CN115027903A - Real-time monitoring and obstacle removing device for belt conveyor - Google Patents
Real-time monitoring and obstacle removing device for belt conveyor Download PDFInfo
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- CN115027903A CN115027903A CN202210539883.8A CN202210539883A CN115027903A CN 115027903 A CN115027903 A CN 115027903A CN 202210539883 A CN202210539883 A CN 202210539883A CN 115027903 A CN115027903 A CN 115027903A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G43/00—Control devices, e.g. for safety, warning or fault-correcting
- B65G43/02—Control devices, e.g. for safety, warning or fault-correcting detecting dangerous physical condition of load carriers, e.g. for interrupting the drive in the event of overheating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G15/00—Conveyors having endless load-conveying surfaces, i.e. belts and like continuous members, to which tractive effort is transmitted by means other than endless driving elements of similar configuration
- B65G15/30—Belts or like endless load-carriers
- B65G15/32—Belts or like endless load-carriers made of rubber or plastics
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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Abstract
The invention is suitable for the field of monitoring of equipment running states, and provides a real-time monitoring and obstacle removing device for a belt conveyor. The robot can detect the equipment and the environment near the track in real time and transmit information to the remote control center, and the staff can know the detected information in real time and can send a control instruction to the robot. The robot has stable detection result, does not need personnel to go to the site for detection, and saves labor; the robot can rapidly arrive at the scene in dangerous situations, and field data and information are obtained.
Description
Technical Field
The invention relates to the technical field of equipment running state monitoring, in particular to a real-time monitoring and obstacle removing device for a belt conveyor.
Background
In the coal production process, the belt conveyor is used as important coal conveying equipment and is widely applied, however, in the running process of the belt conveyor, the environmental conditions are required to be: such as on-site dust concentration, toxic and harmful gas and combustible gas content, environmental temperature, humidity and the like; the equipment state: abnormal temperature of a carrier roller, fault audio positioning of a belt conveyor, abnormal vibration of a motor speed reducer, deviation of a belt, tearing of edges and the like; safety behaviors: unsafe actions such as site illegal operation, illegal personnel invasion and the like are automatically identified and detected, so that accidents such as huge foreign matters, coal flow overload, roller damage, belt damage and the like are avoided, and serious loss of equipment and even personnel is caused.
On the other hand, in the process of polling and maintaining the belt conveyor, polling workers face huge risks when detecting and maintaining the belt conveyor in real time, and the coal mining process requires that the belt conveyor system cannot stop at any time or for a long time.
Disclosure of Invention
In order to solve the technical problems, the invention provides a real-time monitoring and obstacle removing device for a belt conveyor, which has the flexibility and intelligence of manual inspection, overcomes and makes up for some defects and shortcomings in manual inspection, can realize real-time monitoring and obstacle removing of the belt conveyor, ensures stable operation of a coal conveying line, improves the production efficiency, is a development direction of intelligent and unmanned inspection technologies, and has wide application prospect.
The invention discloses a real-time monitoring and obstacle removing device for a belt conveyor, which comprises a robot body, a main control unit, an energy module, a detection assembly for detecting equipment and the surrounding environment and a wireless communication module for exchanging data with a remote control center, wherein the robot body is connected with the main control unit through a wireless communication module;
the real-time monitoring and obstacle removing device for the belt conveyor and the carrier roller temperature monitoring system have information interaction, the carrier roller temperature monitoring system is a carrier roller temperature monitoring module based on infrared thermal imagery, and the carrier roller temperature monitoring system is fixed on a carrier roller frame. The carrier roller temperature monitoring module collects infrared images by using a thermal infrared imager, processes the collected infrared images of the belt conveyor, analyzes temperature information of a carrier roller area, carries out fault early warning, and simultaneously transmits acquired information to the main control unit and the remote control center of the real-time monitoring and obstacle removing device for the belt conveyor.
The carrier roller temperature monitoring module collects infrared images of the transportation equipment by using a thermal infrared imager and processes the collected infrared images of the belt conveyor: intercepting the area where the carrier roller is located by utilizing vertical and horizontal projections; filtering the image edges by adopting the long-short axis ratio and the area information based on the connected components, eliminating the false edges formed by edge detection of the intercepted images and keeping the real edges of the carrier rollers; connecting the edge gaps of the carrier roller by using morphological closed operation, obtaining the closed contour of the carrier roller through boundary tracking and filling a seed region, thereby realizing automatic division of the carrier roller region; and finally, analyzing the temperature information of the carrier roller area and carrying out fault early warning.
