CN113911629A - Intelligent coal flow conveying system - Google Patents
Intelligent coal flow conveying system Download PDFInfo
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- CN113911629A CN113911629A CN202111214369.9A CN202111214369A CN113911629A CN 113911629 A CN113911629 A CN 113911629A CN 202111214369 A CN202111214369 A CN 202111214369A CN 113911629 A CN113911629 A CN 113911629A
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- 239000003245 coal Substances 0.000 title claims abstract description 109
- 230000005540 biological transmission Effects 0.000 claims abstract description 20
- 239000000463 material Substances 0.000 claims abstract description 14
- 238000007781 pre-processing Methods 0.000 claims abstract description 11
- 238000000605 extraction Methods 0.000 claims abstract description 10
- 238000005070 sampling Methods 0.000 claims abstract description 6
- 238000012545 processing Methods 0.000 claims description 16
- 238000001514 detection method Methods 0.000 claims description 11
- 238000007689 inspection Methods 0.000 claims description 11
- 238000001931 thermography Methods 0.000 claims description 5
- 238000004891 communication Methods 0.000 claims description 3
- 238000003860 storage Methods 0.000 claims description 3
- 239000000284 extract Substances 0.000 claims description 2
- 238000005265 energy consumption Methods 0.000 abstract description 5
- 230000000694 effects Effects 0.000 abstract description 3
- 238000005299 abrasion Methods 0.000 abstract 1
- 239000007789 gas Substances 0.000 description 6
- 238000006243 chemical reaction Methods 0.000 description 5
- 238000012544 monitoring process Methods 0.000 description 5
- 238000000034 method Methods 0.000 description 3
- 230000002035 prolonged effect Effects 0.000 description 3
- 238000010586 diagram Methods 0.000 description 2
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- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 229910002091 carbon monoxide Inorganic materials 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
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- 230000007613 environmental effect Effects 0.000 description 1
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- 238000012423 maintenance Methods 0.000 description 1
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- 230000002265 prevention Effects 0.000 description 1
- 230000011218 segmentation Effects 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G15/00—Conveyors having endless load-conveying surfaces, i.e. belts and like continuous members, to which tractive effort is transmitted by means other than endless driving elements of similar configuration
- B65G15/30—Belts or like endless load-carriers
- B65G15/32—Belts or like endless load-carriers made of rubber or plastics
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G43/00—Control devices, e.g. for safety, warning or fault-correcting
- B65G43/08—Control devices operated by article or material being fed, conveyed or discharged
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G2201/00—Indexing codes relating to handling devices, e.g. conveyors, characterised by the type of product or load being conveyed or handled
- B65G2201/04—Bulk
- B65G2201/045—Sand, soil and mineral ore
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G2203/00—Indexing code relating to control or detection of the articles or the load carriers during conveying
- B65G2203/02—Control or detection
- B65G2203/0208—Control or detection relating to the transported articles
- B65G2203/0241—Quantity of articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G2203/00—Indexing code relating to control or detection of the articles or the load carriers during conveying
- B65G2203/04—Detection means
- B65G2203/041—Camera
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G2203/00—Indexing code relating to control or detection of the articles or the load carriers during conveying
- B65G2203/04—Detection means
- B65G2203/042—Sensors
Abstract
The invention discloses an intelligent coal flow conveying system, which belongs to the technical field of coal flow conveying and solves the problem of ineffective abrasion of a transmission part of the coal flow conveying system, thus greatly improving the energy consumption of the whole system and reducing the service life and the running reliability of equipment. The laser image preprocessing module is used for determining an identification area; the limit contour extraction module is used for extracting a lower limit contour line in no-load according to an upper limit contour line extracted when the coal material is in the maximum load on the conveying belt; the coal material cross section contour extraction module obtains coal quantity data according to the instantaneous cross section contour, the sampling frequency of the camera for the conveyed image and the transmission speed, and achieves the effects of improving the working reliability, saving energy and reducing consumption.
Description
Technical Field
The invention relates to the field of coal flow conveying, in particular to an intelligent coal flow conveying system.
