CN112927205A - Gantry crane steel wire rope deflection monitoring method and device based on machine vision - Google Patents
Gantry crane steel wire rope deflection monitoring method and device based on machine vision Download PDFInfo
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- CN112927205A CN112927205A CN202110221125.7A CN202110221125A CN112927205A CN 112927205 A CN112927205 A CN 112927205A CN 202110221125 A CN202110221125 A CN 202110221125A CN 112927205 A CN112927205 A CN 112927205A
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- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 120
- 239000010959 steel Substances 0.000 title claims abstract description 120
- 238000000034 method Methods 0.000 title claims abstract description 18
- 238000012544 monitoring process Methods 0.000 title claims description 15
- 238000004364 calculation method Methods 0.000 claims description 9
- 238000000605 extraction Methods 0.000 claims description 7
- 238000012806 monitoring device Methods 0.000 claims description 6
- 239000010720 hydraulic oil Substances 0.000 description 11
- 238000010586 diagram Methods 0.000 description 6
- 241000406668 Loxodonta cyclotis Species 0.000 description 5
- 230000003340 mental effect Effects 0.000 description 4
- 239000003921 oil Substances 0.000 description 4
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- 230000003068 static effect Effects 0.000 description 1
- 239000000725 suspension Substances 0.000 description 1
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T7/00—Image analysis
- G06T7/0002—Inspection of images, e.g. flaw detection
- G06T7/0004—Industrial image inspection
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- G06T5/70—
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- G06T5/80—
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T7/00—Image analysis
- G06T7/30—Determination of transform parameters for the alignment of images, i.e. image registration
- G06T7/33—Determination of transform parameters for the alignment of images, i.e. image registration using feature-based methods
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T7/00—Image analysis
- G06T7/70—Determining position or orientation of objects or cameras
- G06T7/73—Determining position or orientation of objects or cameras using feature-based methods
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T2207/00—Indexing scheme for image analysis or image enhancement
- G06T2207/10—Image acquisition modality
- G06T2207/10004—Still image; Photographic image
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T2207/00—Indexing scheme for image analysis or image enhancement
- G06T2207/30—Subject of image; Context of image processing
- G06T2207/30108—Industrial image inspection
- G06T2207/30164—Workpiece; Machine component
Abstract
The patent refers to the field of 'hoisting or lowering machines or engines'. The method comprises the following steps: acquiring images of a steel wire rope on a plane of an arm support and a plane vertical to the arm support; carrying out image distortion correction, image distortion smooth enhancement and image registration processing on the acquired image; carrying out feature recognition on the processed picture to extract a steel wire rope feature image; comparing the obtained characteristic image of the steel wire rope with a reference image of the steel wire rope in a vertical hanging and loading state, judging the deflection direction of the steel wire rope, and calculating the deflection angle of the steel wire rope; and outputting the deflection angle of the steel wire rope in real time, and giving an early warning when the deflection angle is larger than a set threshold value.
Description
Technical Field
The invention relates to a method and a device for monitoring the deflection of a steel wire rope of a gantry crane in real time based on machine vision, in particular to a method and a device for monitoring the deflection of the steel wire rope of the gantry crane in real time by utilizing a camera to acquire the deflection image information of the steel wire rope and then utilizing an image processing technology to monitor the deflection angle of the steel wire rope on the plane of an arm support and the plane vertical to the arm support.
Background
The portal crane can generate deflection due to the steel wire rope during rotation, amplitude variation, operation, lifting and descending movement and under the action of wind load when in hoisting, if the deflection angle is too large, great friction can be generated between the steel wire rope and the pulley to directly influence the strength of the steel wire rope, the service life of the steel wire rope is seriously influenced, and the potential safety hazard of port operation is increased. Therefore, the method has great practical significance for monitoring and early warning the deflection angle of the steel wire rope of the gantry crane caused by self or external load.
Disclosure of Invention
The invention provides a method and a device for monitoring the deflection of a steel wire rope of a portal crane based on machine vision, aiming at acquiring the deflection image information of the steel wire rope by a camera, monitoring the deflection angle of the steel wire rope during hoisting in real time by an image processing technology, preventing the increase of the friction force between the steel wire rope and a pulley caused by the overlarge deflection angle of the steel wire rope so as to directly influence the strength of the steel wire rope and further reduce the operation risk of the portal crane.
