CN114146456A - Intelligent inspection device for belt conveyor under complex industrial environment - Google Patents
Intelligent inspection device for belt conveyor under complex industrial environment Download PDFInfo
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- CN114146456A CN114146456A CN202111340862.5A CN202111340862A CN114146456A CN 114146456 A CN114146456 A CN 114146456A CN 202111340862 A CN202111340862 A CN 202111340862A CN 114146456 A CN114146456 A CN 114146456A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D21/00—Separation of suspended solid particles from liquids by sedimentation
- B01D21/02—Settling tanks with single outlets for the separated liquid
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J11/00—Manipulators not otherwise provided for
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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
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- G—PHYSICS
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- G01H—MEASUREMENT OF MECHANICAL VIBRATIONS OR ULTRASONIC, SONIC OR INFRASONIC WAVES
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- G—PHYSICS
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- G01J—MEASUREMENT OF INTENSITY, VELOCITY, SPECTRAL CONTENT, POLARISATION, PHASE OR PULSE CHARACTERISTICS OF INFRARED, VISIBLE OR ULTRAVIOLET LIGHT; COLORIMETRY; RADIATION PYROMETRY
- G01J5/00—Radiation pyrometry, e.g. infrared or optical thermometry
- G01J5/48—Thermography; Techniques using wholly visual means
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- G—PHYSICS
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/8851—Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges
- G01N2021/8854—Grading and classifying of flaws
- G01N2021/888—Marking defects
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Abstract
An intelligent inspection device of a belt conveyor in a complex industrial environment comprises a track system and an inspection robot; the rail system includes a rail and a hanger assembly; the track is hoisted and fixed through the hanger assembly, so that the track and the belt to be inspected are arranged in parallel; the inspection robot is hoisted on the track through a hoisting assembly and is used for completing the acquisition of inspection data; the hoisting assembly consists of pulley blocks arranged on each supporting leg of the inspection robot, each pulley block comprises two fixed pulleys fixedly arranged with the supporting leg, a track is arranged between the two fixed pulleys, and a rack parallel to the track is arranged between the tracks; the inspection robot is provided with a gear meshed with the rack, and the gear and the rack are meshed to drive two fixed pulleys on each supporting leg to rotate along the track and move forwards under the driving of the power of the inspection robot.
Description
Technical Field
The invention relates to the field of machine vision identification, in particular to identification of defects of a belt conveyor under a complex industrial environment.
Background
The blast furnace system is the core system of iron making in the iron and steel plant, and blast furnace material conveying is the most important ring in the blast furnace system, and timely and accurate batching and feeding are the prerequisite of guaranteeing blast furnace output and product quality. The material conveying system has the characteristics of multiple devices, long transmission distance, complex operation mode, severe operation environment, multiple fault factors and the like, and accidents are easy to happen to cause economic loss.
For a long time, the routing inspection work of a material conveying system mainly depends on manual inspection at regular time, the manual inspection is easily influenced by personal experience and subjective consciousness, and is limited by monitoring means, data recording and data analysis, a large amount of manpower is generally spent, an effective data result cannot be obtained, the obtained data is difficult to form systematicness, and the reference significance is not large; particularly, as the service life of the equipment is longer, the risk of equipment failure is higher, more and more manpower needs to be invested for routing inspection and maintenance, and the production cost is increased to a great extent; in addition, the concentration of dust on a conveying site is high, and a large number of repeated routing inspection works in the area can bring health hidden troubles to operators.
Disclosure of Invention
The technical problem solved by the invention is as follows: the condition of belt operation is effectively monitored under complicated industrial environment, and the safety and health risk of patrolling and examining operating personnel are reduced simultaneously to the assurance equipment safety.
The technical scheme of the invention is as follows: an intelligent inspection device of a belt conveyor in a complex industrial environment comprises a track system and an inspection robot; the rail system includes a rail and a hanger assembly; the track is hoisted and fixed through the hanger assembly, so that the track and the belt to be inspected are arranged in parallel; the inspection robot is hoisted on the track through a hoisting assembly and is used for completing the acquisition of inspection data; the hoisting assembly consists of pulley blocks arranged on each supporting leg of the inspection robot, each pulley block comprises two fixed pulleys fixedly arranged with the supporting leg, a track is arranged between the two fixed pulleys, and a rack parallel to the track is arranged between the tracks; the inspection robot is provided with a gear meshed with the rack, and the gear and the rack are meshed to drive two fixed pulleys on each supporting leg to rotate along the track and move forwards under the driving of the power of the inspection robot.