Background
At present, chinese patent publication No. CN110950002A discloses an operation control method for a high-voltage frequency-conversion intelligent main coal flow conveying system. In the above-mentioned published documents, the high-voltage frequency-conversion main coal flow intelligent conveying system comprises a torque detection system, a control system and a high-voltage frequency-conversion transmission system, wherein the high-voltage frequency-conversion transmission system comprises a conveying belt driven by a plurality of frequency-conversion motors; the torque detection system sends a torque sampling signal of the variable frequency motor to the control system, the control system converts the torque sampling signal into torque data, estimates the coal amount of the current conveyor belt load according to the torque data, controls the high-voltage variable frequency transmission system according to the torque data and/or the estimated coal amount, and adjusts the running speed of the conveyor belt.
The scheme only solves a part of problems in the coal remaining and conveying process, and the conventional system runs at full speed in the conveying process after being started, so that energy consumption is high, transmission parts of the coal flow conveying system are worn inefficiently, and the energy consumption of the whole system is greatly improved, the service life of equipment is prolonged, and the running reliability is reduced.
Disclosure of Invention
The invention aims to solve the technical problems in the related art at least to a certain extent aiming at the defects in the prior art, and provides an intelligent coal flow conveying system which has the advantages of stable and reliable work and energy consumption reduction.
In order to solve the technical problems, the technical scheme of the invention is as follows:
an intelligent coal flow conveying system comprises a belt conveyor, a laser emitter and a camera are erected on the belt conveyor and connected with a computing terminal, the camera is used for acquiring image data,
the computing terminal includes:
the laser image preprocessing module is used for determining an identification area;
the limit contour extraction module is used for extracting a lower limit contour line in no-load according to an upper limit contour line extracted when the coal material is in the maximum load on the conveying belt;
the coal material cross section contour extraction module is used for identifying a laser contour line on a laser image, fitting the bottom contour of the belt conveyor to form an instantaneous cross section contour of the coal material, and obtaining coal quantity data according to the instantaneous cross section contour, the sampling frequency of the camera on the conveying image and the transmission speed;
and when the coal quantity data is lower than the threshold value, warning and controlling the transmission speed of the transmission belt.
Preferably, the belt conveyors are provided with a plurality of belt conveyors and are mutually connected to transmit coal materials, each belt conveyor is connected to the intelligent speed regulation controller, the intelligent speed regulation controller specifies a plurality of levels of given speeds according to an area where the coal quantity is located, the coal quantity is divided into n coal quantity areas from small to large in sequence, and n given speeds from small to large are set corresponding to the n coal quantity areas.
Preferably, the value of n is three, the three coal quantity areas are respectively a lower limit area, a middle limit area and an upper limit area, and the corresponding given perusal is respectively a first constant speed value, a second constant speed value and a third constant speed value.
Preferably, the overlapping mode of the belt conveyor comprises one or more of the following four modes, namely belt conveyor tandem overlapping, belt conveyor convergent overlapping, belt conveyor overlapping coal bunker and coal bunker overlapping belt conveyor.
Preferably, a track inspection trolley is arranged on a transmission path of the belt conveyor, a camera device, a thermal imaging device and a harmful gas detection device are arranged on the track inspection trolley, and the track inspection trolley is in data communication and storage with a background server through a wireless network.
Preferably, the computing terminal further comprises a video image processing module, the boundary of the coal can be distinguished by computing the standard deviation of the pixel values of the same pixel point on the multi-frame image, and the coal amount is obtained through boundary data of the coal amount.
Preferably, the computing terminal comprises a switching module for selecting one or two of the video image processing module and the laser image preprocessing module to obtain the coal quantity data.
Preferably, the switching module selects a switch of the video image processing module according to the ambient temperature and the light data to assist the laser image preprocessing module in working.
Compared with the background technology, the technical effects of the invention are mainly reflected in the following aspects:
1. the coal quantity data and the distribution condition of the coal quantity on a transmission belt can be rapidly and accurately acquired in real time, and data support and early warning processing are provided for the system;
2. the coal conveying speed is improved, the work tasks of different belt conveyors are reasonably distributed, the work efficiency is improved, the energy consumption is saved, and the service life of equipment is prolonged.