According to an aspect of the embodiments of the present invention, a gantry crane wire rope deflection monitoring method based on machine vision is provided, including: acquiring images of a steel wire rope on a plane of an arm support and a plane vertical to the arm support; carrying out image distortion correction, image distortion smooth enhancement and image registration processing on the acquired image; carrying out feature recognition on the processed picture to extract a steel wire rope feature image; comparing the obtained characteristic image of the steel wire rope with a reference image of the steel wire rope in a vertical hanging and loading state, judging the deflection direction of the steel wire rope, and calculating the deflection angle of the steel wire rope; and outputting the deflection angle of the steel wire rope in real time.
In some examples, a warning is given when the yaw angle is greater than a set threshold.
In some examples, the camera that acquires the images of the boom plane and the wire rope on the vertical boom plane is disposed on a camera pan head that is automatically held horizontal.
According to another aspect of the embodiments of the present invention, there is provided a gantry crane steel wire rope deflection monitoring device based on machine vision, including: the camera is used for acquiring images of the arm support plane and the steel wire rope on the vertical arm support plane; the image processing module is used for carrying out image distortion correction, image distortion smooth enhancement and image registration processing on the acquired image; the image characteristic identification and extraction module is used for carrying out characteristic identification on the processed picture to extract a steel wire rope characteristic image; the image matching module is used for comparing the obtained steel wire rope characteristic image with a reference image of the steel wire rope in a suspended load vertical state; the steel wire rope deflection amount calculation module is used for judging the deflection direction of the steel wire rope according to the comparison result of the image matching module and calculating the deflection angle of the steel wire rope; and the output module is used for outputting the deflection angle of the steel wire rope in real time.
In some examples, the system further comprises a yaw angle early warning module for early warning when the yaw angle is larger than a set threshold value.
In some examples, the camera is disposed on a camera pan/tilt head that is automatically held horizontal.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings of the embodiments will be briefly described below.
FIG. 1 is a flow chart of a gantry crane wire rope deflection monitoring method based on machine vision.
Fig. 2 is a layout diagram of a gantry crane wire rope deflection real-time monitoring device camera.
Fig. 3 is a schematic diagram of wire rope yaw.
Fig. 4 is a reference diagram for the suspension of the wire rope at a standstill.
Fig. 5 is a schematic diagram of calculation of the wire rope runout amount.
Fig. 6 is a schematic view of the horizontal state of the camera pan-tilt.
Fig. 7 is a schematic view of camera pan-tilt horizontal compensation.
FIG. 8 is a camera platform level compensation hydraulic control diagram.
Description of reference numerals:
1-gantry crane elephant nose bridge;
2-a pulley;
3-lifting the steel wire rope;
4-shooting a steel wire rope hanging deflection camera perpendicular to the plane of the arm support;
5-a camera for shooting the hanging deflection of the plane steel wire rope of the arm support;
6-camera pan-tilt;
7-cradle head support;
8-a level meter;
9-a hydraulic oil cylinder;
10-a three-position four-way reversing valve;
11-a hydraulic pump;
12-left hydraulic control check valve;
13-left check valve;
14-a hydraulic oil cylinder;
15-right hydraulic control one-way valve;
16-right throttle valve;
17-right check valve;
18-left throttle.
Detailed Description
Fig. 1 shows a flow chart of a gantry crane wire rope deflection monitoring method based on machine vision, which comprises the following steps:
step 1, obtaining images of a steel wire rope on a plane of an arm support and a plane vertical to the arm support.
Referring to fig. 2, two cameras 4, 5 are directed to the center line of the wire rope from different directions, respectively. The camera 4 is used for shooting the deflection amount of the steel wire rope when the steel wire rope is suspended in a plane perpendicular to the arm support, and the camera 5 is used for shooting the deflection amount of the steel wire rope when the steel wire rope is suspended in the plane of the arm support. The deflection direction in the plane of the arm support is defined as the x direction and the outward deflection is defined as the positive direction of the x axis, the deflection direction in the plane vertical to the arm support is defined as the y direction, and the anticlockwise direction is defined as the positive direction of the y axis. Fig. 3 shows the deflection of the wire rope in the boom plane, i.e. in the x-direction.
Two cameras 4, 5 take steel wire rope pictures, the pictures taken are divided into 1 minute groups, and one group takes a plurality of pictures (5 can be) continuously within 1 second. And taking the average value of the deflection amounts of the steel wire ropes of the continuous pictures as the deflection amount of the steel wire rope at the moment. Fig. 4 shows a reference picture of a static hoisting of a steel wire rope, and the cameras 4 and 5 need to take pictures of the steel wire rope in a vertical hoisting state at first and process the pictures to be used as reference pictures for measuring the deflection of the steel wire rope. In addition, the two cameras 4, 5 should be fixed on two camera holders 6 with automatic level compensation function respectively, so as to be able to photograph the accurate swing of the steel wire rope, and the two camera holders 6 are fixed on the holder support 7 at the lower part of the portal crane elephant nose bridge 1.
