CN113682576B - Real-time detection system for walking of synchronous toothed conveying belt of high-speed packaging machine - Google Patents
Real-time detection system for walking of synchronous toothed conveying belt of high-speed packaging machine Download PDFInfo
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- CN113682576B CN113682576B CN202110954017.0A CN202110954017A CN113682576B CN 113682576 B CN113682576 B CN 113682576B CN 202110954017 A CN202110954017 A CN 202110954017A CN 113682576 B CN113682576 B CN 113682576B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B57/00—Automatic control, checking, warning, or safety devices
- B65B57/18—Automatic control, checking, warning, or safety devices causing operation of audible or visible alarm signals
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B57/00—Automatic control, checking, warning, or safety devices
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Abstract
The invention discloses a real-time detection system for the walking position of a synchronous toothed conveying belt of a high-speed packaging machine, and belongs to the technical field of cigarette packaging equipment. The real-time detection system comprises an AI image recognition sensor, a monochromatic LED point light source, a polarizer accessory, a sensor controller, software, an intelligent display, a counting sensor, an audible and visual alarm, a sensor-controller cable, an intelligent display power cable and the like. The synchronous toothed conveyer belt fault early warning device can adapt to different equipment running speeds, achieves real-time monitoring of running states of appearance, position, upstream and downstream matching and the like of the synchronous toothed conveyer belt which moves at high speed intermittently, achieves automatic warning and equipment shutdown, can call abnormal information and related abnormal images through the intelligent display to perform problem recognition and fault diagnosis, quickly locks the abnormal position of the toothed conveyer belt, improves maintenance efficiency, and provides timely and reliable diagnosis information for high-speed packaged synchronous toothed conveyer belt fault early warning.
Description
Technical Field
The invention belongs to the technical field of cigarette packaging equipment, and particularly relates to a real-time detection system for the displacement of a synchronous toothed conveying belt of a high-speed packaging machine.
Background
The high-speed cigarette packaging equipment generally refers to production equipment with the running speed exceeding 600 packets/minute, and under the running state, in order to realize the accurate conveying of high-speed cigarette packets, strict requirements are provided for the condition of a synchronous toothed conveyer belt.
For the synchronous tooth-shaped conveying belt, slight abrasion deformation and small-amplitude walking cannot cause equipment conveying blockage and stop, but great hidden troubles of product packaging quality exist, for example, tobacco packets interfere with walking lugs to cause clamping injury, touch injury and the like, quality problems are easy to leak and flow into a next procedure, even flow onto the market, and the sale of cigarette retail households and the sensory experience of consumers are seriously influenced. On the other hand, the synchronous toothed conveyer belt of the high-speed packaging machine has extremely high phase angle matching requirements during maintenance adjustment or replacement, so that great manpower and material resources are consumed for maintenance adjustment at one time, and great yield loss is caused.
The invention designs and develops a real-time detection system for the walking of the synchronous toothed conveyer belt of the high-speed packaging machine, can timely find the abnormal early stage and the early stage of degradation of the conveyer belt, adopts a maintenance and adjustment strategy, and avoids the problem of fine wear from being controlled to continuously deepen the degradation, thereby causing more serious shutdown loss and saving the production cost.
Disclosure of Invention
In order to solve the problems, the invention provides a visual detection system, which can realize the monitoring of the running state of a high-speed synchronous toothed conveyer belt, the real-time detection system of the walking position of the synchronous toothed conveyer belt of the high-speed packaging machine with the functions of walking position alarm control and shutdown, and provide timely and reliable diagnosis information for the early warning of the fault of the synchronous toothed conveyer belt of the high-speed packaging.
In order to realize the purpose, the invention is realized by adopting the following technical scheme: the synchronous profile of tooth conveyer belt of high-speed packagine machine walk real-time detection system of position by AI image recognition sensor 1, monochromatic LED pointolite 2, polarizer annex 3, sensor controller 4, intelligent display 6, count sensor 7, audible-visual annunciator 8, sensor-controller cable 9, intelligent display power cable 10 and constitute, AI image recognition sensor 1, monochromatic LED pointolite 2, polarizer annex 3, count sensor 7 pass through sensor-controller cable 9 with sensor controller 4 and be connected, sensor controller 4 is connected with intelligent display 6, intelligent display 6 is connected with audible-visual annunciator.
