CN114140733A - Belt running state detection method based on video - Google Patents
Belt running state detection method based on video Download PDFInfo
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Abstract
The invention relates to the technical field of belt conveyor maintenance, in particular to a method for detecting a belt running state based on videos. The method comprises the steps of arranging a camera module, a sensor and a computer component; building a system architecture and a detection system; monitoring the belt conveying device in real time; detecting and identifying the equipment running state and the abnormal fault condition of the belt conveying device based on the video data; judging the running state, and scoring the influence degree of the abnormal condition on the running safety performance of the equipment; setting a safety protection mechanism, executing safety protection measures when abnormal conditions occur, outputting alarm signals, carrying out maintenance scheduling and the like. The design of the invention is based on monitoring video, and the running state of the belt conveying device is detected and judged in real time; evaluating the influence degree of the abnormal condition, accurately evaluating the running state of the belt conveyor, improving the detection efficiency and reducing negligence and mistake and leakage; the potential safety hazard of production can be effectively reduced, the waste is reduced, and the safe operation of production is guaranteed.
Description
Technical Field
The invention relates to the technical field of belt conveyor maintenance, in particular to a method for detecting a belt running state based on videos.
Background
The belt conveyor is one of mechanical equipment used by many enterprises for transporting materials in a continuous mode through friction drive, is widely applied to the fields of metallurgy, mineral separation, petroleum, chemical industry, light industry, building materials, steel mills, ports and the like, and is increasingly developed towards high speed, large scale and ultra-long distance. In industries such as electric power, petrifaction, cement, smelting and processing, a large number of belt conveyors are equipped for conveying bulk materials. The conveying belt is an important component of a belt conveyor, the cost of the belt conveyor accounts for a high proportion of the whole belt conveyor, but the belt tearing accident happens, once the conveying belt with high value is longitudinally torn, conveyed materials invade an equipment mechanical system to cause equipment damage, even serious accidents such as personnel injury and the like, and huge economic loss are caused; meanwhile, in the transportation process of the belt conveyor, abnormal operation conditions such as driving motor faults, belt deviation, overload, no-load, sundry obstacles and the like not only affect the working efficiency of the belt conveyor and cause waste of materials and resources, but also possibly cause serious mechanical faults. Therefore, the normal operation of the belt conveyor apparatus is a key element of safe production.
However, in the prior art, the detection of the belt conveyor mainly relates to the aspects of equipment components or abnormal materials, and the monitoring of the running state of the equipment is mainly completed by means of manpower inspection, so that a large amount of manpower and time are consumed, the detection efficiency is low, and the belt conveyor is easy to neglect and miss, thereby greatly restricting the improvement of the operation efficiency and the dispatching automation level of the belt conveyor conveying system. Therefore, if video monitoring, image recognition and AI intelligent analysis techniques can be introduced, it is expected to improve the automation level of safety supervision of the belt conveyor. In view of this, we propose a video-based belt running state detection method.
Disclosure of Invention
The invention aims to provide a video-based belt running state detection method to solve the problems in the background technology.
In order to solve the above technical problem, an object of the present invention is to provide a video-based belt running state detection method, including the following steps:
s1, arranging corresponding video camera modules and various sensors near the belt of the belt conveying device, and arranging a video processing computer component at the near end or the far end of the belt conveying device;
s2, building a system framework of the running state of the belt by combining the arranged devices and sensors, configuring the running environment of the detection system, and building the running state detection system of the belt;
s3, starting a video-based belt running state detection device, and monitoring the running state of the belt conveying device in real time;
s4, detecting and identifying the running state and abnormal fault conditions of the belt conveying device based on the real-time recorded video data through an AI intelligent analysis technology, an image recognition technology and a neural network learning method;
s5, accurately judging the running state of the belt conveying device by combining the state parameters acquired by various sensors in real time, and scoring the influence degree of the judged abnormal conditions on the running safety performance of the equipment according to a preset scoring standard;
s6, setting a corresponding safety protection mechanism aiming at the abnormal belt running state which possibly occurs, when the belt conveying device has abnormal conditions, executing the measures of the safety protection mechanism according to a preset program, outputting an alarm signal in time, and scheduling and arranging aiming at the maintenance operation.
