CN111855796A

CN111855796A - Contact surface detection device and method for electric energy conduction of rotating equipment

Info

Publication number: CN111855796A
Application number: CN202010922142.9A
Authority: CN
Inventors: 李杰明
Original assignee: Zhejiang Gas & Thermoelectricity Design Institute Co ltd
Current assignee: Zhejiang Gas & Thermoelectricity Design Institute Co ltd
Priority date: 2020-09-04
Filing date: 2020-09-04
Publication date: 2020-10-30
Anticipated expiration: 2040-09-04
Also published as: CN111855796B

Abstract

The invention relates to a contact surface detection device for electric energy conduction of rotating equipment and a method thereof, the scheme comprises a body, wherein an image data acquisition unit which is in communication connection with the body is arranged on the body, and a power supply module, a high-speed acquisition module, a recording and storing module, a data processing unit, a judgment and decision unit, a network module and an information output module are arranged in the body.

Description

Contact surface detection device and method for electric energy conduction of rotating equipment

Technical Field

The invention relates to a detection device, in particular to a contact surface detection device for electric energy conduction of rotating equipment.

Background

At present, for the electric energy conduction of equipment in high-speed rotation, the electric energy conduction media are mostly carbon brushes (also called brushes) at present, currently, more equipment is applied, such as a direct current motor, a generator, a slip ring and the like, the carbon brushes are worn and consumed by natural use and wear in the use process of the equipment, the smoothness degree of the surfaces of a current receiver is changed, so that sparks can be generated on the surfaces of the carbon brushes and the current receiver in the operation of the equipment, and the use is more serious, so that maintenance personnel are required to timely master the spark state, for example, whether the spark state meets the maintenance standard, and whether the equipment fault is caused is evaluated.

When the spark reaches a certain degree, if the maintenance personnel do not timely handle the spark, the equipment can generate annular electric arcs and generate annular fire. The high temperature and energy of the electric arc seriously damage a commutator and an electric brush and cause damage to windings to different degrees; meanwhile, shaft current is generated, and shaft necks and bearing bushes cause secondary hazards such as pits and corrosion marks.

At present, the main detection and judgment scheme is that maintenance personnel continuously perform patrol inspection and judgment, and the judgment is performed by observing the eyes of the maintenance personnel, so that the judgment standard has human factor deviation due to the difference of each person, and the reliability and the accuracy are difficult to guarantee.

Disclosure of Invention

The invention aims to solve the problems in the prior art and provide a contact surface detection device and a method thereof, which have real-time, accurate and reliable electric energy conduction to rotating equipment.

In order to realize the purpose of the invention, the invention adopts the following technical scheme: a contact surface detection device for electric energy conduction of rotating equipment comprises a body, wherein an image data acquisition unit in communication connection with the body is arranged on the body, and a power module, a high-speed acquisition module, a recording and storing module, a data processing unit, a judgment and decision unit, a network module and an information output module are arranged in the body; the power supply module is used for supplying power to each module unit; the high-speed acquisition module is used for preprocessing and storing the data acquired by the image data acquisition unit; the recording and storing module is used for storing preset spark data; the data processing unit is used for carrying out centralized processing on the data in the high-speed acquisition module and the data in the record storage module; the judgment decision unit is used for making a decision according to the set spark grade; the network module is used for carrying out data connection on each module unit and providing an external third-party interface; and the information output module is used for reading the real-time picture of the image data acquisition unit and displaying the information transmitted by the judgment decision unit.

The working principle and the beneficial effects are as follows: when the device works, electric energy is transmitted to a power receiver through the electric brush, the power receiver rotates to form an electric loop, at the moment, an image of an area, close to the power receiver, of the electric brush is continuously shot through the image data acquisition unit, the image is processed and stored through the high-speed acquisition module and then forwarded to the data processing unit, sparks are processed through the data processing unit according to a bionic algorithm to obtain parameters and are forwarded to the judgment decision unit, the judgment decision unit compares spark grade parameters preset in the record storage module, namely characteristic values with the calculated parameters to obtain the spark grade, the processing mode is output to an external display device through the information transmission module according to the processing mode corresponding to the spark grade, compared with the prior art, manual continuous maintenance is not needed, labor cost is greatly saved, the preset parameters are added through a mode similar to human eye observation simulation, compared with manual judgment, the method is more accurate, has no deviation of other factors, and can ensure the reliability and the accuracy.