Drawings
FIG. 1 is a schematic view showing a mounting position of a system component in the embodiment;
FIG. 2 is a schematic processing diagram of a video image processing module according to an embodiment;
FIG. 3 is an example of a gray scale value chart of the video image processing module in the embodiment;
FIG. 4 is an exemplary regulation of the intelligent speed regulator in an embodiment;
FIG. 5 is a block diagram of the module according to the embodiment.
Reference numerals: 1. a belt conveyor; 2. a laser transmitter; 3. a camera; 4. a computing terminal; 41. a laser image preprocessing module; 42. a limit contour extraction module; 43. a coal cross section contour extraction module; 44. a video image processing module; 5. an intelligent speed regulation controller; 6. a track inspection trolley; 61. a camera device; 62. a thermal imaging device; 63. a harmful gas detection device; 7. and a switching module.
Detailed Description
The following detailed description of the embodiments of the present invention is provided in order to make the technical solution of the present invention easier to understand and understand.
Example (b):
the utility model provides an intelligence coal flows conveying system, includes belt conveyor 1, and belt conveyor 1 is put on the shelf and is equipped with laser emitter 2 and camera 3, and laser emitter 2 and camera 3 are connected in computing terminal 4, and camera 3 is used for acquireing image data. The coal quantity detection is the basis for realizing intelligent speed regulation of the coal flow conveying system, so the device and the system need to be applied to the real-time monitoring of the coal quantity. The conveyor belt scale has large detection maintenance amount, and the detection precision can not meet the speed regulation requirement, so the following scheme is adopted to overcome the problems.
The computing terminal 4 includes:
a laser image preprocessing module 41 for determining the identification area; the limit contour extraction module 42 is used for extracting a lower limit contour line in no-load according to an upper limit contour line extracted when the coal material is in the maximum load on the conveying belt; a coal cross-section contour extraction module 43, configured to identify a laser contour on the laser image, fit the bottom contour of the belt conveyor to form an instantaneous cross-section contour of the coal, and obtain coal amount data according to the instantaneous cross-section contour, the sampling frequency of the camera 3 for the conveyed image, and the transmission speed; and when the coal quantity data is lower than the threshold value, warning and controlling the transmission speed of the transmission belt.
Referring to fig. 1, a laser emitter 2 and a digital camera 3 are installed above a conveying belt of a belt conveyor 1, the laser emitter 2 is vertically installed above the conveying belt, and the digital camera 3 is installed above the belt conveyor 1 at an angle, preferably 60 degrees from the horizontal plane in the scheme, so that the digital camera 3 photographs the area of the conveying belt irradiated by the laser emitter 2. The digital camera 3 transmits the shot image to the computing terminal 4 through the network, and the computing terminal 4 extracts the coal contour line on the belt conveyor 1 through video image analysis. The laser line generated by the laser projected on the coal charge level is different from the laser line generated by the laser projected on the conveyor belt of the belt conveyor 1 without coal, and the laser line and the conveyor belt have an obvious difference, so that the outline is identified according to the difference. In combination with the profile of the conveyor belt, an area can be formed, from which the area of the cross section of the coal charge is obtained, and from the monitored speed, the coal quantity can be calculated.
On the basis of the above scheme, the computing terminal 4 further includes a video image processing module 44, which can identify the boundary of the coal by calculating the standard deviation of the pixel values of the same pixel point on the multi-frame image, and obtain the coal amount according to the boundary data of the coal amount. The computing terminal 4 comprises a switching module 7 for selecting one or two of the video image processing module 44 and the laser image preprocessing module 41 to obtain the coal quantity data. The switching module 7 switches the video image processing module 44 according to the ambient temperature and the light data to assist the laser image preprocessing module 41 in working.
The scheme is mainly used for solving the problem that the profile formed by the laser has some environment factor variables, mainly because the laser has interference on external natural light, and some environment temperature also has interference on image data acquisition, and the video photos are required to be used for compensation.