The main control unit, the energy module, the detection assembly and the wireless communication module of the real-time monitoring and obstacle removing device for the belt conveyor are all arranged on the robot body; the main control unit receives a command from a remote control center, controls the robot body to move on the track and executes related commands and actions; the robot body comprises a vehicle body unit, and the vehicle body unit comprises a motion driving module, a pulley block and a charging bin; the motion driving module drives the pulley block to roll on the track; the elastic element of the pulley block is arranged to ensure that the vehicle body stably runs; the charging bin has the functions of cleaning and charging.
Furthermore, the shell comprises a circular groove rail with the circumferential side opened, and the shell is in a shape of Jiong, so that the interference of the shell and a support structure of a running track in the running process is avoided. The body unit may run on a track wrapped therein. The detection assembly comprises a detection module and a sliding block, the detection module is connected with the sliding block in a sliding mode, and the sliding block slides in the circular groove rail. The casing still include one section with tangent linear guide of ring shape grooved rail, detection module can be in the sliding block with the continuous slip of linear guide junction, and then move on the linear guide. The sliding of the sliding block and the sliding of the detection module relative to the sliding block and the linear guide rail increase the detection range of the detection module.
The tracks are arranged on two sides of the coal conveying belt conveyor, namely the tracks are annular, a group of real-time monitoring and obstacle removing devices for the belt conveyor are arranged on the annular tracks, the real-time monitoring and obstacle removing devices are oppositely arranged to run, and the two sides of the same section of belt are monitored simultaneously.
Furthermore, a plurality of groups of detection shifting pieces are arranged at two ends of the track, and when the robot passes through the detection shifting pieces, the detection shifting pieces send real-time signals to the main control unit to judge the synchronism of the pair of robots.
Further, the track end possesses fills electric pile, and the robot real-time supervision electric quantity condition and current position with fill electric pile distance, according to independently returning the strategy of filling, independently navigate to filling electric pile to automatically with fill electric pile communication start-up and charge.
The robot energy module is wireless charging and discharging device, the energy module is arranged on the upper portion of the shell and forms a charging bin with the upper surface of the shape like the Chinese character 'Jiong', and the charging bin can be used for charging and supplying energy to the detection module which slides to the charging bin.
The battery capacity is 7AH, and wireless charging module adopts 100W magnetic resonance principle module, and the duration of charging is 3H. The functions of charging distance sensing detection, load change self-adjustment and the like can be realized. When the robot patrols and examines and finishes and need charge, can trigger the switch that targets in place when getting back to and fill electric pile, can send the signal of opening the charging to filling electric pile after confirming the position, fill electric pile this moment and open and charge, after the robot is full of the electricity, can send the signal that stops charging to filling electric pile.
Further, the detection module comprises an industrial camera and at least one of a camera, a temperature sensor, a humidity sensor, smoke, a dust sensor, an AI camera and an oxygen content sensor.
Further, the internal surface of storehouse upper end that charges sets up automatic cleaning device, works as when detection module includes the camera, the sliding block is in slide under drive gear set's the drive extremely the casing upper end, automatic cleaning device carries out cleaning work to the camera.
Further, the robot also comprises a fire extinguisher, and the fire extinguisher is fixed on the robot body.
Further, the master control unit includes a safeguard system, including:
the foreign matter identification system is used for detecting a conveyed object by sliding the detection module of the real-time monitoring and obstacle removing device for the belt conveyor to the uppermost end of the linear guide rail under the condition of loading of the belt conveyor, and carrying out image denoising and image enhancement preprocessing by using a bilateral filtering and piecewise linear transformation algorithm by using an anchor rod foreign matter existing in a belt image acquired by an industrial camera; carrying out image binarization processing by adopting a generation-selection self-adaptive read value segmentation method; identifying the shape of the anchor rod foreign matter based on the length-width ratio of the connected component circumscribed rectangle to complete the detection and identification of the anchor rod foreign matter target;
the detection module of the real-time monitoring and obstacle removing device for the belt conveyor slides to the uppermost end of the linear guide rail to detect conveyed objects, a profile of the upper cross section of the coal flow is obtained through a two-dimensional laser radar, speed information is measured through a speed sensor, and then the coal flow is obtained through integration of the cross section area of the coal flow and the speed information;
the belt monitoring system is used for monitoring the lower-layer conveying belt in real time by utilizing the belt damage monitoring system when the belt conveyor is under a loaded condition and receiving abnormal information detected by the carrier roller temperature monitoring module, wherein the detection module of the real-time monitoring and obstacle removing device for the belt conveyor slides onto the sliding block; when the belt conveyor is stopped or is in an idle detection condition, the detection module of the real-time monitoring and obstacle removing device for the belt conveyor slides to the uppermost end of the linear guide rail to detect the belt, and the belt damage monitoring system is used for detecting the belt of the belt conveyor.