Preferably, the AI image recognition sensor 1 is installed by selecting at least 3 positions, namely, a starting point of the transfer of the synchronous toothed conveyor belt with the upstream cigarette packet, an ending point of the transfer of the cigarette packet in the conveyor belt with the downstream channel, and an intermediate point within the length range of the conveyor belt.
Preferably, the AI image recognition sensor 1 has auto-focusing and condition adding functions, and can perform initialization setting of "qualified" and "unqualified" images, when the environment changes, a technician can add detection conditions, the top of the image recognition sensor 1 is provided with a monochromatic LED point light source 2 to realize illumination compensation, and the light source 2 is covered with a polarizer accessory 3 to reduce the reflection influence of the transparent paper of the cigarette packet.
Preferably, the sensor controller 4 collects, analyzes and processes image data obtained by the image recognition sensor 1, so as to control a detection target such as an image and control automatic recording and storage of an abnormal picture.
Preferably, the intelligent display 6 is connected with a 24V power cable, and related operations such as initialization setting, sensor parameter adjustment, history record inquiry, abnormal image checking and the like can be performed on the real-time detection system by using a software 5 platform arranged in the display, and the intelligent display is used for displaying the current state of the conveying belt when the real-time detection system normally works, and meanwhile, the stored information such as the abnormal image, the history record, parameter backup and the like can be transmitted and stored through a USB interface, so that the reliability of the real-time detection system is improved.
Preferably, said software 5 is used for the identification of the following features: (1) contour recognition: selecting a detection target, automatically extracting the outline of the target, and identifying the outline by using shape difference; (2) edge pixel identification: according to the boundary point of the light and shade change, recognizing the object or the surface state with unfixed shape by the number of edge pixels; (3) color identification: setting a threshold value for the RGB average value in the detection area to identify differences by colors; (4) and (3) brightness identification: setting a threshold value for the brightness average value in the detection area to identify differences according to brightness; (5) width identification: and identifying the difference of the target according to the width between the edges according to the boundary point of the light and shade change.
Preferably, the counting sensor 7 module provides data information through a self-contained encoder of the device, can adapt to accurate positioning of the phase angle and the lug number of the toothed belt under different running speeds of the device, and automatically records the lug number corresponding to the abnormal position point according to the signal of the AI image recognition sensor controller 4 for fault diagnosis and abnormality recognition.
Preferably, the audible and visual alarm (8) is arranged at the upper part of the frame of the intelligent display (6) and is used for attracting the attention of operators or repair personnel to check and maintain abnormal conditions in advance.
The invention has the beneficial effects that:
the invention relates to a real-time detection system for the walking position of a synchronous toothed conveyer belt of a high-speed packaging machine, which is suitable for the state monitoring and the health management of the synchronous toothed conveyer belt of intermittent motion of high-speed cigarette packaging equipment, can timely find the slight abrasion deformation and small walking position of the conveyer belt and the connection state of the upstream and downstream of a cigarette packet, and can early monitor the faults or quality problems such as clamping, touch and the like caused by the interference of the cigarette packet and walking lugs, avoid the deterioration phenomenon and the aggravation of the problems due to uncontrolled control, replace manual monitoring by an automatic monitoring means, further adopt a preventive maintenance strategy, carry out the health management of wearing parts such as the toothed conveyer belt, ensure that large shutdown loss does not occur, and save the production cost.
Drawings
Fig. 1 is a hardware configuration diagram of a detection system of the present invention.
Fig. 2 is a schematic view of the detection monitoring position of the present invention.
Fig. 3 is a schematic view of the AI image recognition sensor probe installation of the present invention.
Fig. 4 is a schematic diagram of the smart display of the present invention.
FIG. 5 is a flow chart of a detection system control algorithm of the present invention.
In the figure, a 1-AI image recognition sensor, a 2-single color LED point light source, a 3-polarizer accessory, a 4-sensor controller, a 6-intelligent display, a 7-counting sensor, an 8-audible and visual alarm, a 9-sensor-controller cable and a 10-intelligent display power cable.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings to facilitate understanding of the skilled person.