As a further improvement of the present invention, in S1, the video camera modules disposed near the belt conveyor include, but are not limited to: the high-definition camera covers the whole belt conveying device in the visual field, is arranged above the belt at a certain depression angle and is used for shooting the belt, is arranged near the driving motor and is used for shooting the driving motor and is provided with a recording function, and the like; various types of sensors deployed in the vicinity of the belt conveyor include, but are not limited to: the device comprises material flow detection devices respectively arranged at the head end and the tail end of the belt conveying device, speed sensors respectively arranged at the head end and the tail end of the belt conveying device, weighing sensors respectively arranged at the lower parts of bearing support rollers at the head end and the tail end of the belt conveying device, a voltage detection device electrically connected with a driving motor and the like; computer components include, but are not limited to: the system comprises a processor, a display, a network switch, a cloud server, a video/image recognition program module, an AI intelligent analysis terminal and the like.
As a further improvement of this solution, in S4, when the image is identified by the image identification technology, preprocessing such as dimension reduction, color binarization, and image segmentation is required to be performed on the target image, and the method and related algorithm adopted by the method are as follows:
the image dimensionality reduction adopts a PCA dimensionality reduction algorithm, and comprises the following steps:
The algorithm process is as follows:
Step5, multiplying the original matrix by the projection matrix:i.e. reduced dimension data setWhereinIs composed ofThe ratio of vitamin to vitamin is,is vitamin A;
and (3) outputting: reducing the dimension of the data set;
the color binarization processing adopts an Otsu threshold value method, and the algorithm expression is as follows:
for imagesProspect ofThe segmentation threshold of the (target) and background is denoted as T, and the proportion of the number of pixels belonging to the foreground in the whole image is denoted asAverage gray scale of(ii) a The number of background pixels is in proportion to the whole image, and the average gray level is(ii) a The total average gray scale of the image is recorded asThe inter-class variance is recorded as g;
assume that the background of the image is dark and the size of the image isThe number of pixels in the image whose grey value is less than the threshold value T is recorded asThe number of pixels having a pixel gray level greater than the threshold T is counted asThen, there are:
substituting formula (5) for formula (6) yields the equivalent formula:
the formula (7) is the inter-class variance, and the threshold T with the maximum inter-class variance g is obtained by adopting a traversal method, namely the obtained threshold T is the solved threshold;
the image segmentation processing adopts a watershed algorithm, and the algorithm expression is as follows:
the simulation flooding process from bottom to top is a recursion process, and the formula (1) belongs to the initial condition of the recursion process and enables the pixel point with the minimum gray value in the image I; formula (2) is a recursive process;
in the formula, h represents the range of gray scale values,is the minimum value of the gray value range,as a range of gray valuesA maximum value;is a gray scale value and an altitude ofAll of the pixel points of (a) above,indicating that this point belongs to the newly created basin minimum, i.e. atThis altitude in turn creates a new basin;to representPoint and pointThe points are intersected with each other at the same time,is composed ofThe basin where the points are located, thereforeIs characterized byPoint and pointPoints that are co-located in a basin;
through the recursion process, all pixel points in the image I are divided into basins.
As a further improvement of the present invention, in S4, the abnormal failure condition of the belt conveying device includes but is not limited to: driving motor failure, belt deviation, belt tearing, bulk material obstacle, metal sundry abrasion and the like.
As a further improvement of the present technical solution, in S5, the operation state of the belt conveying device includes, but is not limited to: start/stop, no load, loaded, overloaded, material spread, too fast/too slow of a transport speed, material flow source/tail position change, loaded start, etc.
Another object of the present invention is to provide a video-based belt running state detecting system, which includes: the device comprises a video processing module, a monitoring detection module, an identification scoring module and a signal output module; the signal output end of the video processing module is connected with the signal input end of the monitoring detection module, the signal output end of the monitoring detection module is connected with the signal input end of the identification scoring module, and the signal output end of the identification scoring module is connected with the signal input end of the signal output module; wherein:
the video processing module is used for carrying out real-time video recording and storage on the whole of the belt conveying device and the running conditions of various parts such as a belt, a driving motor and the like;
the monitoring detection module is used for identifying the shot video and the image intercepted from the video, screening out the characteristic video with abnormal conditions and transmitting the characteristic video into the identification scoring module;
the judging and scoring module is used for judging and scoring the type of the abnormal condition through a neural network method according to the characteristic video of the abnormal condition and scoring and evaluating the influence degree of the abnormal type on the safety performance of the belt conveying device in the operation process according to a preset scoring rule;
the signal output module is used for outputting the detected abnormal conditions and the grading data thereof, executing a preset safety protection mechanism and outputting an alarm signal.