Further, the image data acquisition unit comprises at least two image detection probes, each image detection probe is provided with a light sensor, and the image detection probes are used for acquiring images between the electric brush and the powered device. This setting can track the light that detects the position through light sensor to the image mode of adjustment image detection probe guarantees image quality, thereby promotes the rate of accuracy that detects.

Further, the image acquisition frequency of the image detection probe is at least one thousand frames per second. According to the arrangement, not only can the image with the best quality be taken out from the image to be processed so as to reduce errors, but also the detection time interval can be reduced, and the detection speed is high.

Further, the data processing unit processes the image through a bionic algorithm. With this arrangement, the object is observed by both eyes and recognized. For the identification of a certain object or objects (hereinafter referred to as identification objects), the identification can not be identified due to the appearance and appearance change of the identification objects, after the identification is compared with the memory in the human brain, the identification can be accurately identified even after years or even longer, the identification is based on the characteristic data in the brain, the characteristic data is fuzzy quantity, the accurate measurement index characteristic data which can be operated is obtained by combining with a fuzzy mathematics accurate processing model, and an accurate judgment result is made according to the characteristic data.

Further, the bionic algorithm comprises the following steps:

s1: reading and preprocessing image data;

s2: performing rasterization analysis on the data;

s3: and establishing a mathematical model of the characteristic data.

The above steps apply the bionic algorithm to the data processing unit, and the calculation accuracy of the spark grade can be greatly improved.

Further, after the mathematical model is stored in the recording storage module, the data are transmitted to the judgment decision unit, and the judgment decision unit compares the characteristic data with the spark characteristic value preset by the recording storage module to obtain a processing scheme. According to the device, the image only exists in the high-speed acquisition module, the calculated image data and the preset spark grade data exist in the recording and storing module, the capacity burden of the recording and storing module is reduced, compared with the situation that the image only exists in one storage module, at least half of data can be reserved in case of failure, the stability is better, the recording and storing module and the high-speed acquisition module can work independently to achieve the same function, in case of failure of one of the storage module and the high-speed acquisition module, only the program needs to be adjusted, and the single storage module can work normally.

Further, the preprocessing comprises analyzing the pixels, size, quality, exposure degree and light of the image, screening out a high-quality image as an analysis processing object, and performing binarization and inverse color processing on the image. And the images are finely selected and processed, so that the detection accuracy is improved.

Furthermore, the detection contact surface of the image obtained by the rasterization analysis is taken as a boundary, the region where the electric brush and the power receiver generate sparks is imaged is taken as a processing region according to the rotation direction of the power receiver, and the image is divided into N step levels from the nearest position to the distant position from the detection contact surface as mathematical model weight coefficients K1 to Kn. According to the characteristics of spark generation, the farther from the contact surface, the smaller the number of sparks generated, and the smaller the density of sparks.

Furthermore, the information output module is a touch display screen or an industrial personal computer. By the arrangement, the maintenance scheme can be visually displayed for the user.

The contact surface detection method for the electric energy conduction of the rotating equipment is characterized in that the contact surface detection device for the electric energy conduction of the rotating equipment comprises the following steps:

n1: acquiring image data through an image data acquisition unit;

n2: the data is transmitted and stored through the high-speed acquisition module and is sent to the data processing unit;

n3: processing the data by a data processing unit;

n4: the processed data and the built-in spark grade characteristics of the record storage module are judged and decided by a decision unit

Comparing the values to obtain the total spark grade in the area;

n5: and displaying the processing scheme through the information output module.

Above-mentioned step, this detection device of application can realize effectively judging the carbon brush of existing equipment also be exactly the brush degree of wear to directly give the maintenance suggestion, need not artifical judgement, saved the cost of labor greatly.

Drawings

FIG. 1 is a schematic view of the installation of the present invention;

FIG. 2 is a schematic structural view of the present invention;

FIG. 3 is a flow chart of the present invention using a biomimetic algorithm.