In the real-time detection system, AI image recognition sensor 1 probes are arranged at 3 positions of a transfer starting point of a synchronous tooth-shaped conveyor belt and an upstream cigarette packet, a transfer finishing point of the cigarette packet in the conveyor belt and a downstream channel and a middle point in the length range of the conveyor belt, illumination compensation is realized by a monochromatic LED point light source 2 arranged at the top of the sensor 1, and a polarizer accessory 3 is covered outside the light source 2 and used for reducing the reflection influence of transparent paper of the cigarette packet. When the conditions of deformation, tooth falling, walking position and the like of the conveying belt are found, the sensor 1 sends signals to the controller 4, the controller is communicated with an upper computer after receiving the information and realizes the access and the output of the information, the real-time monitoring of the tobacco bale handover key area and the position of a lug on the conveying belt is realized, the state of an upstream handover part and a downstream handover part can be considered while the synchronous toothed conveying belt is monitored, and a repair worker can check the real-time image of the operation of the toothed conveying belt through the software 5 on the intelligent display 6. Meanwhile, the counting sensor 7 module records the lug numbers corresponding to the abnormal position points, and alarms, displays information and stops the equipment through the audible and visual alarm 8. After receiving the fault display, the equipment maintenance personnel can take the abnormal information and the related abnormal image to perform abnormal identification and fault diagnosis, thereby improving the maintenance efficiency.
The AI image recognition sensor 1 has the functions of automatic focusing and condition addition, can set up 'qualified' and 'unqualified', and can add detection conditions by technicians when the environment changes, thereby overcoming the problems caused by the change of the actual detection environment, such as fluctuation of an environmental light source, glue and scale accumulation on the surface of a conveyor belt, color difference between the conveyor belt and a new part after long-term operation, inconsistent pattern in a detected area of a cigarette packet caused by product change, and the like, and saving the labor cost caused by sensor change or parameter adjustment and position change caused by each change.
The monochromatic LED point light source 2 is arranged at the top of the sensor 1, provides a light source with constant and stable brightness for a target detection area, ensures the overall brightness of a detected image to be uniform, and eliminates the influence caused by fluctuation of an ambient light source and reflection of transparent paper of a cigarette packet.
The polarizer accessory 3 is arranged in front of the light source 2, so that the influence of halo in a detection area caused by light reflection of the cigarette packet due to wrapping of transparent oil seal paper can be reduced, and the clear and accurate detection image is ensured.
The sensor controller 4 acquires, analyzes and processes the image data obtained by the image recognition sensor with a certain accuracy through the control circuit, further realizes the control of the image and the like on the detection target, and simultaneously controls the automatic recording and storage of the abnormal image and the phase angle.
The software 5 has the following basic functions: (1) contour recognition: selecting a detection target, automatically extracting the outline of the target, and identifying the outline by using shape difference; (2) edge pixel identification: according to the boundary point of the light and shade change, recognizing the object or the surface state with unfixed shape by the number of edge pixels; (3) color identification: setting a threshold value for the RGB average value in the detection area to identify differences by colors; (4) and (3) brightness identification: setting a threshold value for the brightness average value in the detection area to identify the difference by brightness; (5) width identification: and identifying the difference of the target according to the width between the edges according to the boundary point of the light and shade change.
The intelligent display 6 is connected with a 24V power cable, and can perform related operations such as initialization setting, sensor parameter adjustment, historical record inquiry, abnormal image viewing and the like on the real-time detection system by using a software 5 platform arranged in the display, and is used for displaying the current state of the conveying belt during normal work. Meanwhile, the stored information such as abnormal images, historical records, parameter backup and the like can be transmitted and stored through the USB interface, and the reliability of the real-time detection system is improved.
The counting sensor 7 module provides data information through a self-contained encoder of the equipment, can adapt to the accurate positioning of the phase angle and the lug number of the toothed belt under different running speeds of the equipment, and automatically records the lug number corresponding to the abnormal position point according to the signal of the AI image recognition sensor controller 4 for fault diagnosis and abnormal recognition.