As a further improvement of the technical scheme, the video processing module further comprises a video acquisition sub-module, a video transmission sub-module and a video storage sub-module; the signal output end of the video acquisition submodule is connected with the signal input end of the video transmission submodule, and the signal output end of the video transmission submodule is connected with the signal input end of the video storage submodule; the video acquisition submodule is used for shooting and recording a video of the running state of the inner belt of the visual field of the belt conveyor in real time through a video shooting module arranged near the belt conveyor; the video transmission sub-module is used for transmitting the real-time recorded video to the processor for processing through a wired/wireless transmission technology; the video storage submodule is used for transmitting the original video data and the abnormal video identified by processing to the local/cloud storage for storage; the video storage submodule is used for local storage or cloud storage.
As a further improvement of the technical scheme, the monitoring and detecting module also comprises an AI intelligent analysis submodule, an image recognition submodule and a sensing data management submodule; the AI intelligent analysis submodule, the image recognition submodule and the sensing data management submodule are sequentially connected through network communication and run in parallel; the AI intelligent analysis submodule is used for analyzing the video stream through an AI intelligent analysis technology and detecting the video with abnormal conditions in the running state of the belt; the image identification submodule is used for intercepting the image in the video with abnormal conditions for further identification and judgment through an image identification technology; and the sensing data management submodule is used for acquiring the state parameters acquired by each sensor, and performing sorting, statistics, analysis and storage management on the sensing parameters.
As a further improvement of the technical scheme, the judgment and scoring module further comprises a neural network algorithm submodule, a state judgment submodule and a safety influence scoring submodule; the signal output end of the neural network algorithm submodule is connected with the signal input end of the state judgment and identification submodule, and the signal output end of the state judgment and identification submodule is connected with the signal input end of the safety influence scoring submodule; the neural network algorithm submodule is used for monitoring and judging the belt operation abnormal condition which can be identified by naked eyes in the video by adopting a neural network method; the state identification sub-module is used for identifying the running state of the belt conveying device by combining the sensing data at the same time point as the abnormal condition of the belt and roughly analyzing the reason of the abnormal condition of the belt; and the safety influence scoring submodule is used for evaluating and scoring the influence degree of the judged and identified belt abnormal condition on the running safety performance of the belt conveying device according to a preset scoring rule.
As a further improvement of the technical scheme, the signal output module further comprises a safety mechanism sub-module, an alarm signal sub-module and a maintenance scheduling sub-module; the safety mechanism submodule, the alarm signal submodule and the overhaul scheduling submodule are sequentially connected through network communication and run in parallel; the safety mechanism submodule is used for setting a corresponding safety protection mechanism including shutdown according to the possible abnormal type and the influence degree of the abnormal condition on the safety performance in the running process of the belt conveying device, and automatically executing a safety protection program when the preset condition is reached; the alarm signal sub-module is used for sending out alarm signals in various modes when detecting that the belt conveying device has abnormal operating conditions; and the overhaul scheduling submodule is used for scheduling overhaul and maintenance on the abnormal operating condition according to a certain rule or sequence.
The protection program of the security protection mechanism includes but is not limited to: stopping the machine (such as motor faults, severe belt tearing and the like), reducing the conveying speed (such as belt deviation, material scattering and the like), reducing the power of a driving motor (such as overhigh voltage of the driving motor), reducing the conveying capacity (such as slight belt tearing, material scattering, overload, loaded starting and the like) and the like.
Wherein, the alarm mode includes but not limited to: flashing, pop-up, buzzer, warning light, short message notification, etc.
Wherein, the rule or sequence according to which the maintenance scheduling is performed may be: time by time, safety impact degree by size, position by height/front and back, maintenance difficulty and the like.
It is a further object of the present invention to provide an operating apparatus of a video-based belt running state detecting system, which comprises a processor, a memory and a computer program stored in the memory and running on the processor, wherein the processor is configured to implement any of the steps of the video-based belt running state detecting method when executing the computer program.
It is a fourth object of the present invention to provide a computer-readable storage medium storing a computer program which, when executed by a processor, implements the steps of any of the above-described video-based belt running state detecting methods.
