CN114972349A - Carrier roller running state detection method and system based on image processing - Google Patents

Carrier roller running state detection method and system based on image processing Download PDF

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CN114972349A
CN114972349A CN202210913082.3A CN202210913082A CN114972349A CN 114972349 A CN114972349 A CN 114972349A CN 202210913082 A CN202210913082 A CN 202210913082A CN 114972349 A CN114972349 A CN 114972349A
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CN114972349B (en
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郭东进
赵彦燕
贺庆壮
袁绪龙
李栓柱
袁绪彬
徐祥琦
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Shandong Huali Electromechanical Co Ltd
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Shandong Ximanke Technology Co ltd
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Abstract

The invention discloses a method and a system for detecting the running state of a carrier roller based on image processing, and relates to the field of artificial intelligence. The method mainly comprises the following steps: acquiring a multi-frame gray image of the carrier roller to be detected at each moment in the running process of the conveyor belt; overlapping edge vibration areas in adjacent multi-frame gray scale images at each moment to obtain an edge vibration image corresponding to each moment; carrying out non-blind deconvolution on the edge vibration image at each moment to obtain a clear vibration image at each moment; and respectively obtaining the similarity between the edge vibration image and the clear vibration image corresponding to each moment so as to determine whether the carrier roller to be tested is an abnormal carrier roller. According to the embodiment of the invention, the front images of the carrier rollers are processed, so that the state detection result of each carrier roller can be respectively obtained in the operation process of the conveying device provided with the carrier rollers, and the state detection precision of the carrier rollers is improved.

Description

基于图像处理的托辊运行状态检测方法及系统Method and system for detection of idler running state based on image processing

技术领域technical field

本申请涉及人工智能领域,具体涉及一种基于图像处理的托辊运行状态检测方法及系统。The present application relates to the field of artificial intelligence, and in particular to a method and system for detecting the running state of an idler based on image processing.

背景技术Background technique

带式输送机是大型的运输煤矿设备,具有结构简单、运输量大、造价和维护成本低等优点。但由于矿山工作环境较为复杂以及带式输送机的运行状态产生了众多的安全事故,其中托辊是带式输送机中最重要的部件之一,托辊的主要作用是支撑输送带和所传输的物料,在带式输送机运行过程中,托辊可能会由于安装不到位或者托辊表面存在缺陷等原因,使得托辊与传送带无法紧密接触,进而造成托辊出现上下振动,进一步缩短托辊中轴承的使用寿命,并对传送带的使用寿命造成危害。Belt conveyor is a large-scale coal mine transportation equipment, which has the advantages of simple structure, large transportation volume, low construction cost and maintenance cost. However, due to the complex working environment of the mine and the operation state of the belt conveyor, many safety accidents have occurred. Among them, the idler is one of the most important parts of the belt conveyor. The main function of the idler is to support the conveyor belt and the conveyed belt. During the operation of the belt conveyor, the idler may not be in close contact with the conveyor belt due to improper installation or defects on the surface of the idler, which will cause the idler to vibrate up and down and further shorten the idler. The service life of the medium bearing is harmful to the service life of the conveyor belt.

现有技术中主要通过对托辊处的音频进行分析,确定托辊是否存在异常,然而,托辊在运行过程中,存在着物料传输过程中的声音、带式传输机上托辊以外的零部件的声音等各种声音的干扰,使得难以实现对于单独的托辊在运行过程中的音频的采集,从而难以获得对于托辊的准确的状态检测结果。In the prior art, the audio frequency at the idler is mainly analyzed to determine whether there is any abnormality in the idler. However, during the operation of the idler, there are sounds during the material transmission process, and parts other than the idler on the belt conveyor. The interference of various sounds, such as sound, makes it difficult to collect the audio frequency of a single idler during operation, so that it is difficult to obtain an accurate state detection result for the idler.

发明内容SUMMARY OF THE INVENTION

针对上述技术问题,本发明提供了一种基于图像处理的托辊运行状态检测方法及系统,通过对托辊的正面图像进行处理,能够在装有托辊的传送装置的运行过程中,分别获得对每一托辊的状态检测结果,相较于现有技术中通过音频进行托辊的状态检测,能够提高对于托辊的状态检测精度。In view of the above technical problems, the present invention provides a method and system for detecting the running state of an idler based on image processing. As for the state detection result of each idler, compared with the state detection of the idler by audio in the prior art, the state detection accuracy of the idler can be improved.

第一方面,本发明实施例提出了一种基于图像处理的托辊运行状态检测方法,包括:In a first aspect, an embodiment of the present invention proposes a method for detecting the running state of an idler based on image processing, including:

获取传送带运行过程中每一时刻的待测托辊的多帧正面图像,并进行灰度化获得每一时刻对应的多帧灰度图像。Acquire multiple frontal images of the roller to be tested at each moment during the operation of the conveyor belt, and perform grayscale to obtain multiple frames of grayscale images corresponding to each moment.

对每一时刻的相邻多帧灰度图像中的边缘振动区域进行叠加,获得每一时刻对应的边缘振动图像,所述边缘振动区域为位于灰度图像的上下边界的预定高度的区域。The edge vibration regions in the adjacent multi-frame grayscale images at each moment are superimposed to obtain the edge vibration images corresponding to each moment, and the edge vibration regions are regions located at predetermined heights of the upper and lower boundaries of the grayscale images.

利用变分贝叶斯获得每一时刻的边缘振动图像对应的卷积核,并根据卷积核对每一时刻的边缘振动图像进行非盲去卷积去模糊方法,获得去模糊后每一时刻的清晰振动图像。Use variational Bayes to obtain the convolution kernel corresponding to the edge vibration image at each moment, and perform a non-blind deconvolution and deblurring method on the edge vibration image at each moment according to the convolution kernel, and obtain the deblurred image at each moment. Clear vibrating image.