And 2, after the cameras 4 and 5 take the steel wire rope pictures, performing series processing on the obtained steel wire rope images. Image edge distortion due to a photograph taken in a moving state is removed by image distortion correction first. And then filtering the graph to reduce the background noise of the image and enhance the useful information of the image. The acquired set of consecutive images is then registered to continue to enhance the useful information of the image.
And 3, performing feature recognition and extraction on the processed picture, dividing points on the picture into different subsets, wherein the subsets often belong to isolated points, continuous curves or continuous areas, recognizing steel wire rope features in the picture, and eliminating other useless features.
And 4, comparing the obtained characteristic image of the steel wire rope with a reference image of the steel wire rope in a vertical suspended load state, judging the deflection direction of the steel wire rope, and calculating the deflection angle of the steel wire rope.
FIG. 5 shows a schematic diagram of the calculation of the wire rope deflection in the x-direction, in which the wire rope vertical direction and the deflection direction in the processed picture are equally divided into n parts, for example, 5 parts, the deflection angle in the x-direction is
Likewise, so does the yaw angle in the y-direction.
And calculating to obtain the comprehensive deflection angle of the steel wire rope according to the deflection amounts of the steel wire rope in the x direction and the y direction.
The calculation is as follows:
the comprehensive deflection angle of the steel wire rope is
In the formula: c-projection length of wire rope in horizontal plane, i.e. xoy plane after deflection
h-the length of the wire rope in the vertical state
In the formula: a-c projection length in x direction
Projection length of b-c in y direction
a＝lxsinθx
In the formula IxThe projection length of the steel wire rope in the xoz plane
θx-the steel wire rope swings at an angle in the x direction
b＝lysinθy
In the formula Iy-projection length of steel wire rope in yoz plane
θy-the wire rope is deflected in the y direction by an angle
Comprehensive deflection angle theta of substituted steel wire rope
And 5, outputting the obtained steel wire rope deflection angle data to a driver cab so that the driver can obtain the deflection angle of the steel wire rope at any time. The wire rope deflection angle is early-warned, when any of the wire rope deflection amounts in two directions exceeds a threshold value, early-warning prompt is carried out on a driver, the driver can conveniently and effectively adjust in time, and potential safety hazards are avoided.
In some examples, a gantry crane steel wire rope deflection monitoring device based on machine vision is further provided, and the device comprises two cameras, an image processing module, a feature recognition extraction module, an image matching module, a steel wire rope deflection amount calculation module, a deflection angle output module and a deflection angle early warning module.
As described above, the two cameras 4, 5 are arranged on the camera head 6 with automatic level compensation, and the camera head 6 is fixed on the head support 7 at the lower part of the portal crane, such as the bridge of the nose 1. The cameras 4 and 5 finish the image acquisition of the arm support plane and the steel wire rope on the vertical arm support plane under the state that the holder 6 is kept horizontal, and then the acquired images are sent to the image processing module. And processing the image of the steel wire rope in the vertical hanging and loading state to be used as a reference picture for measuring the deflection of the steel wire rope.
And the image processing module is used for carrying out series processing on the acquired steel wire rope images. Image edge distortion due to a photograph taken in a moving state is removed by image distortion correction first. And then filtering the graph to reduce the background noise of the image and enhance the useful information of the image. The acquired set of consecutive images is then registered to continue to enhance the useful information of the image. The processed image is sent to the image feature recognition extraction module. The image feature recognition and extraction module performs feature recognition and extraction on the processed image, divides points on the image into different subsets, the subsets usually belong to isolated points, continuous curves or continuous areas, recognizes steel wire rope features in the image, and eliminates other useless features. The image matching module compares the obtained steel wire rope characteristic image with a reference image of the steel wire rope in a suspended load vertical state, and transmits the comparison image to the steel wire rope deflection amount calculation module. The steel wire rope deflection amount calculation module judges the deflection direction of the steel wire rope and calculates the deflection angle of the steel wire rope, and the specific calculation method is as described above. And the deflection angle output module is used for outputting the obtained steel wire rope deflection angle to the cab so that the driver can obtain the deflection angle of the steel wire rope at any time. The deflection angle early warning module carries out early warning to wire rope deflection angle, when arbitrary the exceeding threshold value of two direction wire rope deflection volume, carries out early warning suggestion to the driver, and the driver of being convenient for is timely effectual adjusts, avoids the potential safety hazard.