Compared with the prior art, the invention has the beneficial effects that:
1. the belt running state detection method based on the video comprises the steps of laying a video camera module and various sensors near a belt conveying device, building an automatic computer framework and a detection system, combining AI intelligent analysis and image recognition technologies, and detecting and judging the running state of the belt conveying device in real time on the basis of monitoring videos;
2. according to the belt running state detection method based on the video, the abnormal conditions existing in the running process of the belt conveyor are detected and judged through the neural network algorithm, and the influence degree of the abnormal conditions on the safety performance of the belt conveyor is evaluated according to a certain rule, so that the running state of the belt conveyor is accurately evaluated, manual inspection is not needed, a large amount of manpower and time are saved, the detection efficiency is improved, and negligence, mistakes and omissions are reduced;
3. according to the belt running state detection method based on the video, through the preset safety protection mechanism, when the system detects an abnormal condition, the system automatically executes and gives an alarm, so that the potential safety hazard of production can be effectively reduced, the waste of materials and resources is reduced, the maintenance and repair of the fault condition are facilitated in time, and the safe running of production is ensured.
Drawings
FIG. 1 is a flow chart of the overall process of the present invention;
FIG. 2 is an overall architecture diagram of the inspection side system of the present invention;
FIG. 3 is a block diagram of an exemplary electronic computer product device in accordance with the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Example 1
As shown in fig. 1 to 3, the present embodiment provides a video-based belt running state detection method, including the following steps:
s1, arranging corresponding video camera modules and various sensors near the belt of the belt conveying device, and arranging a video processing computer component at the near end or the far end of the belt conveying device;
s2, building a system framework of the running state of the belt by combining the arranged devices and sensors, configuring the running environment of the detection system, and building the running state detection system of the belt;
s3, starting a video-based belt running state detection device, and monitoring the running state of the belt conveying device in real time;
s4, detecting and identifying the running state and abnormal fault conditions of the belt conveying device based on the real-time recorded video data through an AI intelligent analysis technology, an image recognition technology and a neural network learning method;
s5, accurately judging the running state of the belt conveying device by combining the state parameters acquired by various sensors in real time, and scoring the influence degree of the judged abnormal conditions on the running safety performance of the equipment according to a preset scoring standard;
s6, setting a corresponding safety protection mechanism aiming at the abnormal belt running state which possibly occurs, when the belt conveying device has abnormal conditions, executing the measures of the safety protection mechanism according to a preset program, outputting an alarm signal in time, and scheduling and arranging aiming at the maintenance operation.
In this embodiment, in S1, the video camera modules disposed near the belt conveyor include, but are not limited to: the high-definition camera covers the whole belt conveying device in the visual field, is arranged above the belt at a certain depression angle and is used for shooting the belt, is arranged near the driving motor and is used for shooting the driving motor and is provided with a recording function, and the like; various types of sensors deployed in the vicinity of the belt conveyor include, but are not limited to: the device comprises material flow detection devices respectively arranged at the head end and the tail end of the belt conveying device, speed sensors respectively arranged at the head end and the tail end of the belt conveying device, weighing sensors respectively arranged at the lower parts of bearing support rollers at the head end and the tail end of the belt conveying device, a voltage detection device electrically connected with a driving motor and the like; computer components include, but are not limited to: the system comprises a processor, a display, a network switch, a cloud server, a video/image recognition program module, an AI intelligent analysis terminal and the like.
In this embodiment, in S4, when the image is identified by the image identification technique, preprocessing such as dimension reduction, color binarization, and image segmentation needs to be performed on the target image, and the method and the related algorithm used in the method are as follows:
the image dimensionality reduction adopts a PCA dimensionality reduction algorithm, and comprises the following steps:
The algorithm process is as follows:
Step5, multiplying the original matrix by the projection matrix:i.e. reduced dimension data setWhereinIs composed ofThe ratio of vitamin to vitamin is,is composed ofMaintaining;
The color binarization processing adopts an Otsu threshold value method, and the algorithm expression is as follows:
for imagesThe segmentation threshold of foreground (target) and background is denoted as T, and the ratio of the number of pixels belonging to foreground to the whole image is denoted asAverage gray scale of(ii) a The number of background pixels is in proportion to the whole imageHaving an average gray scale of(ii) a The total average gray scale of the image is recorded asThe inter-class variance is recorded as g;
assume that the background of the image is dark and the size of the image isThe number of pixels in the image whose grey value is less than the threshold value T is recorded asThe number of pixels having a pixel gray level greater than the threshold T is counted asThen, there are:
substituting formula (5) for formula (6) yields the equivalent formula:
the formula (7) is the inter-class variance, and the threshold T with the maximum inter-class variance g is obtained by adopting a traversal method, namely the obtained threshold T is the solved threshold;
the image segmentation processing adopts a watershed algorithm, and the algorithm expression is as follows:
the simulation flooding process from bottom to top is a recursion process, and the formula (1) belongs to the initial condition of the recursion process and enables the pixel point with the minimum gray value in the image I; formula (2) is a recursive process;
in the formula, h represents the range of gray scale values,is the minimum value of the gray value range,is the maximum value of the gray value range;is a gray scale value and an altitude ofAll of the pixel points of (a) above,indicating that this point belongs to the newly created basin minimum, i.e. atThis altitude in turn creates a new basin;to representPoint and pointThe points are intersected with each other at the same time,is composed ofThe basin where the points are located, thereforeIs characterized byPoint and pointPoints that are co-located in a basin;
through the recursion process, all pixel points in the image I are divided into basins.