The audible and visual alarm 8 needs to be installed at a striking position so as to draw the attention of operators or repair personnel at the highest speed and check and maintain abnormal conditions in advance. When the conditions of deformation, tooth falling, walking position and the like of the conveying belt are found, the AI image recognition sensor 1 sends signals to the controller 4, the controller is communicated with an upper computer after receiving the information and realizes the access and the output of the information, the real-time monitoring of the tobacco bale handover key area and the lug position on the conveying belt is realized, the state of the upstream and downstream handover part can be considered while the synchronous toothed conveying belt is monitored, and repair personnel can check the real-time image of the operation of the toothed conveying belt through the software 5 on the intelligent display 6. Meanwhile, the counting sensor 7 module records the lug number and the equipment phase angle corresponding to the abnormal position point, and alarms, displays information and stops the equipment through the audible and visual alarm 8. After receiving the fault display, the equipment maintenance personnel can take the abnormal information and the related abnormal image to perform abnormal identification and fault diagnosis, thereby improving the maintenance efficiency. The system can realize the monitoring of the running state of the high-speed synchronous toothed conveyer belt, the real-time detection of the walking of the synchronous toothed conveyer belt of the high-speed packaging machine with the functions of walking alarm control and shutdown, and provides timely and reliable diagnosis information for the fault early warning of the synchronous toothed conveyer belt of the high-speed packaging.
Example (b):
in this embodiment, as shown in fig. 2, a synchronous toothed conveyer belt of the high-speed packaging machine selects a starting point of the synchronous toothed conveyer belt for the transfer with the upstream cigarette packet, a finishing point of the transfer with the downstream channel of the cigarette packet in the conveyer belt, and 3 middle points within the length range of the conveyer belt as detection monitoring points.
When the real-time detection system is used for the first time, a qualified image and an unqualified image are required to be set in advance on the intelligent display, namely, a plurality of images are shot as the standard of the qualified state according to the actual running condition of a normal conveying belt, meanwhile, the characteristic states of abrasion deformation, edge abnormity, lug loss, conveying belt dislocation and the like are simulated according to the actual working condition of the abrasion of the conveying belt, and an AI image recognition sensor is used for recording and storing, and is set to the unqualified state, so that the detection initialization setting of the AI image recognition sensor is completed.
The frequency of the AI image recognition sensor is related according to the phase angle of the equipment, and the AI image recognition sensor is connected with an upper computer of the equipment through a connection communication unit and reads the phase angle of an encoder of the equipment. The sensor is driven by the angle encoder signal every time of taking a picture, and the sensor is ensured to carry out automatic adaptation according to the motion rule of the conveyer belt under different running vehicle speeds, namely the conveyer belt takes a picture at the stop moment of every intermittent motion, and the influence of the camera on taking a picture in the conveyer belt motion caused by the change of the running vehicle speed of the equipment is avoided.
When the real-time detection system works normally, the AI image recognition sensor automatically adjusts the image acquisition frequency according to the running speed of the equipment, acquires and checks images at the pause moment of the toothed conveyer belt every time, and outputs the detection result. When the situations of deformation, tooth falling, dislocation and the like of lugs of a conveying belt occur in a detected target image, the AI image recognition sensor sends a signal to the controller, and the controller is communicated with the upper computer after receiving the information and realizes the access and output of the information; and the counting sensor module records the lug numbers corresponding to the abnormal position points, gives an alarm through an audible and visual alarm and controls equipment to stop. The repair personnel can check the real-time image and the abnormal image of the operation of the toothed conveyer belt through software on the intelligent display.
Finally, it is noted that the above-mentioned preferred embodiments illustrate rather than limit the invention, and that, while the invention has been described in detail with reference to the foregoing preferred embodiments, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the scope of the invention as defined by the appended claims; the size of the attached figure is irrelevant to the specific real object, and the size of the real object can be changed at will.