分别获得每一时刻所对应的边缘振动图像与清晰振动图像之间的相似度,并获得预设时长内所有时刻所对应的所有相似度中,小于或等于相似度阈值的相似度所占的比例,在所述比例大于比例阈值的情况下,将待测托辊确定为异常托辊。Obtain the similarity between the edge vibration image corresponding to each moment and the clear vibration image respectively, and obtain the proportion of the similarity less than or equal to the similarity threshold among all the similarities corresponding to all the moments within the preset duration. , in the case that the ratio is greater than the ratio threshold, determine the idler to be tested as an abnormal idler.

进一步的,基于图像处理的托辊运行状态检测方法中,所述方法还包括对每一时刻所对应的相似度进行更新,包括:Further, in the method for detecting the running state of the idler based on image processing, the method further includes updating the similarity corresponding to each moment, including:

获得每一时刻的任一帧灰度图像在运动方向上灰度游程矩阵的长游程低灰度级优势,并将其作为每一时刻的第一特征值,所述运动方向为待测托辊的运动方向在灰度图像中对应的方向;Obtain the long-run and low-gray-level advantage of the gray-scale run-length matrix of any frame of grayscale image at each moment in the movement direction, and use it as the first eigenvalue at each moment, and the movement direction is the roller to be tested. The movement direction of the corresponding direction in the grayscale image;

获得每一时刻的任一帧灰度图像在运动方向以外的每一方向的灰度游程矩阵的长游程低灰度级优势,并将运动方向以外的各方向的灰度游程矩阵的长游程低灰度级优势的均值,作为每一时刻的第二特征值;运动方向以外的各方向为0度、45度、90度和135度中运动方向所对应的方向以外的方向;Obtain the long-run and low-gray-level advantages of the gray-scale run-length matrix of any frame of grayscale image at each moment in each direction other than the motion direction, and set the long-run low-level advantages of the grayscale run-length matrix in all directions other than the motion direction. The mean value of the gray-level advantage is used as the second eigenvalue at each moment; the directions other than the motion direction are directions other than the directions corresponding to the motion directions in 0°, 45°, 90° and 135°;

将每一时刻的第二特征值与第一特征值的除法运算结果作为每一时刻的第三特征值;Taking the division operation result of the second eigenvalue at each moment and the first eigenvalue as the third eigenvalue at each moment;

将每一时刻所对应的相似度,与每一时刻对应的第三特征值的乘积结果,作为对每一时刻对应的更新后的相似度。The result of multiplying the similarity corresponding to each moment and the third eigenvalue corresponding to each moment is taken as the updated similarity corresponding to each moment.

进一步的,基于图像处理的托辊运行状态检测方法中,所述方法还包括根据灰度图像获得待测托辊的运动方向,所述根据灰度图像获得待测托辊的运动方向,包括:Further, in the method for detecting the running state of the idler based on image processing, the method further includes obtaining the moving direction of the idler to be measured according to the grayscale image, and obtaining the moving direction of the idler to be measured according to the grayscale image includes:

将灰度图像中每一像素点与其八邻域内像素点的灰度值差异最小的方向,分别作为灰度图像中每一像素点的特征方向;The direction with the smallest difference between the gray value of each pixel in the grayscale image and the pixel in its eight neighborhoods is taken as the characteristic direction of each pixel in the grayscale image;

将夹角为180度的特征方向作为同一种特征方向,将灰度图像中所有像素点的所有特征方向中频数最大的特征方向作为待测托辊的运动方向。The characteristic direction with an included angle of 180 degrees is taken as the same characteristic direction, and the characteristic direction with the largest intermediate frequency among all characteristic directions of all pixel points in the grayscale image is taken as the moving direction of the roller to be tested.

进一步的,基于图像处理的托辊运行状态检测方法中,对待测托辊的正面图像进行灰度化获得灰度图像前,所述方法还包括:Further, in the method for detecting the running state of the idler based on image processing, before the front image of the idler to be measured is grayed to obtain a grayscale image, the method further includes:

采集包含待测托辊的正面的图像并进行图像分割获得待测托辊的正面图像,所述正面图像中待测托辊以外的像素点的像素值为0。Collect an image including the front surface of the roller to be tested and perform image segmentation to obtain the front image of the roller to be tested, and the pixel value of the pixels other than the roller to be tested in the front image is 0.

进一步的,基于图像处理的托辊运行状态检测方法中,对包含待测托辊的正面的图像进行图像分割获得待测托辊的正面图像是通过DNN实现的。Further, in the method for detecting the running state of the idler based on image processing, image segmentation is performed on the image including the front surface of the idler to be tested to obtain the frontal image of the idler to be tested through DNN.

进一步的,基于图像处理的托辊运行状态检测方法中,获取每一时刻的待测托辊的多帧正面图像前,所述方法还包括确定待测托辊,其中,确定待测托辊的过程包括:Further, in the method for detecting the running state of the idler based on image processing, before acquiring multiple frames of frontal images of the idler to be tested at each moment, the method further includes determining the idler to be measured, wherein the determination of the idler to be measured is determined. The process includes:

在传送带运行过程中分别采集每一托辊处的音频,并将托辊处的音频与标准托辊的差异度大于差异度阈值的托辊确定为待测托辊。During the operation of the conveyor belt, the audio frequency of each idler is collected respectively, and the idler whose difference between the audio frequency at the idler and the standard idler is greater than the difference threshold is determined as the idler to be tested.

进一步的,基于图像处理的托辊运行状态检测方法中,每一时刻所对应的边缘振动图像与清晰振动图像之间的相似度为结构相似性SSIM。Further, in the method for detecting the running state of the idler based on image processing, the similarity between the edge vibration image corresponding to each moment and the clear vibration image is the structural similarity SSIM.

第二方面,本发明实施例提出了一种基于图像处理的托辊运行状态检测系统,包括:存储器和处理器,所述处理器执行所述存储器存储的计算机程序,以实现本发明实施例中基于图像处理的托辊运行状态检测方法。In a second aspect, an embodiment of the present invention provides an image processing-based system for detecting the running state of an idler, including: a memory and a processor, where the processor executes a computer program stored in the memory to implement the embodiments of the present invention A method for detecting the running state of idlers based on image processing.