In this embodiment, in S4, the abnormal failure condition of the belt conveying device includes, but is not limited to: driving motor failure, belt deviation, belt tearing, bulk material obstacle, metal sundry abrasion and the like.
In this embodiment, in S5, the operation state of the belt conveying device includes, but is not limited to: start/stop, no load, loaded, overloaded, material spread, too fast/too slow of a transport speed, material flow source/tail position change, loaded start, etc.
As shown in fig. 2, the present embodiment provides a video-based belt running state detection system, including: the device comprises a video processing module, a monitoring detection module, an identification scoring module and a signal output module; the signal output end of the video processing module is connected with the signal input end of the monitoring detection module, the signal output end of the monitoring detection module is connected with the signal input end of the identification scoring module, and the signal output end of the identification scoring module is connected with the signal input end of the signal output module; wherein:
the video processing module is used for carrying out real-time video recording and storage on the whole of the belt conveying device and the running conditions of various parts such as a belt, a driving motor and the like;
the monitoring detection module is used for identifying the shot video and the image intercepted from the video, screening out the characteristic video with abnormal conditions and transmitting the characteristic video into the identification scoring module;
the judging and scoring module is used for judging and scoring the type of the abnormal condition through a neural network method according to the characteristic video of the abnormal condition and scoring and evaluating the influence degree of the abnormal type on the safety performance of the belt conveying device in the operation process according to a preset scoring rule;
the signal output module is used for outputting the detected abnormal conditions and the grading data thereof, executing a preset safety protection mechanism and outputting an alarm signal.
In this embodiment, the video processing module further includes a video acquisition sub-module, a video transmission sub-module, and a video storage sub-module; the signal output end of the video acquisition submodule is connected with the signal input end of the video transmission submodule, and the signal output end of the video transmission submodule is connected with the signal input end of the video storage submodule; the video acquisition submodule is used for shooting and recording a video of the running state of the inner belt of the visual field of the belt conveyor in real time through a video shooting module arranged near the belt conveyor; the video transmission sub-module is used for transmitting the real-time recorded video to the processor for processing through a wired/wireless transmission technology; the video storage submodule is used for transmitting the original video data and the abnormal video identified by processing to the local/cloud storage for storage; the video storage submodule is used for local storage or cloud storage.
In this embodiment, the monitoring and detecting module further includes an AI intelligent analysis submodule, an image recognition submodule, and a sensing data management submodule; the AI intelligent analysis submodule, the image recognition submodule and the sensing data management submodule are sequentially connected through network communication and run in parallel; the AI intelligent analysis submodule is used for analyzing the video stream through an AI intelligent analysis technology and detecting the video with abnormal conditions in the running state of the belt; the image identification submodule is used for intercepting the image in the video with abnormal conditions for further identification and judgment through an image identification technology; and the sensing data management submodule is used for acquiring the state parameters acquired by each sensor, and performing sorting, statistics, analysis and storage management on the sensing parameters.
