CN112669315B - Method and device for detecting wire breakage of steel wire rope of winch - Google Patents
Method and device for detecting wire breakage of steel wire rope of winch Download PDFInfo
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- CN112669315B CN112669315B CN202110112928.9A CN202110112928A CN112669315B CN 112669315 B CN112669315 B CN 112669315B CN 202110112928 A CN202110112928 A CN 202110112928A CN 112669315 B CN112669315 B CN 112669315B
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Abstract
The invention discloses a method and a device for detecting wire breakage of a steel wire rope of a winch. The method for detecting the broken wire of the steel wire rope of the winch comprises the following steps of S1, enabling the steel wire rope to pass through a sleeve, wherein a cotton yarn ring is arranged in the sleeve, the cotton yarn ring is connected with a broken wire detection marker, and an inner ring of the cotton yarn ring is in contact with the steel wire rope; s2, drawing the steel wire rope to enable the steel wire rope to move for a certain distance; s3, capturing a video image of the broken wire detection marker by a camera device, and transmitting the acquired video image to an embedded computer by a data acquisition module; s4, analyzing and processing the video image by the embedded computer to obtain a binary image with the broken yarn detection marker separated from the image background; and S5, the embedded computer identifies the displacement of the wire breakage detection marker in the real-time monitoring video image according to the binary image, and judges whether the wire rope is broken according to the displacement. The invention can identify the wire breaking condition of the steel wire rope of the winch, can reduce the labor intensity of workers and improve the working safety.
Description
Technical Field
The invention belongs to the field of engineering machinery, and particularly relates to a method and a device for detecting wire breakage of a steel wire rope of a winch.
Background
The working stability and the safety of the winch are directly related to personal safety, production facilities and property safety. The steel wire rope is one of important components of the winch, the steel wire rope is quickly abraded, deformed and structurally damaged due to rope disorder, excessive load, rubbing and friction with other objects and the like of the winch, namely, broken steel wire ropes can be generated, the steel wire rope is scrapped after the steel wire rope is abraded and broken to a certain degree, a new steel wire rope needs to be replaced, the mechanical operation cost and the maintenance cost are increased, and if an accident occurs due to the fact that the new steel wire rope is not replaced in time, the personal safety can be directly influenced.
In order to know the actual condition of the steel wire rope in time, the broken wire of the steel wire rope of the winch needs to be identified. At present, the wire breaking condition of the steel wire rope of the winch is identified mainly by means of manual direct inspection or manual watching of video monitoring to judge the wire breaking, time and labor are wasted, generally, the wire breaking condition of the steel wire rope cannot be timely eliminated due to the fact that the wire breaking of the steel wire rope is too slight to enable naked eyes to observe difficultly, or due to negligence of an operator, and great potential safety hazards are easily left for engineering construction.
Disclosure of Invention
Aiming at the potential safety hazard brought to engineering construction by the broken wire of the winch steel wire rope and the problems in the manual rope inspection process, the invention aims to provide a method and a device for detecting the broken wire of the winch steel wire rope.
The invention provides a method for detecting the broken wire of a steel wire rope of a winch, which comprises the following steps:
s1, enabling a steel wire rope to pass through a split double-layer sleeve which is through from front to back, wherein a cotton yarn ring is arranged in the split double-layer sleeve, the cotton yarn ring is connected with a broken yarn detection marker, and an inner ring of the cotton yarn ring is in contact with the steel wire rope;
s2, drawing the steel wire rope to enable the steel wire rope to move for a certain distance;
s3, capturing a real-time monitoring video image of the broken wire detection marker by a camera device, and transmitting the acquired real-time monitoring video image into an embedded computer by a data acquisition module;
s4, analyzing and processing the real-time monitoring video image by the embedded computer to obtain a binary image of the broken wire detection marker separated from the image background;
and S5, the embedded computer identifies the displacement of the wire breakage detection marker in the real-time monitoring video image according to the binary image, and judges whether the wire rope is broken according to the displacement.
Further, the specific steps of analyzing and processing the real-time monitoring video image are as follows: the embedded computer reads real-time monitoring video images frame by frame, converts the i frame image read frame by frame into a gray image, wherein i =1,2,3.. N, performs noise reduction filtering processing on the gray image, performs self-adaptive binarization processing on the gray image subjected to the noise reduction filtering processing, separates a broken wire detection marker and an image background from the gray image subjected to the noise reduction filtering processing by utilizing the gray value difference between the image background and the broken wire detection marker, and converts the gray image into a binary image with a broken wire detection marker pixel value of 1 and a background pixel value of 0.