In the figure, 1, electric energy; 2. a conductor; 3. a first carbon brush; 4. a second carbon brush; 5. a first contact surface; 6. a second contact surface; 7. a power receiver; 8. a first image detection probe; 9. a second image detection probe; 10. a first data conductor; 11. a second data conductor; 12. a body; 13. a power supply module; 14. an image data acquisition unit; 15. a high-speed acquisition module; 16. a record storage module; 17. a data processing unit; 18. a decision-making judgment unit; 19. a network module; 20. and an information output module.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments that can be derived by one of ordinary skill in the art from the embodiments given herein are intended to be within the scope of the present invention.

It will be understood by those skilled in the art that in the present disclosure, the terms "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," and the like are used in an orientation or positional relationship indicated in the drawings for ease of description and simplicity of description, and do not indicate or imply that the referenced devices or components must be constructed and operated in a particular orientation and thus are not to be considered limiting.

As shown in fig. 1, the electric energy is transmitted to the first carbon brush 3 and the second carbon brush 4 through the conductor 2, and is transmitted to the power receiver 7 through the carbon brushes, the power receiver 7 is a rotating device, and an electric loop formed in this way constitutes a complete transmission of the electric energy 1 to the power receiver 7, wherein the electric energy 1 is a power supply device of the system, is provided by a converter, is generally in a direct current power supply form, is convenient for construction and laying because the conductor 2 is a general cable through the conductor 2, and is made into a carbon product through the first carbon brush 3 and the second carbon brush 4, adding necessary auxiliary materials, and is a good electric conductor 2 through processes such as cutting and polishing. The electrical energy 1 is transmitted to the powered device, the first contact surface 5 and the second contact surface 6 being shown as detection sites, carbon brushes being brushes.

As shown in fig. 1 and 2, the contact surface detection device for conducting electric energy 1 of a rotating device comprises a body 12, an image data acquisition unit 14 in communication connection with the body 12 is arranged on the body 12, a power module 13, a high-speed acquisition module 15, a recording storage module 16, a data processing unit 17, a decision-making judgment unit 18, a network module 19 and an information output module 20 are arranged in the body 12, wherein the power module 13 is a common battery or a commercial power and can also be directly connected with the electric energy 1, the image data acquisition unit 14 is about 20-25cm away from a detection surface according to the positions of a first contact surface 5 and a second contact surface 6 in a map and can be adjusted according to actual requirements to acquire spark images, the image data acquisition unit 14 comprises at least two image detection probes, each image detection probe is provided with an optical sensor, the image detection probe is used for acquiring images between the electric brush and the power receiving equipment. According to the arrangement, the light rays at the detection position can be tracked through the optical sensor, so that the image mode of the image detection probe is adjusted, the image quality is ensured, and the detection accuracy is improved;

wherein the first image detection probe 8 and the second image detection probe 9 are connected with the body 12 through a first data wire 10 and a second data wire 11, respectively.

Preferably, the image detection probe acquires images at a frequency of at least one thousand frames per second. According to the arrangement, not only can the image with the best quality be taken out from the image to be processed so as to reduce errors, but also the detection time interval can be reduced, and the detection speed is high.

The power module 13 is used for supplying power to each module unit; the high-speed acquisition module 15 is used for preprocessing and storing the data acquired by the image data acquisition unit 14;

the recording storage module 16 is used for storing preset spark data;

the data processing unit 17 is used for processing the data in the high-speed acquisition module 15 and the record storage module 16 in a centralized manner;

a decision unit 18 for making a decision according to the set spark level;

the network module 19 is used for performing data connection on each module unit, providing an external third-party interface, and communicating with external equipment through WIFI, 4G/5G and the like to realize remote control;

and the information output module 20 is used for reading the real-time picture of the image data acquisition unit 14 and displaying the information transmitted by the judgment decision unit 18, and the information output module 20 is a touch display screen or an industrial computer. By the arrangement, the maintenance scheme can be visually displayed for the user.