Preferably, the hanger assembly comprises a Z-shaped bracket and a main bracket; the upper end face of the main support is a plane and is used for being fixed with a top wall body or a steel frame through a Z-shaped support, the lower end face of the main support is of an inward flanging opening structure, two inward flanging edges are respectively used for installing and fixing slide rails, the two slide rails form the track, through holes are formed in the two slide rails according to a preset distance, a screw rod is installed between the two slide rails through the through holes, and the screw rod is used for installing the rack.
Preferably, the sliding rails are connected through a cylindrical connecting shaft to increase the length of the sliding rails.
Preferably, the device further comprises a spring suspension mechanism; the gear as the main drive on the inspection robot is installed in the spring suspension mechanism, the distance between the gear and the rack is adjusted in real time through the spring suspension mechanism, and the gear and the rack can be reliably meshed under any working conditions.
Preferably, the inspection robot finishes the acquisition of inspection data by carrying a camera, a thermal infrared imager, a sound pick-up and an environmental data acquisition sensor; the camera shoots a belt picture at a preset place, the thermal infrared imager follows the inspection robot to collect the temperature of a belt bearing in the whole process, and the sound pickup follows the inspection robot to collect sound in the whole process and is used for monitoring abnormal sound; the environmental data acquisition sensor follows the inspection robot to acquire smoke information in the whole process.
Preferably, the inspection data collected by the inspection robot is transmitted to the background management system through the communication system; and the background management system stores, analyzes and displays the data.
Preferably, the communication system comprises a communication base station, a wireless communication network and a wired communication network; the polling data is transmitted to the communication base station through the wireless communication network, and the communication base station sends the data to the background management system through the wired communication network.
Preferably, the background management system comprises an image acquisition module, a noise generation module, an anti-noise enhancement system and a defect detection system;
the image acquisition module is used for periodically acquiring pictures started by the inspection robot, marking abnormal positions in the images and using the images as original training data of the model;
the noise generation module is used for generating various random noises;
the anti-noise enhancement module is used for carrying out noise enhancement on the random noise generated by the noise generation module and the original training data of the image acquisition module to serve as new training data and carrying out multi-task learning training through a neural network to obtain output of abnormal detection;
and the abnormality identification module is used for outputting the current picture to be analyzed by using the trained neural network and positioning the abnormal position and the abnormal type to obtain the loss state of the current belt.
Compared with the prior art, the invention has the beneficial effects that:
the intelligent inspection robot system is used for inspecting the material conveying system, the operation and maintenance personnel can inspect the material conveying system through the control robot in the control center, check the real-time information acquired by the robot, control the state of the material conveying system, do not need frequent on-site inspection, improve the inspection frequency and the inspection quality on the basis of reducing the work burden and the safety risk of the operation and maintenance personnel, promote the intelligent construction of an iron and steel plant, and improve the operation maintenance efficiency and the production management level of the iron and steel plant.
The belt conveyor provided by the invention spans a plurality of workshops and floors, and the track meanders. The invention can ensure that the inspection robot can smoothly run on the track under the complex industrial environment, thereby ensuring that a camera, a thermal infrared imager, a pickup and an environmental data acquisition sensor carried by the inspection robot can effectively acquire the abnormal conditions of the belt, and replacing manpower to realize intelligent inspection.
Drawings
FIG. 1 is a system architecture diagram;
FIG. 2 is a diagram of an example of track installation;
FIG. 3 is a schematic view of a charge control box style and opening size;
FIG. 4 is a schematic diagram of the connection of the charging control box
FIG. 5 is a schematic view of the charging unit mounting;
FIG. 6 is a schematic diagram of the overall arrangement of a communication base station
FIG. 7 is a diagram of a background management system;
fig. 8 is a schematic diagram of hoisting the inspection robot and the track according to the invention.
Detailed Description
The invention is further illustrated by the following examples.
The invention takes an inspection robot as a core and is provided with a track system, a power supply system, a communication system and a background management system. The system architecture is shown in FIG. 1; the inspection robot carries on information acquisition equipment such as visible light camera, infrared thermal imager, the adapter, accessible orbital motion is independently gone to each and is patrolled and examined the position and carry out information acquisition to relevant equipment, the video of patrolling and examining the robot collection, the image, sound, harmful gas's content in the air, information such as data such as warning pass through communication system and transmit back to the system backstage, carry out classified storage, analysis, show in the system backstage, the realization is patrolled and examined the full coverage closed loop of iron and steel plant ironmaking blast furnace defeated material system, it provides powerful support to manage the defeated material system equipment state of maintenance personnel control.