Further, the specific step of identifying the displacement error _ s of the broken wire detection marker in the real-time monitoring video image is as follows: the embedded computer records the coordinates (Xi, yi) of the centroid of the broken wire detection marker in the ith frame binary image, and the coordinates are determined according to the formula:
and calculating to obtain the displacement error _ s of the broken wire detection marker 6.
Further, the method for judging whether the wire breakage occurs in the steel wire rope comprises the following steps: the embedded computer compares the calculated displacement error _ s of the broken wire detection marker with a displacement threshold value max _ s arranged on the embedded computer, if the displacement error _ s is larger than the displacement threshold value max _ s, the broken wire of the steel wire rope of the winch is judged, and if the displacement error _ s is smaller than the displacement threshold value max _ s, the broken wire of the steel wire rope of the winch is judged.
The invention also provides a device for detecting broken wire of the steel wire rope of the winch, which comprises a split double-layer sleeve for placing the cotton yarn ring and enabling the steel wire rope to pass through, the cotton yarn ring which is pressed on the surface of the steel wire rope by the split double-layer sleeve and is connected with a broken wire detection marker, a broken wire detection marker for prompting the existence of broken wire of the steel wire rope, a camera device for capturing a real-time monitoring video image of the broken wire detection marker, a data acquisition module for transmitting the real-time monitoring video image acquired by the camera device into an embedded computer, the real-time monitoring video image acquired by the camera device is analyzed and processed to identify the displacement error _ s of the broken wire detection marker of the real-time monitoring video image, the embedded computer for identifying whether the steel wire rope is broken according to the displacement error _ s of the broken wire detection marker of the real-time monitoring video image, a rack for fixing the split double-layer sleeve, the camera device, the data acquisition module and the embedded computer, wherein the camera device is connected with the embedded computer through the data acquisition module, and the split double-layer sleeve is connected with the rack in a sliding way.
Further, to the outer upper and lower part of double-deck sleeve of open by threaded connection, sleeve outer lower half and rack portion sliding connection, the sleeve inlayer is two mutual dispositions's half-circular arc clamp plate, and each half-circular arc clamp plate links to each other through two bolts with half sleeve skin, and the bolt is used for adjusting half-circular arc clamp plate and sleeve skin distance, and the through-hole has all been opened with the sleeve skin to half-circular arc clamp plate.
Further, the cotton yarn ring is pressed on the surface of the steel wire rope by the semi-arc-shaped pressing plate, the cotton yarn ring is connected with the broken yarn detection marker through a connecting line, and the connecting line penetrates through the semi-arc-shaped pressing plate and the through hole of the sleeve.
Further, the broken wire detection marker is an arc-shaped thin plate and is placed on the outer surface of the outer layer of the upper half sleeve.
Furthermore, the camera device comprises more than one industrial camera, and the industrial camera is erected right above the split double-layer sleeve and used for capturing real-time monitoring video images of the broken wire detection markers.
Further, the embedded computer comprises a memory storing a computer program and a processor implementing the steps of the method of any of claims 1 to 5 when executing the computer program.
By adopting the method and the device for detecting the broken wire of the winch steel wire rope, the broken wire state of the steel wire rope can be identified in the running or overhauling process of the winch steel wire rope, the broken wire can be judged by replacing manual direct inspection or manual video monitoring, early warning is provided for workers, and the labor intensity is reduced.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention and not to limit the invention. In the drawings:
fig. 1 is a configuration diagram of a wire breakage detection device of a hoist rope according to an embodiment of the present invention;
FIG. 2 is a schematic view of the structure of FIG. 1 from another perspective;
fig. 3 is a flowchart of a method of detecting a wire breakage of a hoist rope according to an embodiment of the present invention;
FIG. 4 is a schematic illustration of the coordinates of the centroid of a wire break detection marker identified in accordance with an embodiment of the present invention in a binary image;
a description of the reference numerals;
1 split double-layer sleeve 2 cotton yarn ring 3 broken yarn detection marker 4 camera device 5 data acquisition module 6 embedded computer 7 frame.
Detailed Description
The following detailed description of embodiments of the invention refers to the accompanying drawings. It should be understood that the detailed description and specific examples, while indicating the present invention, are given by way of illustration and explanation only, not limitation.
