
Conversion to time within a cycle
Acquiring the positive template data frame at the same time in the same period
。
Step S403: real-time video synchronization data
And the positive template data frame of the time in the same period
Comparing the templates to obtain a characteristic diagram
(ii) a In the feature diagram
Performing sliding convolution operation to obtain a local characteristic diagram; and (4) sending the local feature map into an SVM classifier for classification and prediction, judging whether a fault or foreign matter invasion condition exists at the position corresponding to the convolution kernel, and identifying the detection result. Among them, the real-time video frame in FIG. 8
Pertaining to real-time video synchronization data
Moment of movement in the figure
Pertaining to time within a cycle
Good product picture
Belonging to positive template data frame
。
The template comparison algorithm abstracts one frame of image in a characteristic graph mode, extracts key element points for detection, avoids detecting the whole image, improves the detection efficiency and has the advantage of high real-time performance.
In the above embodiment, the intelligent security motion controller and the intelligent security control system have the following advantages:
1) the invention utilizes the video interface module 102 to receive the external video collector 1, and can monitor the motion action of the mechanical execution part in real time.
2) The invention utilizes the data synchronization matching module 104 to perform clock synchronization on the video data and the motion track data and monitor and analyze whether the motion track is consistent with the motion action of the mechanical execution part.
3) By arranging the storage unit, the video synchronization data can be stored, and the fault tracing is facilitated.
4) The intelligent safety motion controller has a video comparison function, can record action video data of the motion of a normal mechanical execution component in advance, monitors the motion of the mechanical execution component in real time later, compares the action video data with the action video data of the motion of the normal mechanical execution component recorded in advance, intelligently analyzes and diagnoses whether the mechanical execution component is abraded, faulted and invaded by other foreign matters, and realizes intelligent analysis, diagnosis and safe motion control.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents and improvements made within the spirit and principle of the present invention are intended to be included within the scope of the present invention.
Claims (6)
1. An intelligent safety motion controller, comprising:
the motion control unit is used for generating motion track data;
CPU, is used for data operation, program control;
the video interface module is used for receiving the video data of the external video collector and transmitting the video data to the CPU;
the I/O interface module is used for receiving the safety data of the external safety component and transmitting the safety data to the CPU;
a clock for generating clock data;
the data synchronization matching module generates video synchronization data by matching the motion track data, the video data and the clock data transmitted by the CPU in a clock synchronization manner;
the storage unit is used for storing video synchronization data generated by the data synchronization matching module and receiving action video data of normal external mechanical execution part movement, which is recorded in advance by an external video collector, by the CPU through the video interface module;
the communication interface module is used for transmitting the video synchronous data to an external video display terminal;
the servo driving module drives an external servo motor according to the motion track data generated by the motion control unit;
the power supply module is used for supplying power;
the CPU transmits the motion track data generated by the motion control unit, the video data acquired by the video interface module and the clock data generated by the clock to the data synchronization matching module in real time, generates video synchronization data in a clock synchronization matching mode and transmits the video synchronization data to the storage unit for storage; meanwhile, the servo driving module drives an external servo motor according to the motion track data generated by the motion control unit, and the servo motor drives the mechanical execution part to perform corresponding action; reading the video synchronization data in the storage unit to a display terminal through a communication interface module;
the CPU receives the action video data of the normal external mechanical execution part movement recorded in advance by the external video collector through the video interface module and stores the action video data into the storage unit;
then, when the CPU receives real-time video data of real-time movement of the external mechanical execution part through the video interface module, the real-time video data is compared with pre-stored action video data of normal external mechanical execution part movement, wherein the real-time video data is obtained by recording the real-time movement of the external mechanical execution part through an external video collector;
when the comparison result is inconsistent, indicating that the safety information of mechanical abrasion, failure or foreign matter invasion exists;
meanwhile, the CPU reads the safety data of the external safety component through the I/O interface module, the CPU transmits the safety data to the motion control unit, and the motion control unit drives the servo driving module to stop working emergently;
the monitoring method of the mechanical wear comprises the following steps:
the CPU reads the motion track data of the motion control unit and judges whether the motion state is switched;
when the previous motion state is switched to the next motion state, sending an instruction to a video interface module, capturing static image data in the current motion state from video stream data, and performing size measurement and surface defect detection on the static image data in different motion states;
when the size error exceeds a preset threshold value or surface defect abrasion occurs, sending alarm information of a corresponding level;
the CPU acquires alarm information, if mechanical abrasion is found, the safety information of the mechanical abrasion is transmitted to the motion control unit, and the motion control unit drives the servo driving module to emergently stop working;
the method for dimension measurement and surface defect detection is as follows:
step S301: gathering different movementsStatus of state
、
、...、
Lower corresponding static good image
、
、...、
Taking the static good product image as a good product comparison template; static good image is marked in advance by adopting manual method
，
，...，
Dividing the region of interest to obtain a corresponding region of interest set
，
，...，
(ii) a Wherein n is a positive integer;
step S302: capturing the current motion state
In real time
Calculating a static image
And static good image
，
，...，
Similarity between still images, the still image having the greatest similarity
Corresponding motion state
The current motion state is obtained; at the same time, the static image of the current motion state is taken
Corresponding region of interest
Delivery to images
；
Wherein the content of the first and second substances,
different motion states are represented, and the value range is a positive integer;
a motion state representing a current position;
in order to be the maximum value of the similarity,
a solution of maximum similarity for motion states;
is a similarity function;
is a function of taking the minimum value;
step S303: in the image
Traversing all the regions of interest, extracting features by adopting a row gradient difference value and a column gradient difference value to obtain a discrete point set of a straight line and an oblique line, and extracting features by adopting a radial gradient difference value to obtain a discrete point set of a circular arc;
carrying out interference point elimination on the discrete point set by using open and close operation, and carrying out least square fitting on the discrete point set after the interference points are eliminated to obtain a curve equation; solving the vertical distance, the arc radius or the center point coordinate between the curve equations, namely measuring the corresponding dimension value;
step S304: performing difference on the direct matrix, and calculating a characteristic map of the image
，
Wherein the content of the first and second substances,
calculating absolute value;
obtaining a feature map of an image
Then, carrying out convolution operation by using a small convolution kernel, and extracting local features; then, carrying out similarity judgment on Euclidean distance on the local features, and if the Euclidean distance similarity judgment exceeds a set threshold, taking the local covered by the convolution kernel as a whole to carry out defect position identification recording; identifying all locations marked as defects to an image
And finally obtaining a detection effect graph.