本发明提供了一种基于图像处理的托辊运行状态检测方法及系统,相比于现有技术,本发明实施例的有益效果在于:通过对托辊的正面图像进行处理,能够在装有托辊的传送装置的运行过程中,分别获得对每一托辊的状态检测结果,相较于现有技术中通过音频进行托辊的状态检测,能够提高对于托辊的状态检测精度。The present invention provides a method and system for detecting the running state of an idler roller based on image processing. Compared with the prior art, the beneficial effect of the embodiment of the present invention is: by processing the front image of the idler roller, it can be During the operation of the roller conveying device, the state detection result of each idler is obtained separately, which can improve the state detection accuracy of the idler compared to the state detection of the idler by audio in the prior art.

附图说明Description of drawings

为了更清楚地说明本发明实施例或现有技术中的技术方案,下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍,显而易见地,下面描述中的附图仅仅是本发明的一些实施例,对于本领域普通技术人员来讲,在不付出创造性劳动性的前提下,还可以根据这些附图获得其他的附图。In order to explain the embodiments of the present invention or the technical solutions in the prior art more clearly, the following briefly introduces the accompanying drawings that need to be used in the description of the embodiments or the prior art. Obviously, the accompanying drawings in the following description are only These are some embodiments of the present invention, and for those of ordinary skill in the art, other drawings can also be obtained from these drawings without any creative effort.

图1是本发明实施例提供的一种基于图像处理的托辊运行状态检测方法的流程示意图;1 is a schematic flowchart of a method for detecting the running state of an idler based on image processing provided by an embodiment of the present invention;

图2是本发明实施例提供的托辊正面与传送带运动方向的相对位置的示意图;2 is a schematic diagram of the relative position of the front surface of the idler and the moving direction of the conveyor belt provided by an embodiment of the present invention;

图3是本发明实施例提供的对每一时刻所对应的相似度进行更新的流程示意图。FIG. 3 is a schematic flowchart of updating the similarity corresponding to each moment according to an embodiment of the present invention.

具体实施方式Detailed ways

为了使本发明的目的、技术方案及优点更加清楚明白,以下结合附图及实施例,对本发明进行进一步详细说明。应当理解,此处所描述的具体实施例仅用以解释本发明,并不用于限定本发明。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。In order to make the objectives, technical solutions and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention, but not to limit the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

以下描述中,为了说明而不是为了限定,提出了诸如特定系统结构、技术之类的具体细节,以便透彻理解本申请实施例。然而,本领域的技术人员应当清楚,在没有这些具体细节的其它实施例中也可以实现本申请。在其它情况中,省略对众所周知的系统、装置、电路以及方法的详细说明,以免不必要的细节妨碍本申请的描述。In the following description, for the purpose of illustration rather than limitation, specific details such as a specific system structure and technology are set forth in order to provide a thorough understanding of the embodiments of the present application. However, it will be apparent to those skilled in the art that the present application may be practiced in other embodiments without these specific details. In other instances, detailed descriptions of well-known systems, devices, circuits, and methods are omitted so as not to obscure the description of the present application with unnecessary detail.

术语“第一”、“第二”仅用于描述目的,而不能理解为指示或暗示相对重要性或者隐含指明所指示的技术特征的数量。由此,限定有“第一”、“第二”的特征可以明示或者隐含地包括一个或者更多个该特征;在本实施例的描述中,除非另有说明,“多个”的含义是两个或两个以上。The terms "first" and "second" are only used for descriptive purposes, and should not be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined with "first" and "second" may explicitly or implicitly include one or more of the features; in the description of this embodiment, unless otherwise specified, the meaning of "multiple" are two or more.

本发明实施例提供了一种基于图像处理的托辊运行状态检测方法,如图1所示,包括:An embodiment of the present invention provides a method for detecting the running state of an idler based on image processing, as shown in FIG. 1 , including:

步骤S100、获取传送带运行过程中每一时刻的待测托辊的多帧正面图像,并进行灰度化获得每一时刻对应的多帧灰度图像。Step S100 , acquiring multiple frames of front images of the roller to be tested at each moment during the running process of the conveyor belt, and performing grayscale to obtain multiple frames of grayscale images corresponding to each moment.

在传送带运行过程中,需要通过托辊支撑传送带以及传送带上方的物料,然而,当托辊由于表面存在的凹坑等缺陷时,会使得托辊与传送带无法充分接触,从而造成托辊在上下方向进行振动,并进一步缩短托辊中轴承的使用寿命,因此,需要及时发现托辊中所出现的异常振动情况。During the operation of the conveyor belt, the conveyor belt and the materials above the conveyor belt need to be supported by the idler roller. However, when the idler roller has defects such as pits on the surface, the idler roller and the conveyor belt cannot be fully contacted, resulting in the idler roller in the up and down direction. Vibration and further shorten the service life of the bearings in the idler. Therefore, it is necessary to find out the abnormal vibration in the idler in time.

图2为本发明实施例中托辊正面与传送带运动方向的相对位置的示意图,可以从托辊的正面,采集在传送带运行过程中待测托辊的多帧正面图像,所采集到的多帧正面图像为RGB图像,RGB是一种颜色标准,通过对红(R)、绿(G)、蓝(B)三个颜色通道的变化以及它们相互之间的叠加来得到各式各样的颜色,RGB即是代表红、绿、蓝三个通道的颜色。Figure 2 is a schematic diagram of the relative position of the front surface of the idler and the moving direction of the conveyor belt in the embodiment of the present invention. Multiple frames of front images of the idler to be tested during the running process of the conveyor belt can be collected from the front of the idler. The collected multiple frames The front image is an RGB image. RGB is a color standard. Various colors are obtained by changing the three color channels of red (R), green (G), and blue (B) and superimposing them on each other. , RGB is the color representing the three channels of red, green and blue.