The manner of the horizontal compensation of the camera head 6 will be described in detail below. Referring to fig. 6 and 7, when the gantry crane performs amplitude variation and lifting motion, the elephant nose bridge is driven to move in the plane of the arm support, and at the moment, the tripod head support 7 fixed on the elephant nose bridge tilts in the x plane along with the elephant nose bridge, so that the camera tripod head 6 and the cameras 4 and 5 fixed on the tripod head support 7 lose the horizontal state. At this time, the level 8 installed on the camera pan/tilt head 6 immediately monitors the tilt state of the camera pan/tilt head 6, and measures the included angle θ between the camera pan/tilt head 6 and the horizontal plane in real time, wherein the counterclockwise tilt θ of the pan/tilt head support 7 in the arm support plane is defined as a positive value. The calculation center in the automatic level compensation module of the camera pan-tilt 6 calculates the amount of mental shrinkage of each hydraulic oil cylinder 9 when the camera pan-tilt 6 is adjusted to be horizontal and then transmits the mental shrinkage to the controller, and the controller guides the hydraulic oil cylinders 9 to act to realize the level compensation of the camera pan-tilt 6. The center of the lower surface of the camera pan/tilt head 6 is set as an original point O, and the coordinate values of the connecting points of the two oil cylinders 9 and the camera pan/tilt head 6 are set as (x)1,y1) And (x)2,y2) I.e. the amount of extension and retraction required for each cylinder is respectively
And
referring to fig. 8, the calculation center in the automatic level compensation module of the camera pan-tilt 6 calculates the mental shrinkage of each hydraulic cylinder 9 and feeds back the mental shrinkage to the controller. Then, the controller enables the three-position four-way reversing valve 10A2 to be powered according to the extension of the hydraulic oil cylinder 9 (taking the extension of a piston of the hydraulic cylinder as an example, and the piston retracts in the same way), the three-position four-way reversing valve 10 is arranged at the right station, hydraulic oil flows out of the hydraulic pump 11, flows into a rodless cavity of the hydraulic oil cylinder 14 through the three-position four-way reversing valve 10, the left hydraulic control one-way valve 12 and the left check valve 13, the right hydraulic control one-way valve 15 is opened at the same time, oil in a rod cavity of the hydraulic oil cylinder 14 flows back to an oil tank through the right throttle valve 16, the right hydraulic control one-way valve 15 and the three. When the piston of the hydraulic oil cylinder 14 extends to a calculated value, the controller controls the three-position four-way reversing valve 10A2 to lose power, the reversing valve 10 is located in the middle position, meanwhile, the right-side hydraulic control one-way valve 15 is closed, hydraulic oil cannot flow back to the oil tank, a loop is interrupted, and therefore the piston of the hydraulic oil cylinder 14 stops extending and is in a pressure maintaining state. If the camera pan-tilt 6 tilts again, the adjusting cylinder is extended or retracted according to the method, so that horizontal compensation is realized.
Claims (8)
1. A gantry crane steel wire rope deflection monitoring method based on machine vision is characterized by comprising the following steps:
acquiring images of a steel wire rope on a plane of an arm support and a plane vertical to the arm support;
carrying out image distortion correction, image distortion smooth enhancement and image registration processing on the acquired image;
carrying out feature recognition on the processed picture to extract a steel wire rope feature image;
comparing the obtained characteristic image of the steel wire rope with a reference image of the steel wire rope in a vertical hanging state, judging the deflection direction of the steel wire rope, and calculating the deflection angle of the steel wire rope on the plane of the arm support and the plane vertical to the arm support;
and outputting the deflection angle of the steel wire rope in real time.
2. The machine vision-based gantry crane steel wire rope deflection monitoring method as claimed in claim 1, wherein an early warning is given when the deflection angle of the steel wire rope in the plane of the boom or the plane perpendicular to the boom is greater than a set threshold.
3. The machine vision-based gantry crane wire rope yaw monitoring method of claim 1, wherein cameras that acquire images of the wire rope on the boom plane and vertical boom plane are disposed on a camera pan tilt that automatically maintains horizontal.