As shown in fig. 3 and 4, a camera is installed above the belt conveyor 1 to acquire a video image, and the edge of the coal distributed on the belt conveyor 1 is detected by analyzing and processing the image, so that the width of the coal distributed on the belt conveyor 1 is obtained. As shown in fig. 3, the conveyor belt is arc-shaped, and the deformation of the conveyor belt is different when the coal amount is different, so that the instantaneous coal amount can be calculated according to the coal accumulation contour line. The key of the detection method is the detection of the coal edge, namely, the difference between the pixel value of the transmission belt of a coal-free area and the pixel value of a coal-containing area is distinguished. Firstly, a high-definition camera is adopted to collect video images, and then the images are preprocessed, namely, noise filtering of the images and segmentation of different areas of the images are carried out. The image noise is mainly impact noise caused by instantaneous coal charge increase and decrease on the belt conveyor 1, and extreme value median filtering is adopted for extracting effective coal charge signals to the image to eliminate the noise in the image.
Since the coal edge points are generally located at the positions where the gray values in the image change drastically, i.e., where the derivative of the gray values is large or extremely large, the edges of the image are sharpened spatially by gradient or differential algorithms. By processing the multi-frame images which are continuous in time, the pixel value of the same pixel point in the coal-containing area is changed violently, and the pixel value of the same pixel point in the coal-free area is not changed greatly. According to the characteristic, the boundary of the coal material can be distinguished by calculating the standard deviation of the pixel values of the same pixel point on a multi-frame image. The standard deviation can reflect the fluctuation of a group of data, and the numerical value corresponding to the standard deviation changes dramatically when the gray value is 150, i.e. the boundary between the coal-containing region and the coal-free region is shown in fig. 4. The gray value is within the interval of 250-300, the value of the standard deviation also changes drastically, i.e. the boundary between another coal-containing region and another coal-free region.
For speed regulation, a plurality of belt conveyors 1 are arranged and are mutually connected to transmit coal materials, each belt conveyor 1 is connected to an intelligent speed regulation controller 5, the intelligent speed regulation controller 5 specifies multistage given speeds according to the area where the coal quantity is located, the coal quantity is sequentially divided into n coal quantity areas from small to large, and n given speeds from small to large are set corresponding to the n coal quantity areas. And n is three, the three coal quantity areas are respectively a lower limit area, a middle limit area and an upper limit area, and the corresponding given perusal is respectively a first constant speed value, a second constant speed value and a third constant speed value.
According to the yield, the optimal height of the coal on the section of the belt conveyor 1 is optimized, the speed of the belt conveyor 1 is adjusted, the energy-saving effect is about 20%, and the service life of the equipment is prolonged by more than 50%. The speed regulation is not needed when the transportation volume is 80 percent, the speed regulation and the energy saving are realized when the transportation volume is 40 percent, the frequent speed regulation is avoided, and the transportation volume is little or not stopped. The belt speed versus load relationship is shown in fig. 4.
The overlapping mode of the belt conveyor 1 comprises one or more of the following four modes of overlapping the belt conveyor 1 in a serial mode, overlapping the belt conveyor 1 in a collecting mode, overlapping the belt conveyor 1 with a coal bunker and overlapping the belt conveyor 1 with the coal bunker.
Finally, referring to fig. 5, a track inspection trolley 6 is arranged on the transmission path of the belt conveyor 1, a camera 61, a thermal imaging device 62 and a harmful gas detection device 63 are arranged on the track inspection trolley 6, and the track inspection trolley 6 performs data communication and storage with a background server through a wireless network.
During the operation of the coal flow conveying system, various accidents such as carrier roller damage, belt breakage, longitudinal tearing, deviation, slippage, coal piling, fire and the like easily occur, and great hidden dangers are caused to the safety production of personnel and mechanical equipment. In these accidents, environmental factors, equipment failures, human factors account for a considerable proportion, and effective monitoring and prevention is essential. The traditional monitoring mode usually adopts manual inspection or fixed-point monitoring of a fixed camera, the former wastes manpower, has low efficiency, and the severe condition threatens the personal safety.