分别对所采集的每一时刻的多帧正面图像进行灰度化,获得每一时刻对应的多帧灰度图像,其中灰度化的过程可以采用最大值灰度化或平均值灰度化。Grayscale is performed on the multi-frame frontal images collected at each moment, respectively, to obtain multi-frame grayscale images corresponding to each moment, wherein the grayscale process can adopt maximum value grayscale or average value grayscale.

可选的,还可以在对待测托辊的正面图像进行灰度化获得灰度图像前,采集包含待测托辊的正面的图像,并对包含待测托辊的正面的图像进行图像分割,获得待测托辊的正面图像,其中,分割后得到的正面图像中待测托辊以外的像素点的像素值为0,如此,能够去除托辊以外部分像素点对检测结果的不良影响。Optionally, before graying the front image of the roller to be tested to obtain a grayscale image, collect an image containing the front of the roller to be tested, and perform image segmentation on the image containing the front of the roller to be tested, The front image of the roller to be tested is obtained, wherein the pixel value of the pixels other than the roller to be tested in the front image obtained after segmentation is 0. In this way, the adverse effects of the pixels other than the roller on the detection result can be removed.

对包含待测托辊的正面的图像分割过程,可以通过DNN(Deep Neural Networks,深度神经网络)实现,同时DNN的训练过程可以包括如下步骤:将包含托辊的正面的图像中的像素点进行人工标注,将其中的像素点划分成托辊类和托辊以外的背景类,将背景类的像素的标注为0,并利用标注完成后的图像对DNN进行训练,同时,可以在训练过程中采用交叉熵损失函数对训练过程进行监督。The image segmentation process of the front containing the roller to be tested can be realized by DNN (Deep Neural Networks, deep neural network), and the training process of the DNN can include the following steps: the pixels in the image containing the front of the roller are processed. Manual labeling, dividing the pixels into the idler class and the background class other than the idler, labeling the pixels of the background class as 0, and using the labeled images to train the DNN. At the same time, during the training process The training process is supervised using a cross-entropy loss function.

可选的,获取每一时刻的待测托辊的多帧正面图像前,还可以从所有的托辊中确定出待测托辊,具体可以包括:在传送带运行过程中分别采集每一托辊处的音频,并将托辊处的音频与标准托辊的差异度大于差异度阈值的托辊确定为待测托辊,需要说明的是,不同货物你载重情况以及运动速度下托辊,所对应的音频会呈现不同的状态,当托辊的音频与其当前状态下对应的标准音频的差异度大于差异度阈值时,托辊更有可能是存在故障的托辊,可以将其确定为待测托辊,如此,可以实现对于托辊的初步筛选。Optionally, before acquiring multiple frames of front images of the rollers to be tested at each moment, the rollers to be tested may also be determined from all the rollers, which may specifically include: collecting each roller separately during the operation of the conveyor belt. and the difference between the audio frequency at the idler and the standard idler is greater than the difference threshold as the idler to be tested. It should be noted that the idler under the load conditions of different goods and the moving speed, so The corresponding audio frequency will be in different states. When the difference between the audio frequency of the idler and the standard audio corresponding to the current state is greater than the difference threshold, the idler is more likely to be a faulty idler, and it can be determined as the one to be tested. The idler, in this way, can realize the preliminary screening of the idler.

其中,对于音频之间的差异度,可以通过确定音频的幅值,所述幅值为音频的最大值与最小值之间的差值,将不同音频之间的幅值的差值的绝对值,作为不同音频之间的差异度。Wherein, for the degree of difference between the audios, the amplitude of the audio can be determined, the amplitude is the difference between the maximum value and the minimum value of the audio, and the absolute value of the difference between the amplitudes between different audios can be determined. , as the degree of difference between different audios.

步骤S200、对每一时刻的相邻多帧灰度图像中的边缘振动区域进行叠加,获得每一时刻对应的边缘振动图像,所述边缘振动区域为位于灰度图像的上下边界的预定高度的区域。Step S200, superimpose the edge vibration areas in the adjacent multi-frame grayscale images at each moment to obtain the edge vibration images corresponding to each moment, and the edge vibration areas are located at the predetermined height of the upper and lower boundaries of the grayscale image. area.

本发明实施例中对每一时刻的相邻多帧灰度图像中的边缘振动区域进行叠加的原因在于,通过单帧的边缘振动区域,无法有效反映其在同一时刻内的上下振动情况,同时,由于托辊的正面的灰度图像中上下边界部分能够有效反映其上下振动情况,因此,本发明实施例中边缘振动区域为位于灰度图像的上下边界的预定高度的区域。The reason for superimposing the edge vibration areas in the adjacent multi-frame grayscale images at each moment in the embodiment of the present invention is that the edge vibration area of a single frame cannot effectively reflect the up and down vibration at the same moment. , since the upper and lower boundary parts of the grayscale image on the front side of the idler can effectively reflect the upper and lower vibrations, the edge vibration area in the embodiment of the present invention is an area located at a predetermined height of the upper and lower boundaries of the grayscale image.

步骤S300、利用变分贝叶斯获得每一时刻的边缘振动图像对应的卷积核,并根据卷积核对每一时刻的边缘振动图像进行非盲去卷积去模糊方法,获得去模糊后每一时刻的清晰振动图像。Step S300, use variational Bayes to obtain the convolution kernel corresponding to the edge vibration image at each moment, and perform a non-blind deconvolution and deblurring method on the edge vibration image at each moment according to the convolution kernel, and obtain each time after deblurring. A clear vibrating image of a moment.