In this embodiment, the identification scoring module further comprises a neural network algorithm submodule, a state identification submodule and a safety influence scoring submodule; the signal output end of the neural network algorithm submodule is connected with the signal input end of the state judgment and identification submodule, and the signal output end of the state judgment and identification submodule is connected with the signal input end of the safety influence scoring submodule; the neural network algorithm submodule is used for monitoring and judging the belt operation abnormal condition which can be identified by naked eyes in the video by adopting a neural network method; the state identification sub-module is used for identifying the running state of the belt conveying device by combining the sensing data at the same time point as the abnormal condition of the belt and roughly analyzing the reason of the abnormal condition of the belt; and the safety influence scoring submodule is used for evaluating and scoring the influence degree of the judged and identified belt abnormal condition on the running safety performance of the belt conveying device according to a preset scoring rule.
The method comprises the following steps of combining sensing data at the same time point with the abnormal condition of the belt, judging the running state of the belt conveying device and roughly analyzing the reason of the abnormal condition of the belt, wherein possible reasons include but are not limited to: belt deviation caused by no-load/overload/loaded start, belt deviation caused by too high/too low conveying speed, belt tearing/material scattering caused by overload, belt deviation/driving motor fault caused by too low conveying speed/belt deviation/large material obstacle caused by large material obstacle, driving motor fault caused by too high voltage, belt deviation/large material obstacle caused by material flow source/tail position change, belt tearing caused by large material obstacle/metal sundry abrasion and the like.
In this embodiment, the signal output module further includes a safety mechanism sub-module, an alarm signal sub-module and an overhaul scheduling sub-module; the safety mechanism submodule, the alarm signal submodule and the overhaul scheduling submodule are sequentially connected through network communication and run in parallel; the safety mechanism submodule is used for setting a corresponding safety protection mechanism including shutdown according to the possible abnormal type and the influence degree of the abnormal condition on the safety performance in the running process of the belt conveying device, and automatically executing a safety protection program when the preset condition is reached; the alarm signal sub-module is used for sending out alarm signals in various modes when detecting that the belt conveying device has abnormal operating conditions; and the overhaul scheduling submodule is used for scheduling overhaul and maintenance on the abnormal operating condition according to a certain rule or sequence.
The protection program of the security protection mechanism includes but is not limited to: stopping the machine (such as motor faults, severe belt tearing and the like), reducing the conveying speed (such as belt deviation, material scattering and the like), reducing the power of a driving motor (such as overhigh voltage of the driving motor), reducing the conveying capacity (such as slight belt tearing, material scattering, overload, loaded starting and the like) and the like.
Wherein, the alarm mode includes but not limited to: flashing, pop-up, buzzer, warning light, short message notification, etc.
Wherein, the rule or sequence according to which the maintenance scheduling is performed may be: time by time, safety impact degree by size, position by height/front and back, maintenance difficulty and the like.
As shown in fig. 3, the present embodiment also provides an operating apparatus of a video-based belt running state detecting system, which includes a processor, a memory, and a computer program stored in the memory and running on the processor.
The processor comprises one or more processing cores, the processor is connected with the memory through the bus, the memory is used for storing program instructions, and the steps of the video-based belt running state detection method are realized when the processor executes the program instructions in the memory.
Alternatively, the memory may be implemented by any type or combination of volatile or non-volatile memory devices, such as Static Random Access Memory (SRAM), electrically erasable programmable read-only memory (EEPROM), erasable programmable read-only memory (EPROM), programmable read-only memory (PROM), read-only memory (ROM), magnetic memory, flash memory, magnetic or optical disks.
In addition, the present invention also provides a computer readable storage medium, which stores a computer program, and when the computer program is executed by a processor, the steps of the video-based belt running state detection method are implemented.
Optionally, the present invention also provides a computer program product containing instructions which, when run on a computer, cause the computer to perform the steps of the video-based belt running status detection method of the above aspects.
It will be understood by those skilled in the art that the processes for implementing all or part of the steps of the above embodiments may be implemented by hardware, or may be implemented by a program instructing relevant hardware, and the program may be stored in a computer-readable storage medium, and the above-mentioned storage medium may be a read-only memory, a magnetic disk or an optical disk, etc.
The foregoing shows and describes the general principles, essential features, and advantages of the invention. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, and the preferred embodiments of the present invention are described in the above embodiments and the description, and are not intended to limit the present invention. The scope of the invention is defined by the appended claims and equivalents thereof.