Fig. 1 shows a structural diagram of a wire breakage detection device for a steel wire rope of a winch according to an embodiment of the present invention, which includes a split double-layered sleeve 1 for placing a cotton yarn ring and allowing the steel wire rope to pass therethrough, a cotton yarn ring 2 for being pressed on the surface of the steel wire rope by the split double-layered sleeve and connecting a wire breakage detection marker, a wire breakage detection marker 3 for prompting the presence of wire breakage of the steel wire rope, a camera 4 for capturing a real-time monitoring video image of the wire breakage detection marker, a data acquisition module 5 for inputting the real-time monitoring video image acquired by the camera into an embedded computer, an embedded computer 6 for analyzing and processing the real-time monitoring video image acquired by the camera 4, identifying a displacement error _ s of the wire breakage detection marker 3 in the real-time monitoring video image, and identifying whether the steel wire rope is broken according to the displacement error _ s of the wire breakage detection marker 3 in the real-time monitoring video image, and a frame 7 for fixing the split double-layered sleeve 1, the camera 4, the data acquisition module 5, and the embedded computer 6.
The input end of the data acquisition module 5 is connected with the output end of the camera device 4 through a cable and used for acquiring the image information of the camera device 4, and the output end of the data acquisition module 5 is connected with the input end of the embedded computer 6 through a cable and used for storing the image information acquired by the camera device 4.
In a preferred embodiment, a method for detecting a wire break of a wire rope of a winch is provided, and the method for detecting a wire break of a wire rope of a winch includes the steps of:
s1, enabling a steel wire rope to pass through a split double-layer sleeve 1 which is through from front to back, arranging a cotton yarn ring 2 in the split double-layer sleeve 1, connecting the cotton yarn ring 2 with a broken yarn detection marker 3, and enabling an inner ring of the cotton yarn ring 2 to be in contact with the steel wire rope;
s2, drawing the steel wire rope to enable the steel wire rope to move for a certain distance;
s3, capturing a real-time monitoring video image of the broken wire detection marker 3 by the camera device 4, and transmitting the acquired real-time monitoring video image into the embedded computer 6 by the data acquisition module 5;
s4, analyzing and processing the real-time monitoring video image by the embedded computer 6 to obtain a binary image of the broken wire detection marker 3 separated from the image background;
and S5, the embedded computer 6 identifies the displacement of the wire breakage detection marker 3 in the real-time monitoring video image according to the binary image, and judges whether the steel wire rope is broken according to the displacement.
In a preferred embodiment, the embedded computer 5 analyzes and processes the real-time image, first, the embedded computer 6 reads the real-time monitoring video image frame by frame, converts the i-th frame image read frame by frame into a gray map, wherein i =1,2,3.. N, performs noise reduction filtering processing on the gray map, performs adaptive binarization processing on the gray map subjected to the noise reduction filtering processing, separates the broken filament detection marker 3 and the image background from the gray map subjected to the noise reduction filtering processing by using the gray value difference between the image background and the broken filament detection marker 3, and converts the gray image into a binary image in which the pixel value of the broken filament detection marker 3 is 1 and the background pixel value is 0.
In a preferred embodiment, the embedded computer 6 first records the coordinates (Xi, yi) of the centroid of the broken filament detection marker in the ith frame binary image by identifying the displacement error _ s of the broken filament detection marker 3 in the real-time monitoring video image according to the formula:
and calculating to obtain the displacement error _ s of the broken wire detection marker 6.
In a preferred embodiment, the method for determining whether a wire break occurs in a steel wire rope includes: the embedded computer 6 compares the calculated displacement error _ s of the broken wire detection marker 3 with a displacement threshold value max _ s arranged on the embedded computer 6, if the displacement error _ s is larger than the displacement threshold value max _ s, the broken wire of the steel wire rope of the winch is judged, and if the displacement error _ s is smaller than the displacement threshold value max _ s, the broken wire of the steel wire rope of the winch is judged.
In a preferred embodiment, there is further provided a wire breakage detection device for a steel wire rope of a hoisting machine, as shown in fig. 3, the camera device 4 includes 1 industrial camera, the camera device 4 is disposed on a connecting rod directly above a frame 7 of the split-type double-layer sleeve 1, and is located at a centroid of the wire breakage detection marker 3, and is configured to collect real-time monitoring video image information of the wire breakage detection marker 3 and identify a displacement error _ s of the wire breakage detection marker 3 in the real-time monitoring video image, the wire breakage detection marker 3 is disposed in a slot on an upper surface of the split-type double-layer sleeve 1, a connecting wire of the wire breakage detection marker 3 passes through a through hole on the split-type double-layer sleeve 1 to be connected with the cotton yarn ring 2, the cotton yarn ring 2 is pressed on the surface of the steel wire rope by a pressing plate, the wear amount of the cotton yarn ring 2 or the displacement amount of the initial position of the cotton yarn ring 2 should be replaced when reaching a set threshold value, the camera device 4 is connected with the computer 6 through a data acquisition module 5, the embedded computer 6 is fixedly mounted in the frame 7, and the embedded position of the split-type double-layer sleeve 1 can be adjusted in the up-down direction of the frame 7.