本发明实施例利用去运动模糊算法,获得边缘振动图像对应的清晰振动图像,由于振动幅度越大,造成的图像的模糊的程度越深,从而进行去运动模糊前后的相似度就越小,因此本发明实施例在后续步骤中通过比较对边缘振动图像去模糊前后图像之间的相似性,来反映待测托辊的振动强度。In the embodiment of the present invention, a de-motion blurring algorithm is used to obtain a clear vibration image corresponding to the edge vibration image. Since the larger the vibration amplitude is, the more blurred the image is, and the similarity before and after the de-motion blur is smaller. Therefore, In the embodiment of the present invention, in the subsequent steps, the vibration intensity of the roller to be tested is reflected by comparing the similarity between the images before and after the edge vibration image is deblurred.

步骤S400、分别获得每一时刻所对应的边缘振动图像与清晰振动图像之间的相似度,并获得预设时长内所有时刻所对应的所有相似度中,小于或等于相似度阈值的相似度所占的比例,在所述比例大于比例阈值的情况下,将待测托辊确定为异常托辊。Step S400, obtain the similarity between the edge vibration image corresponding to each moment and the clear vibration image respectively, and obtain all the similarities corresponding to all the moments in the preset duration, the similarity less than or equal to the similarity threshold. If the ratio is greater than the ratio threshold, the idler to be tested is determined to be an abnormal idler.

由于托辊的振动幅度越大,给边缘振动区域造成的模糊程度越大,则使得去模糊后得到的清晰振动图像与边缘振动图像的相似度越小,因此本发明实施例中,通过确定边缘振动图像与其对应的清晰振动图像之间的相似度,可以反映托辊在边缘处的振动幅度。Since the larger the vibration amplitude of the idler is, the greater the degree of blur caused to the edge vibration area, the smaller the similarity between the clear vibration image obtained after deblurring and the edge vibration image. Therefore, in the embodiment of the present invention, by determining the edge vibration The similarity between the vibration image and its corresponding clear vibration image can reflect the vibration amplitude of the idler at the edge.

作为一种可行的实施方式,本发明实施例中边缘振动图像与清晰振动图像之间的相似度的获得过程包括:As a feasible implementation manner, the process of obtaining the similarity between the edge vibration image and the clear vibration image in the embodiment of the present invention includes:

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是边缘振动图像中像素点的灰度均值,
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是清晰振动图像中像素点的灰度均值,
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是边缘振动图像中像素点的灰度值的方差,
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是清晰振动图像中像素点的灰度值的方差,
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是边缘振动图像与清晰振动图像中像素点的灰度值的协方差,
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,其中,
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为预设第二数值,作为一个示例,本发明实施例中
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is the gray mean of the pixels in the edge vibration image,
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is the covariance of the gray value of the pixel points in the edge vibration image and the clear vibration image,
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is a preset second value. As an example, in this embodiment of the present invention,
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.

作为另一种可行的实施方式,本发明实施例中边缘振动图像与清晰振动图像之间的相似度采用结构相似度SSIM进行计算,需要说明的是,结构相似度SSIM(structuralsimilarity index)是一种衡量两幅图像相似度的指标,其从图像组成的角度,将结构信息定义为独立于亮度、对比度的,反映场景中物体结构的属性,并将失真建模为亮度、对比度和结构三个不同因素的组合,其中均值作为亮度的估计,标准差作为对比度的估计,协方差作为结构相似程度的度量。As another feasible implementation, in the embodiment of the present invention, the similarity between the edge vibration image and the clear vibration image is calculated by using the structural similarity SSIM. It should be noted that the structural similarity SSIM (structural similarity index) is a kind of An index to measure the similarity of two images. From the perspective of image composition, it defines the structure information as independent of brightness and contrast, reflecting the properties of the object structure in the scene, and models the distortion as three different brightness, contrast and structure. A combination of factors, where the mean is an estimate of brightness, the standard deviation is an estimate of contrast, and the covariance is a measure of structural similarity.

作为又一个可行的实施方式,本发明实施例中边缘振动图像与清晰振动图像之间的相似度采用皮尔逊相关系数进行计算,需要说明的是,在统计学中,皮尔逊相关系数,又称皮尔逊积矩相关系数(Pearson product-moment correlation coefficient,简称PPMCC或PCCs),可以将其应用于计算两张图像之间的相似性。As another feasible implementation manner, in the embodiment of the present invention, the similarity between the edge vibration image and the clear vibration image is calculated by using the Pearson correlation coefficient. It should be noted that, in statistics, the Pearson correlation coefficient, also known as the Pearson correlation coefficient Pearson product-moment correlation coefficients (PPMCCs or PCCs for short), which can be applied to calculate the similarity between two images.

在预设时长内所有时刻所对应的所有相似度中,小于或等于相似度阈值的相似度所占的比例大于比例阈值的情况下,可以将待测托辊确定为异常托辊;作为一个示例,本发明实施例中相似度阈值为0.7,实施者可以根据实际需求确定相似度阈值的取值。In the case where the proportion of the similarity less than or equal to the similarity threshold is greater than the proportion threshold among all the similarities corresponding to all the moments within the preset time period, the roller to be tested can be determined as an abnormal roller; as an example , in this embodiment of the present invention, the similarity threshold is 0.7, and the implementer may determine the similarity threshold according to actual needs.

需要说明的是,当预设时长内的所有相似度中小于或等于相似度阈值的相似度的比值大于比例阈值,说明托辊的振动超过了允许的范围,可以将待测托辊确定为存在异常的托辊。It should be noted that when the ratio of the similarity less than or equal to the similarity threshold among all the similarities within the preset time period is greater than the proportional threshold, it means that the vibration of the idler exceeds the allowable range, and the idler to be tested can be determined to exist. Abnormal idler.

可选的,可以在确定出存在异常的托辊之后,对异常的托辊进行更换,同时,对于异常托辊的更换过程,可以利用托辊更换装置,暂时代替待更换的异常托辊完成支撑传送带的工作,待完成对托辊的更换后,卸下托辊更换装置,利用更换后的托辊继续支撑传送带。Optionally, after it is determined that there is an abnormal idler, the abnormal idler can be replaced. At the same time, for the replacement process of the abnormal idler, the idler replacement device can be used to temporarily replace the abnormal idler to be replaced to complete the support. In the work of the conveyor belt, after the replacement of the idler rollers is completed, the idler roller replacement device is removed, and the replaced idler rollers are used to continue supporting the conveyor belt.