Claims (10)
1. A belt running state detection method based on videos is characterized by comprising the following steps: the method comprises the following steps:
s1, arranging corresponding video camera modules and various sensors near the belt of the belt conveying device, and arranging a video processing computer component at the near end or the far end of the belt conveying device;
s2, building a system framework of the running state of the belt by combining the arranged devices and sensors, configuring the running environment of the detection system, and building the running state detection system of the belt;
s3, starting a video-based belt running state detection device, and monitoring the running state of the belt conveying device in real time;
s4, detecting and identifying the running state and abnormal fault conditions of the belt conveying device based on the real-time recorded video data through an AI intelligent analysis technology, an image recognition technology and a neural network learning method;
s5, accurately judging the running state of the belt conveying device by combining the state parameters acquired by various sensors in real time, and scoring the influence degree of the judged abnormal conditions on the running safety performance of the equipment according to a preset scoring standard;
s6, setting a corresponding safety protection mechanism aiming at the abnormal belt running state which possibly occurs, when the belt conveying device has abnormal conditions, executing the measures of the safety protection mechanism according to a preset program, outputting an alarm signal in time, and scheduling and arranging aiming at the maintenance operation.
2. The video-based belt run status detection method of claim 1, wherein: in S1, the video camera modules disposed near the belt conveyor include, but are not limited to: the high-definition camera covers the whole belt conveying device in the visual field, is arranged above the belt at a certain depression angle and is used for shooting the belt, is arranged near the driving motor and is used for shooting the driving motor and is provided with a recording function, and the like; various types of sensors deployed in the vicinity of the belt conveyor include, but are not limited to: the device comprises material flow detection devices respectively arranged at the head end and the tail end of the belt conveying device, speed sensors respectively arranged at the head end and the tail end of the belt conveying device, weighing sensors respectively arranged at the lower parts of bearing support rollers at the head end and the tail end of the belt conveying device, a voltage detection device electrically connected with a driving motor and the like; computer components include, but are not limited to: the system comprises a processor, a display, a network switch, a cloud server, a video/image recognition program module, an AI intelligent analysis terminal and the like.
3. The video-based belt run status detection method of claim 1, wherein: in S2, the belt running state detecting system includes: the device comprises a video processing module, a monitoring detection module, an identification scoring module and a signal output module; the signal output end of the video processing module is connected with the signal input end of the monitoring detection module, the signal output end of the monitoring detection module is connected with the signal input end of the identification scoring module, and the signal output end of the identification scoring module is connected with the signal input end of the signal output module; wherein:
the video processing module is used for carrying out real-time video recording and storage on the whole of the belt conveying device and the running conditions of various parts such as a belt, a driving motor and the like;
the monitoring detection module is used for identifying the shot video and the image intercepted from the video, screening out the characteristic video with abnormal conditions and transmitting the characteristic video into the identification scoring module;
the judging and scoring module is used for judging and scoring the type of the abnormal condition through a neural network method according to the characteristic video of the abnormal condition and scoring and evaluating the influence degree of the abnormal type on the safety performance of the belt conveying device in the operation process according to a preset scoring rule;
the signal output module is used for outputting the detected abnormal conditions and the grading data thereof, executing a preset safety protection mechanism and outputting an alarm signal.
4. The video-based belt run status detection method of claim 3, wherein: the video processing module also comprises a video acquisition sub-module, a video transmission sub-module and a video storage sub-module; the signal output end of the video acquisition submodule is connected with the signal input end of the video transmission submodule, and the signal output end of the video transmission submodule is connected with the signal input end of the video storage submodule; the video acquisition submodule is used for shooting and recording a video of the running state of the inner belt of the visual field of the belt conveyor in real time through a video shooting module arranged near the belt conveyor; the video transmission sub-module is used for transmitting the real-time recorded video to the processor for processing through a wired/wireless transmission technology; the video storage submodule is used for transmitting the original video data and the abnormal video identified by processing to the local/cloud storage for storage; the video storage submodule is used for local storage or cloud storage.
5. The video-based belt run status detection method of claim 3, wherein: the monitoring detection module also comprises an AI intelligent analysis submodule, an image recognition submodule and a sensing data management submodule; the AI intelligent analysis submodule, the image recognition submodule and the sensing data management submodule are sequentially connected through network communication and run in parallel; the AI intelligent analysis submodule is used for analyzing the video stream through an AI intelligent analysis technology and detecting the video with abnormal conditions in the running state of the belt; the image identification submodule is used for intercepting the image in the video with abnormal conditions for further identification and judgment through an image identification technology; and the sensing data management submodule is used for acquiring the state parameters acquired by each sensor, and performing sorting, statistics, analysis and storage management on the sensing parameters.