Specifically, the data processing unit 17 processes the image by a biomimetic algorithm. With this arrangement, the object is observed by both eyes and recognized. For the identification of a certain object or objects (hereinafter referred to as identification objects), the identification can not be identified due to the appearance and appearance change of the identification objects, after the identification is compared with the memory in the human brain, the identification can be accurately identified even after years or even longer, the identification is based on the characteristic data in the brain, the characteristic data is fuzzy quantity, the accurate measurement index characteristic data which can be operated is obtained by combining with a fuzzy mathematics accurate processing model, and an accurate judgment result is made according to the characteristic data.

As shown in fig. 3, the biomimetic algorithm comprises the following steps:

s1: reading and preprocessing image data, reading a high-definition image stored in a storage area of the high-speed acquisition module 15 into the data processing unit 17, reading image pixels and image size, analyzing parameters such as image quality, exposure degree and light, screening out a high-quality image as an analysis processing object, and performing binarization, reverse color and other processing on the image;

s2: the data is subjected to rasterization analysis, and an area where the brush and the power receiver 7 form an image in which sparks are generated is set as a processing area according to the rotation direction of the power receiver 7 with the detected contact surface position of the image as a boundary. According to the characteristics of spark generation, the farther from the contact surface, the smaller the number of sparks generated, and the smaller the density of sparks. Dividing the image from the nearest part of the contact surface from near to far into N step levels as mathematical model weight coefficients K1-Kn;

s3: establishing a mathematical model of the characteristic data by using the following formula:

wherein Sn is the obtained characteristic data of each region; h1 is a grade 1 spark; n is the number; k is a step weight coefficient and is also a preset value of the system, and the value of K can be K1... Kn; a is unit area and is a preset value of the system; s is the weighted eigenvalue, and S1, S2.. Sn is the eigenvalue in the first formula.

In step S3, different feature data S1, S2.. Sn are calculated by a first formula, and then substituted into a second formula to calculate a feature weight S.

The judgment basis of the preset spark size in the recording and storing module 16 is that the spark size is larger than 10X10, namely the spark is considered to be a tiny spark component, and the larger spark is an effective spark component and is connected together to form an irregular sphere, which is obviously different from the current receiver 7, the carbon brush and the like in the image after being processed. Therefore, the device is divided into 1 to m grades according to the size, recorded as H1 to Hm, and respectively and correspondingly records corresponding maintenance suggestions, and the device is also divided according to the grades through a characteristic value calculated by a bionic algorithm.

The contact surface detection device for the electric energy conduction of the rotating equipment comprises the following steps:

n1: image data is acquired by the image data acquisition unit 14;

n2: the data is transmitted, stored and sent to the data processing unit 17 through the high-speed acquisition module 15;

n3: the data are processed by the data processing unit 17, that is, the characteristic weighted value S is calculated by applying the bionic algorithm;

n4: the characteristic weighted value S and the built-in sparks and the like of the record storage module 16 are judged and decided by the judgment decision unit 18

Comparing the level characteristic values, and obtaining a processing scheme according to the spark level;

n5: the processing scheme is displayed by the information output module 20.

In step N4, the most approximate spark grade is selected as the actual spark grade by comparing the judged characteristic weighted value S with each characteristic value of the preset spark grades, so as to give a corresponding overhaul suggestion, and if there is a sudden change of characteristic value, warning information is timely popped up through the information output module 20, so that the maintainer can timely master the current state and make a reasonable processing scheme.

Preferably, after a total spark grade is calculated, the characteristic data of S1, S2.. Sn is compared with the characteristic value of the spark grade built in the record storage module 16, that is, the corresponding spark grade in the whole detection area is subdivided according to the distribution number of S1, S2.. Sn in the whole detection area, and the maintenance suggestion can be adjusted according to the grade in which the spark grade is higher, that is, the grade which is very needed to be maintained, so that the judgment precision of the spark grade can be effectively improved.

In this embodiment, a self-learning method is further included, which includes the following steps:

x1: the parameter setting mode is selected through the display device connected with the information output module 20;

x2: recording normal characteristic data of the equipment in the figure 1, and collecting multiple groups of data;

x3: and selecting a certain self-learning parameter, selecting and applying the parameter, wherein the parameter is independent from a preset spark grade parameter, and the parameter plays a role in comparison and judges whether the equipment is in a normal operation state.