可选的,本发明实施例中还可以对每一时刻所对应的相似度进行更新,如图3所示,具体可以包括如下步骤:Optionally, in this embodiment of the present invention, the similarity corresponding to each moment may also be updated, as shown in FIG. 3 , which may specifically include the following steps:

步骤S110、获得每一时刻的任一帧灰度图像在运动方向上灰度游程矩阵的长游程低灰度级优势,并将其作为每一时刻的第一特征值,所述运动方向为待测托辊的运动方向在灰度图像中对应的方向。Step S110: Obtain the long-run and low-gray-level advantage of the gray-scale run-length matrix of the grayscale run-length matrix in the motion direction of any frame of grayscale images at each moment, and use it as the first eigenvalue at each moment, and the motion direction is to be Measure the direction of movement of the idler in the corresponding direction in the grayscale image.

由于在传送带运行过程中,在托辊的运动速度也会影响到托辊的振动情况,同时,相同纹理的托辊在不同的运动速度下,其正面图像中所呈现的纹理不同,主要表现为运动速度更快的托辊的正面图像中,会存在更多沿运动方向的呈长条状的连通域。During the operation of the conveyor belt, the movement speed of the idler will also affect the vibration of the idler. At the same time, under different movement speeds of the idler with the same texture, the texture presented in the front image is different, mainly as follows: In the front image of the roller with faster moving speed, there will be more elongated connected domains along the moving direction.

与此同时,利用灰度游程矩阵的长游程第灰度能够很好的反映该特征,因此,本发明实施例中,获得每一时刻的任一帧灰度图像在运动方向上灰度游程矩阵的长游程低灰度级优势,并将其作为每一时刻的第一特征值。At the same time, this feature can be well reflected by using the long-run grayscale of the grayscale run-length matrix. Therefore, in the embodiment of the present invention, the grayscale run-length matrix in the motion direction of any frame of grayscale image at each moment is obtained. The long-run low-gray-level advantage of , and take it as the first eigenvalue at each moment.

需要说明的是,图像的灰度游程矩阵反映了图像的灰度关于方向、相邻间隔和变化幅度等综合信息,其是对所分析的图像的局部模式和其排列规则基础之一。灰度游程矩阵可以实现对一幅图像中同一方向同一灰度值连续出现个数的统计,在一幅图像上,在某一方向上连续的像素点具有相同的灰度值,灰度游程矩阵就是通过对这些像素点的分布进行统计得到纹理特征。It should be noted that the grayscale run-length matrix of an image reflects the comprehensive information of the grayscale of the image, such as direction, adjacent interval, and variation range, which is one of the basis for the local pattern of the analyzed image and its arrangement rules. The grayscale run-length matrix can realize the statistics of the number of consecutive occurrences of the same grayscale value in the same direction in an image. On an image, consecutive pixels in a certain direction have the same grayscale value, and the grayscale run-length matrix is The texture features are obtained by statistical distribution of these pixel points.

具体的,灰度图像的灰度共生矩阵的长游程第灰度优势的获得过程包括:Specifically, the process of obtaining the long-run gray-level advantage of the gray-level co-occurrence matrix of the gray-level image includes:

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方向的灰度共生矩阵的长游程第灰度优势,
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个灰度级的像素点沿着
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方向的游程为
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为0度、45度、90度和135度中的任意一种。In the formula,
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The gray-scale advantage of the long-run gray co-occurrence matrix of the direction,
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The run in the direction is
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is the maximum run length in the grayscale run length matrix,
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is the number of grayscale levels in the grayscale image, and the run length refers to the number of consecutive occurrences. At the same time,
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Any of 0 degrees, 45 degrees, 90 degrees and 135 degrees.

可选的,还可以根据灰度图像获得待测托辊的运动方向,具体可以包括:将灰度图像中每一像素点与其八邻域内像素点的灰度值差异最小的方向,分别作为灰度图像中每一像素点的特征方向;将夹角为180度的特征方向作为同一种特征方向,将灰度图像中所有像素点的所有特征方向中频数最大的特征方向作为待测托辊的运动方向。Optionally, the moving direction of the roller to be tested can also be obtained according to the grayscale image, which may specifically include: taking the direction with the smallest difference between the grayscale values of each pixel in the grayscale image and the pixels in its eight neighborhoods as the grayscale respectively. The characteristic direction of each pixel point in the grayscale image; the characteristic direction with an included angle of 180 degrees is regarded as the same characteristic direction, and the characteristic direction with the largest frequency among all characteristic directions of all pixel points in the grayscale image is used as the characteristic direction of the roller to be tested. direction of movement.

步骤S120、获得每一时刻的任一帧灰度图像在运动方向以外的每一方向的灰度游程矩阵的长游程低灰度级优势,并将运动方向以外的各方向的灰度游程矩阵的长游程低灰度级优势的均值,作为每一时刻的第二特征值;运动方向以外的各方向为0度、45度、90度和135度中运动方向所对应的方向以外的方向。Step S120: Obtain the long-run and low-gray-level advantages of the gray-scale run-length matrix of any frame of grayscale image at each moment in each direction other than the motion direction, and use the grayscale run-length matrix of each direction other than the motion direction. The mean value of the advantages of long run and low gray level is used as the second eigenvalue at each moment; the directions other than the motion direction are directions other than the directions corresponding to the motion directions in 0°, 45°, 90° and 135°.