2. The intelligent security motion controller of claim 1, wherein the control flow of the video synchronization data comprises the following steps:
step S101: reading video data
The CPU receives video data through the video interface module and transmits the video data to the data synchronization matching module, and then step S102 is executed;
step S102: reading motion track data
The CPU reads the motion track data generated by the motion control unit and transmits the motion track data to the data synchronization matching module, and then step S103 is executed;
step S103: reading clock data
The CPU reads the clock data generated by the clock and transmits the clock data to the data synchronization matching module, and then step S104 is executed;
step S104: generating video synchronization data
The data synchronization matching module synchronizes and matches the video data, the motion trail data and the clock data in a clock synchronization mode to generate video synchronization data, synchronizes the video data and the motion trail data under the same clock, and then executes the step S105;
step S105: storing video synchronization data
The data synchronization matching module transmits the video synchronization data to the storage unit and stores the video synchronization data, and then step S106 is executed;
step S106: transmitting video synchronization data
The CPU reads the video synchronization data in the storage unit, transmits the video synchronization data to the communication interface module, and the external display terminal reads and displays the video synchronization data through the communication interface module, and then returns to the step S101 for execution.
3. The intelligent security motion controller of claim 1, wherein the process of the intelligent security motion controller for intelligent security control comprises the following steps:
step S201: reading the video data, and then executing step S202;
step S202: judging whether the motion video of the normal external mechanical execution part motion is stored or not, and if the judgment result is yes, executing the step S203; if the determination result is negative, executing step S204;
step S203: storing the motion video of the normal external mechanical execution part motion, and then returning to the step S201 for execution;
step S204: judging whether the read video data are consistent with the stored motion video of the normal external mechanical execution component, if so, executing the step S205; if the determination result is negative, go to step S207;
step S205: reading the security data of the external security component, and then performing step S206;
step S206: judging whether an external safety component sends out a safety signal or not, and if so, executing the step S207; if the judgment result is no, returning to the step S201 for execution;
step S207: and (4) emergency stopping.
4. The intelligent safety motion controller according to claim 1, wherein the monitoring method of the fault or the intrusion of the foreign object is as follows:
receiving video data through a video interface module, carrying out real-time video online monitoring on faults or foreign matter invasion through a template comparison algorithm, and acquiring a monitoring result by a CPU (central processing unit); if the safety information of the fault or the intrusion of the foreign matters is found, the safety information of the fault or the intrusion of the foreign matters is transmitted to the motion control unit, and the motion control unit drives the servo driving module to emergently stop working;
step S401: collecting action video clips of normal movement of an external mechanical execution part in a complete movement period as a positive template;
step S402: reading real-time video synchronization data
Time of day
Conversion to time within a cycle
Acquiring the positive template data frame at the same time in the same period
；
Step S403: real-time video synchronization data
And the positive template data frame of the time in the same period
Comparing the templates to obtain a characteristic diagram
(ii) a In the feature diagram
Performing sliding convolution operation to obtain a local characteristic diagram; and (4) sending the local feature map into an SVM classifier for classification and prediction, judging whether a fault or foreign matter invasion condition exists at the position corresponding to the convolution kernel, and identifying the detection result.
5. An intelligent safety control system, comprising an intelligent safety motion controller as claimed in any one of claims 1-4.
6. The intelligent safety control system according to claim 5, wherein the safety component is a safety light curtain, a safety pedal or a safety pull rope, and the intelligent safety motion controller records and stores motion video data of normal external mechanical execution component motion through a video collector; then, the intelligent safety motion controller acquires real-time motion video data of the external mechanical execution component through the video collector, and compares the real-time motion video data with stored motion video data of the normal external mechanical execution component; when the comparison result is inconsistent, indicating that the safety information of mechanical abrasion, failure or foreign matter invasion exists; simultaneously, the intelligent safety motion controller reads the safety data of the safety light curtain, the safety pedal and the safety pull rope; when the safety light curtain, the safety pedal or the safety pull rope sends out a safety signal, the intelligent safety motion controller drives the servo motor to stop working emergently, and intelligent safety motion control is achieved.
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