The inspection robot: the inspection robot is the core of the whole system and mainly has the functions of carrying equipment such as a camera, a thermal infrared imager, a pickup, an environmental data acquisition sensor and the like to acquire inspection data;
a track system: the inspection robot is hung on the rail and travels on the rail;
a power supply system: the distributed charging stations are installed at proper positions in the inspection line and charge the storage battery of the robot body;
a communication system: the robot is divided into a wireless communication network and a wired communication network, data interaction is carried out between the robot and a communication base station on the site of a material conveying channel through a wireless network, and the communication base station is connected with a background management system through the wired network;
a background management system: the system consists of hardware such as a background server, a display, a switch and the like and background software, and is a data receiving, processing and displaying center of the whole inspection system.
1. Basic mounting mode of track
The robot track is fixed on the top wall body or the steelframe of well suitable position through special gallows subassembly, the erection space of track gallows: one set is installed for 1.5 meters of the straight rail, and 1 set is installed for 1 meter of the curved rail. When the installation environment does not meet the requirement of directly using the hanging bracket for hoisting, components such as a newly-built track supporting beam or a portal frame are required to be used for installing a track system and a robot. The track installation pattern is shown in fig. 8 and 2: the inspection robot is hoisted on the track through a hoisting assembly and is used for completing the acquisition of inspection data; the hoisting assembly consists of pulley blocks arranged on each supporting leg of the inspection robot, each pulley block comprises two fixed pulleys fixedly arranged with the supporting leg, a track is arranged between the two fixed pulleys, and a rack parallel to the track is arranged between the tracks; the inspection robot is provided with a gear meshed with the rack, and the gear and the rack are meshed to drive two fixed pulleys on each supporting leg to rotate along the track and move forwards under the driving of the power of the inspection robot. The hanger assembly comprises a Z-shaped bracket and a main bracket; the upper end face of the main support is a plane and is used for being fixed with a top wall body or a steel frame through a Z-shaped support, the lower end face of the main support is of an inward flanging opening structure, two inward flanging edges are respectively used for installing and fixing slide rails, the two slide rails form a track, through holes are formed in the two slide rails according to a preset distance, a screw rod is installed between the two slide rails through the through holes, and the screw rod is used for installing a rack.
The robot body is connected with the track through a set of spring suspension mechanism, a main driving wheel (the gear) of the robot body is installed in the spring suspension mechanism, and the plane distance between a main driving gear of the robot and a rack on the track is adjusted in real time through the spring suspension mechanism, so that the main driving gear of the robot and the rack on the track can be reliably meshed at any time.
2. Power supply system embodiments
The robot power supply system mainly comprises a charging control box and a charging part.
1) Charging control box installation
The charging control box is installed on a wall or at a proper position on a steel frame, and the installation height meets the requirement that after a box door is opened, a worker can operate and test all devices in the box body in a normal standing posture. The charging control box takes power (220V 50Hz) from a proper position near the installation position, and supplies power to the charging part by arranging a power line. The charging control box style and opening size are shown in fig. 3, and the charging control box wiring schematic is shown in fig. 4.
2) Charging part mounting
The charging part is installed on the inner side of a C-shaped hanging bracket of the track as shown in figure 5, and meanwhile, the wire outlet side is aligned with the hanging bracket, so that wiring is facilitated.
The robot is accessed into the network through wireless WIFI so as to communicate with the background management system, and the field communication base station equipment mainly comprises a communication control box and a base station antenna. The general arrangement of the communication base station is shown in fig. 6.
3. Background management system embodiments
The project is provided with 1 set of background management system, and the background system installation hardware mainly comprises a server and accessories (a display, a keyboard, a mouse, a microphone, a sound box and the like) thereof, and a photoelectric hybrid exchange machine.
As shown in fig. 7, the system includes: the device comprises an image acquisition module, a noise generation module, an anti-noise enhancement module and an abnormality detection module.
And the image acquisition module is used for periodically acquiring the images of the industrial components, marking abnormal positions in the images and using the abnormal positions as original training data of the model.
And the noise generation module is used for generating various noises, combining the noises with image data for amplification and assisting the model training through an auxiliary sequencing task in the anti-noise enhancement system.
The anti-noise enhancement module performs multi-task learning through the neural network to obtain output of abnormal detection, performs training of detection tasks by using data and labels of the image acquisition device, and performs training of auxiliary sequencing tasks by using data of the noise acquisition module in combination.
And the abnormality identification module is used for processing the output of the neural network, positioning the abnormal position and the abnormal type and obtaining the loss state of the current industrial component.