步骤S130、将每一时刻的第二特征值与第一特征值的除法运算结果作为每一时刻的第三特征值;将每一时刻所对应的相似度,与每一时刻对应的第三特征值的乘积结果,作为对每一时刻对应的更新后的相似度。Step S130, taking the division operation result of the second eigenvalue at each moment and the first eigenvalue as the third eigenvalue at each moment; taking the similarity corresponding to each moment and the third characteristic corresponding to each moment The result of the product of the values is used as the updated similarity corresponding to each moment.

如此,可以使获得的更新后的相似度中包含由于运动速度给振动带来的影响,以便获得更为精准的托辊状态检测结果。In this way, the obtained updated similarity can include the influence of the vibration caused by the movement speed, so as to obtain a more accurate detection result of the idler state.

基于与上述方法相同的发明构思,本实施例还提供了一种基于图像处理的托辊运行状态检测系统,本实施例中基于图像处理的托辊运行状态检测系统包括存储器和处理器,所述处理器执行所述存储器存储的计算机程序,以实现如基于图像处理的托辊运行状态检测方法实施例中所描述的对托辊状态进行检测。Based on the same inventive concept as the above method, this embodiment also provides an image processing-based idler running state detection system. In this embodiment, the image processing-based idler running state detection system includes a memory and a processor. The processor executes the computer program stored in the memory to realize the detection of the state of the idler as described in the embodiment of the method for detecting the running state of the idler based on image processing.

由于基于图像处理的托辊运行状态检测方法实施例中已经对托辊的状态进行检测的方法进行了说明,此处不再赘述。Since the method for detecting the state of the idler has already been described in the embodiment of the method for detecting the running state of the idler based on image processing, it will not be repeated here.

综上所述,本发明提供了一种基于图像处理的托辊运行状态检测方法及系统,通过对托辊的正面图像进行处理,能够在装有托辊的传送装置的运行过程中,分别获得对每一托辊的状态检测结果,相较于现有技术中通过音频进行托辊的状态检测,能够提高对于托辊的状态检测精度。To sum up, the present invention provides a method and system for detecting the running state of the idler based on image processing. By processing the front image of the idler, it is possible to obtain the detection results respectively during the operation of the conveying device equipped with the idler. As for the state detection result of each idler, compared with the state detection of the idler by audio in the prior art, the state detection accuracy of the idler can be improved.

本发明中涉及诸如“包括”、“包含”、“具有”等等的词语是开放性词汇,指“包括但不限于”,且可与其互换使用。这里所使用的词汇“或”和“和”指词汇“和/或”,且可与其互换使用,除非上下文明确指示不是如此。这里所使用的词汇“诸如”指词组“诸如但不限于”,且可与其互换使用。Words such as "including", "comprising", "having", etc. referred to herein are open-ended words meaning "including but not limited to" and are used interchangeably therewith. As used herein, the words "or" and "and" refer to and are used interchangeably with the word "and/or" unless the context clearly dictates otherwise. As used herein, the word "such as" refers to and is used interchangeably with the phrase "such as but not limited to".

还需要指出的是,在本发明的方法和系统中,各部件或各步骤是可以分解和/或重新组合的。这些分解和/或重新组合应视为本公开的等效方案。It should also be pointed out that in the method and system of the present invention, each component or each step can be decomposed and/or recombined. These disaggregations and/or recombinations should be considered equivalents of the present disclosure.

上述实施例仅仅是为清楚地说明所做的举例,并不构成对本发明的保护范围的限制。对于所属领域的普通技术人员来说,在上述说明的基础上还可以做出其它不同形式的变化或变动,这里无需也无法对所有的实施方式予以穷举。凡是与本发明相同或相似的设计均属于本发明的保护范围之内。The above-mentioned embodiments are only examples for clear description, and do not limit the protection scope of the present invention. For those of ordinary skill in the art, changes or modifications in other different forms can also be made on the basis of the above description, and it is not necessary and impossible to list all the implementations here. All the same or similar designs as the present invention fall within the protection scope of the present invention.

Claims (8)