It is understood that the terms "a" and "an" should be interpreted as meaning that a number of one element or element is one in one embodiment, while a number of other elements is one in another embodiment, and the terms "a" and "an" should not be interpreted as limiting the number.

Although the terms of the electric energy 1, the conductor 2, the first carbon brush 3, the second carbon brush 4, the first contact surface 5, the second contact surface 6, the current receiver 7, the first image detection probe 8, the second image detection probe 9, the first data wire 10, the second data wire 11, the body 12, the power module 13, the image data acquisition unit 14, the high-speed acquisition module 15, the recording storage module 16, the data processing unit 17, the judgment decision unit 18, the network module 19, the information output module 20, and the like are used more frequently, the possibility of using other terms is not excluded. These terms are used merely to more conveniently describe and explain the nature of the present invention; they are to be construed as being without limitation to any additional limitations that may be imposed by the spirit of the present invention.

The present invention is not limited to the above-mentioned preferred embodiments, and any other products in various forms can be obtained by anyone in the light of the present invention, but any changes in the shape or structure thereof, which have the same or similar technical solutions as those of the present application, fall within the protection scope of the present invention.

Claims

1. A contact surface detection device for electric energy conduction of rotating equipment is characterized by comprising a body, wherein an image data acquisition unit in communication connection with the body is arranged on the body, and a power module, a high-speed acquisition module, a recording and storing module, a data processing unit, a judgment and decision unit, a network module and an information output module are arranged in the body; the power supply module is used for supplying power to each module unit; the high-speed acquisition module is used for preprocessing and storing the data acquired by the image data acquisition unit; the recording and storing module is used for storing preset spark data; the data processing unit is used for carrying out centralized processing on the data in the high-speed acquisition module and the data in the record storage module; the judgment decision unit is used for making a decision according to the set spark grade; the network module is used for carrying out data connection on each module unit and providing an external third-party interface; and the information output module is used for reading the real-time picture of the image data acquisition unit and displaying the information transmitted by the judgment decision unit.

2. The apparatus of claim 1, wherein the image data acquisition unit comprises at least two image detection probes, each of the image detection probes is provided with a light sensor, and the image detection probes are used for acquiring images between the brushes and the powered device.

3. A rotary device electrical energy conduction contact surface sensing apparatus as claimed in claim 2, wherein said image sensing probe captures images at a frequency of at least one thousand frames per second.

4. The apparatus of claim 1, wherein the data processing unit processes the image by a biomimetic algorithm.

5. The apparatus of claim 4, wherein the biomimetic algorithm comprises the following steps:

reading and preprocessing image data;

performing rasterization analysis on the data;

and establishing a mathematical model of the characteristic data.

6. The device for detecting the contact surface for the electric energy conduction of the rotating equipment as claimed in claim 5, wherein the mathematical model is stored in the recording storage module and then data is transmitted to the judgment and decision unit, and the judgment and decision unit compares the characteristic data with a spark characteristic value preset in the recording storage module to obtain a processing scheme.

7. The apparatus of claim 5, wherein the preprocessing comprises analyzing pixels, size, quality, exposure and light of the image, screening out high quality image as the object of analysis processing, and performing binarization and color reversal processing on the image.

8. The apparatus of claim 7, wherein the contact surface is defined by a detection contact surface that is subjected to rasterization analysis to generate an image, an image of a spark generated between the brush and the receiver is processed by defining a region where the image is formed according to a rotation direction of the receiver, and the image is divided into N number of steps from the nearest to the distant from the detection contact surface as mathematical model weight coefficients K1 to Kn.

9. The device for detecting the contact surface for the electric energy conduction of the rotating equipment as claimed in claim 1, wherein the information output module is a touch display screen or an industrial personal computer.

10. A contact surface detecting method for electric energy conduction of a rotating device, which is applied to the contact surface detecting device for electric energy conduction of a rotating device according to any one of claims 1 to 9, and comprises the following steps:

acquiring image data through an image data acquisition unit;

the data is transmitted and stored through the high-speed acquisition module and is sent to the data processing unit;

processing the data by a data processing unit;

comparing the processed data with the characteristic value of the spark grade built in the record storage module through a judgment decision unit to obtain the total spark grade in the area;

and displaying the processing scheme through the information output module.