The specific equipment installation is explained as follows:
a server: pre-installing a positive version windows operating system and configuring background system software; connecting accessories such as a display, a keyboard, a mouse, a microphone, a sound box and the like to a server, and debugging normally; all the accessory connecting cables need to be straightened and tied by using a binding belt;
photoelectric hybrid switch: the server and the communication base station are both connected into the switch, and both ends of all network cables need to be provided with labels (which indicate equipment and interfaces connected with opposite ends); meanwhile, security configurations such as MAC binding, access control, port isolation and the like are made in the switch;
the equipment needs electricity getting: AC220V 50 Hz.
It should be noted that the installation manner between the inspection robot and the rail in fig. 1 is another implementation manner.
Although the present invention has been described with reference to the preferred embodiments, it is not intended to limit the present invention, and those skilled in the art can make variations and modifications of the present invention without departing from the spirit and scope of the present invention by using the methods and technical contents disclosed above.
The invention has not been described in detail in part in the common general knowledge of a person skilled in the art.
Claims (8)
1. The utility model provides a belt feeder intelligence inspection device under complicated industrial environment which characterized in that: the system comprises a track system and an inspection robot; the rail system includes a rail and a hanger assembly; the track is hoisted and fixed through the hanger assembly, so that the track and the belt to be inspected are arranged in parallel; the inspection robot is hoisted on the track through a hoisting assembly and is used for completing the acquisition of inspection data; the hoisting assembly consists of pulley blocks arranged on each supporting leg of the inspection robot, each pulley block comprises two fixed pulleys fixedly arranged with the supporting leg, a track is arranged between the two fixed pulleys, and a rack parallel to the track is arranged between the tracks; the inspection robot is provided with a gear meshed with the rack, and the gear and the rack are meshed to drive two fixed pulleys on each supporting leg to rotate along the track and move forwards under the driving of the power of the inspection robot.
2. The apparatus of claim 1, wherein: the hanger assembly comprises a Z-shaped bracket and a main bracket; the upper end face of the main support is a plane and is used for being fixed with a top wall body or a steel frame through a Z-shaped support, the lower end face of the main support is of an inward flanging opening structure, two inward flanging edges are respectively used for installing and fixing slide rails, the two slide rails form the track, through holes are formed in the two slide rails according to a preset distance, a screw rod is installed between the two slide rails through the through holes, and the screw rod is used for installing the rack.
3. The apparatus of claim 2, wherein: the slide rails are connected through a cylindrical connecting shaft to increase the length of the slide rails.
4. The apparatus of claim 1, wherein: the device also comprises a spring suspension mechanism; the gear as the main drive on the inspection robot is installed in the spring suspension mechanism, the distance between the gear and the rack is adjusted in real time through the spring suspension mechanism, and the gear and the rack can be reliably meshed under any working conditions.
5. The apparatus of claim 1, wherein: the inspection robot finishes the acquisition of inspection data by carrying a camera, a thermal infrared imager, a pickup and an environmental data acquisition sensor; the camera shoots a belt picture at a preset place, the thermal infrared imager follows the inspection robot to collect the temperature of a belt bearing in the whole process, and the sound pickup follows the inspection robot to collect sound in the whole process and is used for monitoring abnormal sound; the environmental data acquisition sensor follows the inspection robot to acquire smoke information in the whole process.
6. The apparatus of claim 1, wherein: the inspection data collected by the inspection robot is transmitted to the background management system through the communication system; and the background management system stores, analyzes and displays the data.
7. The apparatus of claim 6, wherein: the communication system comprises a communication base station, a wireless communication network and a wired communication network; the polling data is transmitted to the communication base station through the wireless communication network, and the communication base station sends the data to the background management system through the wired communication network.
8. The apparatus of claim 1, wherein: the background management system comprises an image acquisition module, a noise generation module, an anti-noise enhancement system and a defect detection system;
the image acquisition module is used for periodically acquiring pictures started by the inspection robot, marking abnormal positions in the images and using the images as original training data of the model;
the noise generation module is used for generating various random noises;
the anti-noise enhancement module is used for carrying out noise enhancement on the random noise generated by the noise generation module and the original training data of the image acquisition module to serve as new training data and carrying out multi-task learning training through a neural network to obtain output of abnormal detection;
and the abnormality identification module is used for outputting the current picture to be analyzed by using the trained neural network and positioning the abnormal position and the abnormal type to obtain the loss state of the current belt.
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| CN202111340862.5A CN114146456A (en) | 2021-11-12 | 2021-11-12 | Intelligent inspection device for belt conveyor under complex industrial environment |
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Application publication date: 20220308 |