In a preferred embodiment, the upper part and the lower part of the outer layer of the split double-layer sleeve 1 are connected through threads, the lower half part of the outer layer of the sleeve is connected with the part 7 of the rack in a sliding manner, the inner layer of the sleeve is formed by two semi-arc pressing plates which are arranged oppositely, each semi-arc pressing plate is connected with the outer layer of the half sleeve through two bolts, the bolts are used for adjusting the distance between the semi-arc pressing plates and the outer layer of the sleeve, and the semi-arc pressing plates and the outer layer of the sleeve are provided with through holes.
In a preferred embodiment, the cotton yarn ring 2 is pressed on the surface of the steel wire rope by a semi-circular arc-shaped pressing plate, the cotton yarn ring 2 is connected with the broken yarn detection marker 3 through a connecting line, and the connecting line penetrates through the semi-circular arc-shaped pressing plate and a through hole of the sleeve.
In a preferred embodiment, the broken wire detection marker 3 is a circular arc-shaped thin plate and is placed on the outer surface of the outer layer of the upper half part of the sleeve.
In a preferred embodiment, the camera device 4 is composed of more than one industrial camera, and the industrial camera is erected right above the split double-layer sleeve 1 and used for capturing real-time monitoring video images of the broken wire detection marker 3.
The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and it is apparent that those skilled in the art can make various changes and modifications to the present invention without departing from the spirit and scope of the present invention. Thus, if such modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include such modifications and variations.
Claims (4)
1. The utility model provides a hoist engine wire rope detection device that breaks which characterized in that: the device comprises a split double-layer sleeve, a cotton yarn ring, a broken wire detection marker, a camera device, a data acquisition module, an embedded computer, a frame, a data acquisition module and a data acquisition module, wherein the split double-layer sleeve is used for placing the cotton yarn ring and enabling a steel wire rope to pass through, the cotton yarn ring is pressed on the surface of the steel wire rope by the split double-layer sleeve and is connected with the broken wire detection marker, the broken wire detection marker is used for prompting that the steel wire rope has broken wires, the camera device is used for capturing a real-time monitoring video image of the broken wire detection marker, the data acquisition module is used for transmitting the real-time monitoring video image acquired by the camera device into the embedded computer, the embedded computer is used for analyzing and processing the real-time monitoring video image acquired by the camera device, identifying the displacement error _ s of the broken wire detection marker of the real-time monitoring video image, and judging whether the steel wire rope is broken wires or not according to the displacement error _ s of the real-time monitoring video image identification broken wire detection marker, the embedded computer is used for fixing the split double-layer sleeve, the camera device, the data acquisition module and the embedded computer are connected with the frame through the data acquisition module, and the split double-layer sleeve is connected with the frame in a sliding way; the upper and lower parts of the outer layer of the split double-layer sleeve are connected by threads, the lower half part of the outer layer of the sleeve is connected with the frame part in a sliding manner, the inner layer of the sleeve is two semi-arc-shaped pressing plates which are arranged oppositely, each semi-arc-shaped pressing plate is connected with the outer layer of the half sleeve through two bolts, the bolts are used for adjusting the distance between the semi-arc-shaped pressing plates and the outer layer of the sleeve, and through holes are formed in the semi-arc-shaped pressing plates and the outer layer of the sleeve.
2. The wire rope breakage detection device according to claim 1, characterized in that: the cotton yarn ring is pressed on the surface of the steel wire rope by the semi-circular arc-shaped pressing plate, the cotton yarn ring is connected with the broken yarn detection marker through a connecting line, and the connecting line penetrates through the semi-circular arc-shaped pressing plate and the through hole of the sleeve.
3. The wire rope breakage detection device according to claim 1, characterized in that: the broken wire detection marker is an arc-shaped thin plate and is placed on the outer surface of the outer layer of the upper half sleeve.
4. The wire rope breakage detection device according to claim 1, characterized in that: the camera device is composed of more than one industrial camera, and the industrial camera is erected right above the split double-layer sleeve and used for capturing real-time monitoring video images of the broken wire detection markers.
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| JPH07260708A (en) * | 1994-03-18 | 1995-10-13 | Mitsubishi Heavy Ind Ltd | Apparatus for inspecting wire rope |
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