1.一种基于图像处理的托辊运行状态检测方法,其特征在于,包括:1. A method for detecting the running state of an idler based on image processing, characterized in that, comprising: 获取传送带运行过程中每一时刻的待测托辊的多帧正面图像,并进行灰度化获得每一时刻对应的多帧灰度图像;Acquire multiple frontal images of the roller to be tested at each moment during the operation of the conveyor belt, and perform grayscale to obtain multiple frames of grayscale images corresponding to each moment; 对每一时刻的相邻多帧灰度图像中的边缘振动区域进行叠加,获得每一时刻对应的边缘振动图像,所述边缘振动区域为位于灰度图像的上下边界的预定高度的区域;The edge vibration regions in the adjacent multi-frame grayscale images at each moment are superimposed to obtain the edge vibration images corresponding to each moment, and the edge vibration regions are regions located at the predetermined heights of the upper and lower boundaries of the grayscale images; 利用变分贝叶斯获得每一时刻的边缘振动图像对应的卷积核,并根据卷积核对每一时刻的边缘振动图像进行非盲去卷积去模糊方法,获得去模糊后每一时刻的清晰振动图像;Use variational Bayes to obtain the convolution kernel corresponding to the edge vibration image at each moment, and perform a non-blind deconvolution and deblurring method on the edge vibration image at each moment according to the convolution kernel, and obtain the deblurred image at each moment. Clear vibration image; 分别获得每一时刻所对应的边缘振动图像与清晰振动图像之间的相似度,并获得预设时长内所有时刻所对应的所有相似度中,小于或等于相似度阈值的相似度所占的比例,在所述比例大于比例阈值的情况下,将待测托辊确定为异常托辊。Obtain the similarity between the edge vibration image corresponding to each moment and the clear vibration image respectively, and obtain the proportion of the similarity less than or equal to the similarity threshold among all the similarities corresponding to all the moments within the preset duration. , in the case that the ratio is greater than the ratio threshold, determine the idler to be tested as an abnormal idler. 2.根据权利要求1所述的基于图像处理的托辊运行状态检测方法,其特征在于,所述方法还包括对每一时刻所对应的相似度进行更新,包括:2 . The method for detecting the running state of an idler based on image processing according to claim 1 , wherein the method further comprises updating the similarity corresponding to each moment, including: 2 . 获得每一时刻的任一帧灰度图像在运动方向上灰度游程矩阵的长游程低灰度级优势,并将其作为每一时刻的第一特征值,所述运动方向为待测托辊的运动方向在灰度图像中对应的方向;Obtain the long-run and low-gray-level advantage of the gray-scale run-length matrix of any frame of grayscale image at each moment in the movement direction, and use it as the first eigenvalue at each moment, and the movement direction is the roller to be tested. The movement direction of the corresponding direction in the grayscale image; 获得每一时刻的任一帧灰度图像在运动方向以外的每一方向的灰度游程矩阵的长游程低灰度级优势,并将运动方向以外的各方向的灰度游程矩阵的长游程低灰度级优势的均值,作为每一时刻的第二特征值;运动方向以外的各方向为0度、45度、90度和135度中运动方向所对应的方向以外的方向;Obtain the long-run and low-gray-level advantages of the gray-scale run-length matrix of any frame of grayscale image at each moment in each direction other than the motion direction, and set the long-run low-level advantages of the grayscale run-length matrix in all directions other than the motion direction. The mean value of the gray-level advantage is used as the second eigenvalue at each moment; the directions other than the motion direction are directions other than the directions corresponding to the motion directions in 0°, 45°, 90° and 135°; 将每一时刻的第二特征值与第一特征值的除法运算结果作为每一时刻的第三特征值;Taking the division operation result of the second eigenvalue at each moment and the first eigenvalue as the third eigenvalue at each moment; 将每一时刻所对应的相似度,与每一时刻对应的第三特征值的乘积结果,作为对每一时刻对应的更新后的相似度。The result of multiplying the similarity corresponding to each moment and the third eigenvalue corresponding to each moment is taken as the updated similarity corresponding to each moment. 3.根据权利要求2所述的基于图像处理的托辊运行状态检测方法,其特征在于,所述方法还包括根据灰度图像获得待测托辊的运动方向,所述根据灰度图像获得待测托辊的运动方向,包括:3 . The method for detecting the running state of an idler based on image processing according to claim 2 , wherein the method further comprises obtaining the moving direction of the idler to be measured according to the grayscale image, and obtaining the moving direction of the idler to be measured according to the grayscale image. 4 . Measure the direction of movement of the idler, including: 将灰度图像中每一像素点与其八邻域内像素点的灰度值差异最小的方向,分别作为灰度图像中每一像素点的特征方向;The direction with the smallest difference between the gray value of each pixel in the grayscale image and the pixel in its eight neighborhoods is taken as the characteristic direction of each pixel in the grayscale image; 将夹角为180度的特征方向作为同一种特征方向,将灰度图像中所有像素点的所有特征方向中频数最大的特征方向作为待测托辊的运动方向。The characteristic direction with an included angle of 180 degrees is taken as the same characteristic direction, and the characteristic direction with the largest intermediate frequency among all characteristic directions of all pixel points in the grayscale image is taken as the moving direction of the roller to be tested. 4.根据权利要求1所述的基于图像处理的托辊运行状态检测方法,其特征在于,对待测托辊的正面图像进行灰度化获得灰度图像前,所述方法还包括:4. The method for detecting the running state of an idler based on image processing according to claim 1, characterized in that, before the frontal image of the idler to be measured is grayed to obtain a grayscale image, the method further comprises: 采集包含待测托辊的正面的图像并进行图像分割获得待测托辊的正面图像,所述正面图像中待测托辊以外的像素点的像素值为0。Collect an image including the front surface of the roller to be tested and perform image segmentation to obtain the front image of the roller to be tested, and the pixel value of the pixels other than the roller to be tested in the front image is 0. 5.根据权利要求4所述的基于图像处理的托辊运行状态检测方法,其特征在于,对包含待测托辊的正面的图像进行图像分割获得待测托辊的正面图像是通过DNN实现的。5. The method for detecting the running state of an idler based on image processing according to claim 4, characterized in that, performing image segmentation on the image containing the front of the idler to be tested to obtain the frontal image of the idler to be measured is achieved by DNN . 6.根据权利要求1所述的基于图像处理的托辊运行状态检测方法,其特征在于,获取每一时刻的待测托辊的多帧正面图像前,所述方法还包括确定待测托辊,其中,确定待测托辊的过程包括:6 . The method for detecting the running state of an idler based on image processing according to claim 1 , wherein before acquiring multiple frames of front images of the idler to be tested at each moment, the method further comprises determining the idler to be measured. 7 . , wherein, the process of determining the idler to be tested includes: 在传送带运行过程中分别采集每一托辊处的音频,并将托辊处的音频与标准托辊的差异度大于差异度阈值的托辊确定为待测托辊。During the operation of the conveyor belt, the audio frequency of each idler is collected separately, and the idler whose difference between the audio frequency at the idler and the standard idler is greater than the threshold of the difference degree is determined as the idler to be tested. 7.根据权利要求1所述的基于图像处理的托辊运行状态检测方法,其特征在于,每一时刻所对应的边缘振动图像与清晰振动图像之间的相似度为结构相似性SSIM。7 . The method for detecting the running state of an idler based on image processing according to claim 1 , wherein the similarity between the edge vibration image corresponding to each moment and the clear vibration image is the structural similarity SSIM. 8 . 8.一种基于图像处理的托辊运行状态检测系统,包括:存储器和处理器,其特征在于,所述处理器执行所述存储器存储的计算机程序,以实现如权利要求1-7中任一项所述的基于图像处理的托辊运行状态检测方法。8. A system for detecting the running state of idlers based on image processing, comprising: a memory and a processor, wherein the processor executes a computer program stored in the memory to realize any one of claims 1-7 The method for detecting the running state of the idler based on image processing described in item.
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