Claims (1)
1. The utility model provides a high-speed packagine machine synchronous profile of tooth conveyer belt walks real-time detection system of position which characterized in that: the real-time detection system for the walking of the synchronous toothed conveyer belt of the high-speed packaging machine is composed of an AI image recognition sensor (1), a single-color LED point light source (2), a polarizer accessory (3), a sensor controller (4), an intelligent display (6), a counting sensor (7), an audible and visual alarm (8), a sensor-controller cable (9) and an intelligent display power cable (10), wherein the AI image recognition sensor (1), the single-color LED point light source (2), the polarizer accessory (3) and the counting sensor (7) are connected with the sensor controller (4) through the sensor-controller cable (9), the sensor controller (4) is connected with the intelligent display (6), and the intelligent display (6) is connected with the audible and visual alarm (8);
the AI image recognition sensor (1) selects at least 3 positions of a synchronous tooth-shaped conveyer belt and an upstream tobacco bale handover starting point, a tobacco bale handover terminal point in the conveyer belt and a downstream channel handover terminal point and a middle point in the length range of the conveyer belt to be installed;
the AI image recognition sensor (1) has automatic focusing and condition adding functions, can perform initialization setting of 'qualified' and 'unqualified' images, can add detection conditions by technicians when the environment changes, is provided with a monochromatic LED point light source (2) at the top of the AI image recognition sensor (1) to realize illumination compensation, and is covered with a polarizer accessory (3) outside the monochromatic LED point light source (2) to reduce the reflection influence of transparent paper of a cigarette packet;
the sensor controller (4) acquires, analyzes and processes the image data obtained by the AI image recognition sensor (1), so as to control the image to be detected and control the automatic recording and storage of the abnormal image;
the intelligent display (6) is connected with a 24V power cable, and can perform related operations of initialization setting, sensor parameter adjustment, historical record inquiry and abnormal image checking on the real-time detection system by using a software (5) platform arranged in the display;
the software (5) is used for identifying the following characteristics: (1) contour recognition: selecting a detection target, automatically extracting the outline of the target, and identifying the outline by using shape difference; (2) edge pixel identification: according to the boundary point of the light and shade change, recognizing the object or the surface state with unfixed shape by the number of edge pixels; (3) color identification: setting a threshold value for the RGB average value in the detection area to identify differences by colors; (4) and (3) brightness identification: setting a threshold value for the brightness average value in the detection area to identify differences according to brightness; (5) width identification: identifying the difference of the target according to the boundary point of the light and shade change by the width between the edges;
the counting sensor (7) module is provided with data information by a self-contained encoder of the equipment, can adapt to the accurate positioning of the phase angle and the lug number of the toothed belt under different running speeds of the equipment, automatically records the lug number corresponding to the abnormal position point according to the signal of the sensor controller (4), and is used for fault diagnosis and abnormal identification;
the audible and visual alarm (8) is arranged at the upper part of the frame of the intelligent display (6) and is used for arousing the attention of operators or repair personnel to check and maintain abnormal conditions in advance;
when the conditions of deformation, tooth falling and walking of the conveying belt are found, the AI image recognition sensor (1) sends signals to the sensor controller (4), the sensor controller (4) is communicated with an upper computer after receiving the information and realizes the access and output of the information, the real-time monitoring of a tobacco bale handover key area and the positions of lugs on the conveying belt is realized, the states of an upstream handover part and a downstream handover part can be considered while the synchronous toothed conveying belt is monitored, a counting sensor (7) module records the lug numbers and equipment phase angles corresponding to abnormal position points, and an audible and visual alarm (8) is used for alarming, information display and equipment halt; the repair personnel can view the real-time image of the operation of the toothed conveyer belt through the software (5) on the intelligent display (6).
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| CN117023039A (en) * | 2023-07-31 | 2023-11-10 | 嘉兴德鑫电子科技有限公司 | Control method and system for terminal block production conveying line for new energy automobile |
| CN116887475B (en) * | 2023-09-08 | 2023-12-08 | 哈尔滨本晟创新科技有限公司 | Multichannel light quality light quantity band adjustment controller driving circuit and control method thereof |
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| CN101804907A (en) * | 2010-03-17 | 2010-08-18 | 燕山大学 | Machine vision belt tearing detecting and protecting device |
| CN102275723A (en) * | 2011-05-16 | 2011-12-14 | 天津工业大学 | Machine-vision-based online monitoring system and method for conveyer belt |
| CN109230351B (en) * | 2018-08-30 | 2020-06-16 | 精英数智科技股份有限公司 | Method for identifying abnormal operation of belt conveyor |
| CN211768495U (en) * | 2020-01-18 | 2020-10-27 | 晶测自动化(深圳)有限公司 | Intelligent conveying belt and system thereof |
| CN111289529B (en) * | 2020-02-28 | 2023-05-23 | 瑞思特(珠海)科技有限责任公司 | Conveying belt tearing detection system and detection method based on AI intelligent analysis |
| CN111999299A (en) * | 2020-08-24 | 2020-11-27 | 精英数智科技股份有限公司 | Belt detection method, belt detection device and belt detection system |
| CN216140296U (en) * | 2021-08-19 | 2022-03-29 | 红云红河烟草(集团)有限责任公司 | Real-time detection system for walking of synchronous toothed conveying belt of high-speed packaging machine |
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