6. The video-based belt run status detection method of claim 3, wherein: the judgment and scoring module also comprises a neural network algorithm submodule, a state judgment and scoring submodule and a safety influence scoring submodule; the signal output end of the neural network algorithm submodule is connected with the signal input end of the state judgment and identification submodule, and the signal output end of the state judgment and identification submodule is connected with the signal input end of the safety influence scoring submodule; the neural network algorithm submodule is used for monitoring and judging the belt operation abnormal condition which can be identified by naked eyes in the video by adopting a neural network method; the state identification sub-module is used for identifying the running state of the belt conveying device by combining the sensing data at the same time point as the abnormal condition of the belt and roughly analyzing the reason of the abnormal condition of the belt; and the safety influence scoring submodule is used for evaluating and scoring the influence degree of the judged and identified belt abnormal condition on the running safety performance of the belt conveying device according to a preset scoring rule.
7. The video-based belt run status detection method of claim 3, wherein: the signal output module also comprises a safety mechanism submodule, an alarm signal submodule and a maintenance scheduling submodule; the safety mechanism submodule, the alarm signal submodule and the overhaul scheduling submodule are sequentially connected through network communication and run in parallel; the safety mechanism submodule is used for setting a corresponding safety protection mechanism including shutdown according to the possible abnormal type and the influence degree of the abnormal condition on the safety performance in the running process of the belt conveying device, and automatically executing a safety protection program when the preset condition is reached; the alarm signal sub-module is used for sending out alarm signals in various modes when detecting that the belt conveying device has abnormal operating conditions; and the overhaul scheduling submodule is used for scheduling overhaul and maintenance on the abnormal operating condition according to a certain rule or sequence.
8. The video-based belt run status detection method of claim 1, wherein: in S4, when the image is identified by the image identification technique, preprocessing such as dimension reduction, color binarization, and image segmentation is required to be performed on the target image, and the method and the related algorithm adopted by the method are as follows:
the image dimensionality reduction adopts a PCA dimensionality reduction algorithm, and comprises the following steps:
The algorithm process is as follows:
Step5, multiplying the original matrix by the projection matrix:i.e. reduced dimension data setWhereinIs composed ofThe ratio of vitamin to vitamin is,is composed ofMaintaining;
The color binarization processing adopts an Otsu threshold value method, and the algorithm expression is as follows:
for imagesThe segmentation threshold of foreground (target) and background is denoted as T, and the ratio of the number of pixels belonging to foreground to the whole image is denoted asAverage gray scale of(ii) a The number of background pixels is in proportion to the whole imageHaving an average gray scale of(ii) a The total average gray scale of the image is recorded asThe inter-class variance is recorded as g;
assume that the background of the image is dark and the size of the image isThe number of pixels in the image whose grey value is less than the threshold value T is recorded asThe number of pixels having a pixel gray level greater than the threshold T is counted asThen, there are:
substituting formula (5) for formula (6) yields the equivalent formula:
the formula (7) is the inter-class variance, and the threshold T with the maximum inter-class variance g is obtained by adopting a traversal method, namely the obtained threshold T is the solved threshold;
the image segmentation processing adopts a watershed algorithm, and the algorithm expression is as follows:
the simulation flooding process from bottom to top is a recursion process, and the formula (1) belongs to the initial condition of the recursion process and enables the pixel point with the minimum gray value in the image I; formula (2) is a recursive process;
in the formula, h represents the range of gray scale values,is the minimum value of the gray value range,is the maximum value of the gray value range;is a gray scale value and an altitude ofAll of the pixel points of (a) above,indicating that this point belongs to the newly created basin minimum, i.e. atThis altitude in turn creates a new basin;to representPoint and pointThe points are intersected with each other at the same time,is composed ofThe basin where the points are located, thereforeIs characterized byPoint and pointPoints that are co-located in a basin;
through the recursion process, all pixel points in the image I are divided into basins.
9. The video-based belt run status detection method of claim 1, wherein: in S4, the abnormal fault condition of the belt conveying device includes, but is not limited to: driving motor failure, belt deviation, belt tearing, bulk material obstacle, metal sundry abrasion and the like.
10. The video-based belt run status detection method of claim 1, wherein: in S5, the operation state of the belt conveying device includes, but is not limited to: start/stop, no load, loaded, overloaded, material spread, too fast/too slow of a transport speed, material flow source/tail position change, loaded start, etc.
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