The robot carries high definition camera device 61, thermal imaging appearance and multiple harmful gas sensor etc. through the walking drive mode of non-maintaining wire rope, track combined type, can carry out the task of patrolling and examining in the pit of a great deal of coal flow conveying system, replaces traditional manual work to patrol and examine, realizes intelligent control early warning. And monitoring and early warning harmful gases. The robot carries various sensors such as dust, methane, carbon monoxide, temperature and humidity, monitors the concentration of harmful gases and the ambient temperature in real time, and establishes a threshold alarm function.
The above are only typical examples of the present invention, and besides, the present invention may have other embodiments, and all the technical solutions formed by equivalent substitutions or equivalent changes are within the scope of the present invention as claimed.
Claims (8)
1. The utility model provides an intelligence coal flow conveying system, includes belt conveyor (1), characterized by: the belt conveyor (1) is provided with a laser emitter (2) and a camera (3) in an overhead manner, the laser emitter (2) and the camera (3) are connected with a computing terminal (4), the camera (3) is used for acquiring image data,
the computing terminal (4) comprises:
a laser image preprocessing module (41) for determining an identification area;
the limit contour extraction module (42) extracts a lower limit contour line when the coal material is unloaded according to an upper limit contour line extracted when the coal material is at the maximum load on the conveying belt;
the coal material cross section contour extraction module (43) is used for identifying a laser contour line on a laser image, fitting the bottom contour of the belt conveyor to form an instantaneous cross section contour of the coal material, and obtaining coal quantity data according to the instantaneous cross section contour, the sampling frequency of the camera (3) for conveying the image and the transmission speed;
and when the coal quantity data is lower than the threshold value, warning and controlling the transmission speed of the transmission belt.
2. The intelligent coal flow conveying system according to claim 1, wherein: the belt conveyors (1) are provided with a plurality of belt conveyors and are mutually connected to transmit coal materials, each belt conveyor (1) is connected to an intelligent speed regulation controller (5), the intelligent speed regulation controller (5) specifies multi-stage given speed according to an area where the coal quantity is located, the coal quantity is divided into n coal quantity areas from small to large in sequence, and n given speeds from small to large are set corresponding to the n coal quantity areas.
3. The intelligent coal flow conveying system according to claim 2, wherein: and the value of n is three, the three coal quantity areas are respectively a lower limit area, a middle limit area and an upper limit area, and the corresponding given perusal is respectively a first constant speed value, a second constant speed value and a third constant speed value.
4. The intelligent coal flow conveying system according to claim 1, wherein: the overlapping mode of the belt conveyor (1) comprises one or more of the following four modes of serial overlapping of the belt conveyor (1), convergent overlapping of the belt conveyor (1), overlapping of a coal bunker by the belt conveyor (1) and overlapping of the coal bunker by the belt conveyor (1).
5. The intelligent coal flow conveying system according to claim 4, wherein: a track inspection trolley (6) is arranged on a transmission path of the belt conveyor (1), a camera device (61), a thermal imaging device (62) and a harmful gas detection device (63) are arranged on the track inspection trolley (6), and the track inspection trolley (6) is in data communication and storage with a background server through a wireless network.
6. The intelligent coal flow conveying system according to claim 1, wherein: the computing terminal (4) further comprises a video image processing module (44), the boundary of the coal can be distinguished by computing the standard deviation of the pixel values of the same pixel point on the multi-frame image, and the coal amount is obtained through boundary data of the coal amount.
7. The intelligent coal flow conveying system according to claim 6, wherein: the computing terminal (4) comprises a switching module (7) for selecting one or two of a video image processing module (44) and a laser image preprocessing module (41) to obtain the coal quantity data.
8. The intelligent coal flow conveying system according to claim 7, wherein: the switching module (7) is used for selecting a switch of the video image processing module (44) according to the ambient temperature and the light data so as to assist the laser image preprocessing module (41) to work.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117819160A (en) * | 2024-03-04 | 2024-04-05 | 宝鸡杭叉工程机械有限责任公司 | Automatic monitoring method and system for coal flow of belt conveyor based on image processing |
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