4. The machine vision-based gantry crane steel wire rope deflection monitoring method according to claim 1, wherein the deflection direction of the steel wire rope in the boom plane is defined as x direction and outward deflection is defined as x-axis positive direction, the deflection direction in the vertical boom plane is defined as y direction and counterclockwise is defined as y-axis positive direction, and the comprehensive deflection angle θ of the steel wire rope is obtained by the following method:
in the formula: c-projection length of wire rope in horizontal plane, i.e. xoy plane after deflection
h-the length of the wire rope in the vertical state
In the formula: a-c projection length in x direction
Projection length of b-c in y direction
a＝lxsinθx
In the formula IxThe projection length of the steel wire rope in the xoz plane
θx-the steel wire rope swings at an angle in the x direction
b＝lysinθy
In the formula Iy-projection length of steel wire rope in yoz plane
θy-the wire rope is deflected in the y direction by an angle
Obtaining the comprehensive deflection angle theta of the steel wire rope
5. The utility model provides a gantry crane wire rope beat monitoring devices based on machine vision which characterized in that includes:
the camera is used for acquiring images of the arm support plane and the steel wire rope on the vertical arm support plane;
the image processing module is used for carrying out image distortion correction, image distortion smooth enhancement and image registration processing on the acquired image;
the image characteristic identification and extraction module is used for carrying out characteristic identification on the processed picture to extract a steel wire rope characteristic image;
the image matching module is used for comparing the obtained steel wire rope characteristic image with a reference image of the steel wire rope in a suspended load vertical state;
a steel wire rope deflection amount calculation module used for judging the deflection direction of the steel wire rope according to the comparison result of the image matching module,
calculating the deflection angles of the steel wire rope on the plane of the arm support and the plane vertical to the arm support;
and the output module is used for outputting the deflection angle of the steel wire rope in real time.
6. The machine vision-based gantry crane steel wire rope deflection monitoring device according to claim 5, further comprising a deflection angle early warning module for early warning when a deflection angle of the steel wire rope in a boom plane or a vertical boom plane is larger than a set threshold value.
7. The machine vision-based gantry crane wire rope yaw monitoring apparatus of claim 5, wherein the camera is disposed on an automatically maintained horizontal camera pan/tilt head.
8. The machine vision-based gantry crane steel wire rope deflection monitoring device according to claim 5, wherein the deflection direction of the steel wire rope in the boom plane is defined as x direction and the outward deflection is defined as x-axis positive direction, the deflection direction in the vertical boom plane is defined as y direction and the counterclockwise direction is defined as y-axis positive direction, and the comprehensive deflection angle θ of the steel wire rope is obtained by the following method:
in the formula: c-projection length of wire rope in horizontal plane, i.e. xoy plane after deflection
h-the length of the wire rope in the vertical state
In the formula: a-c projection length in x direction
Projection length of b-c in y direction
a＝lxsinθx
In the formula: lxThe projection length of the steel wire rope in the xoz plane
θx-the steel wire rope swings at an angle in the x direction
b＝lysinθy
In the formula: ly-projection length of steel wire rope in yoz plane
θy-the wire rope is deflected in the y direction by an angle
Obtaining the comprehensive deflection angle theta of the steel wire rope
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113562621A (en) * | 2021-07-27 | 2021-10-29 | 衡水京华制管有限公司 | Early warning method for dangerous hanging object of crown block, terminal equipment and readable storage medium |
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| CN104658010A (en) * | 2015-01-26 | 2015-05-27 | 中国矿业大学 | Steel wire rope deflection video detection system and method |
| CN106081907A (en) * | 2016-05-15 | 2016-11-09 | 大连海事大学 | A kind of contactless row hangs lifting rope swing angle monitoring device |
| CN109678057A (en) * | 2019-02-18 | 2019-04-26 | 上海应用技术大学 | The Different Deflection Angle Measurement of overhead crane based on stereoscopic vision |
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2021
- 2021-02-26 CN CN202110221125.7A patent/CN112927205A/en active Pending
Patent Citations (4)
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|---|---|---|---|---|
| CN102701078A (en) * | 2012-05-18 | 2012-10-03 | 上海海事大学 | Device and method for measuring swing angle of double-hanger bridge crane on basis of image detection |
| CN104658010A (en) * | 2015-01-26 | 2015-05-27 | 中国矿业大学 | Steel wire rope deflection video detection system and method |
| CN106081907A (en) * | 2016-05-15 | 2016-11-09 | 大连海事大学 | A kind of contactless row hangs lifting rope swing angle monitoring device |
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| CN113562621A (en) * | 2021-07-27 | 2021-10-29 | 衡水京华制管有限公司 | Early warning method for dangerous hanging object of crown block, terminal equipment and readable storage medium |
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