Under the condition of loading of a belt conveyor, the belt damage online monitoring system based on machine vision information utilizes cracks in belt images acquired by an industrial camera to respectively perform image filtering and image enhancement preprocessing by adopting bilateral filtering and histogram equalization; carrying out image binarization processing by adopting a generation-selection self-adaptive read value segmentation method; removing small-area noise based on morphological region characteristics of the connected components to complete detection and identification of the crack target;
the belt damage online monitoring system based on machine vision information reads a light image of a conveying belt line structure by using a line structure light image acquisition system under the condition that a belt conveyor is stopped or no-load, cuts and grays the image to enhance, extracts a line structure light center line, cuts off a center line image connected domain after optimizing the center line by fitting calculation, determines whether a belt crack occurs according to the obtained connected domain and the number of the connected domains, and determines the accurate position of the belt crack.
Compared with the prior art, the invention has the beneficial effects that: the method comprises the steps of utilizing a machine vision sensor to collect various data information of a belt conveyor in operation in real time, processing relevant data information through a certain algorithm by a computer, judging and analyzing common problems of occurrence of giant foreign matters, coal flow overload, roller damage, belt damage and the like, finally formulating judgment basis of fault types of the belt conveyor, and formulating corresponding safety guarantee control decisions for a driving motor by the computer aiming at the fault types of the belt conveyor when the belt conveyor has the characteristic faults, so that the safety production of the belt conveyor is guaranteed, and meanwhile, the fault and the shutdown time period caused by detection are reduced to the maximum extent.
Drawings
FIG. 1 is a schematic diagram of the operation of a real-time monitoring and troubleshooting device for a belt conveyor according to an embodiment of the present invention;
FIG. 2 is a front view of the real-time monitoring and troubleshooting apparatus for a belt conveyor of FIG. 1 operating on rails;
in the drawings, the reference numbers: 1. a real-time monitoring and obstacle-removing device for the belt conveyer; 2. a real-time monitoring and troubleshooting device for the belt conveyor; 3. side supporting rollers; 4. a main carrier roller; 5. an upper conveying belt; 5', a lower conveying belt; 6. a slider; 7. a circular groove track; 8. the driving module drives the driving gear set; 9. a spring; 10. a second stabilizing pulley; 11. an annular track; 12. a first drive wheel; 13. a linear guide rail.
Detailed Description
To facilitate an understanding of the invention, the invention will now be described more fully hereinafter with reference to the accompanying drawings. The present invention may be embodied in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete.
As shown in fig. 1, a working mode of a real-time monitoring and obstacle-removing device for a belt conveyor includes a pair of robots 1 and 2 which are symmetrically arranged, and the real-time monitoring and obstacle-removing device for a belt conveyor includes a main control unit, an energy module, a detection assembly for detecting equipment and surrounding environment, and a wireless communication module (not shown in the figure) for exchanging data with a remote control center; an upper conveying belt 5 and a lower conveying belt 5'; and side carrier rollers 3 at two sides of the upper conveying belt 5 and a main carrier roller 4 at the lower end.
The detection assembly arranged on the robot 1 monitors the upper conveying belt 5 and the lower conveying belt 5' in the middle of the robot 1, and the detection assembly respectively has monitoring visual angles alpha 1 and alpha 2.
The main control unit receives commands from the remote control center, and controls the robot 1 to move on the track 11 and execute related commands and actions. The energy module provides power for a main control unit, a wireless communication module and the like on the robot 1. The wireless communication module is connected with the main control unit and used for sending the information detected by the detection assembly and the state information of the robot to the remote control center and receiving the action command from the remote control center so as to control the specific operation of the whole robot 1.
The robot 1 of this embodiment shuttles back and forth on the track 11, can carry out real-time detection to the equipment and the environment near the track 11 to transmit the information that detects to remote control center through wireless communication module, the staff can know the specific conditions of equipment and its surrounding environment in real time at control center, and can send the instruction to the robot 1, control its specific operation action.
Compared with manual inspection, the robot has stable detection result, and the operator only needs to control the robot at a remote control center without on-site detection, so that the labor is saved; meanwhile, the robot can go deep into the scene to detect under the dangerous conditions such as fire and the like. Compared with a ground mobile inspection robot, the robot has the advantages of high speed and high efficiency, and is not limited by ground characteristics.
The robot body comprises a vehicle body unit, and the vehicle body unit comprises a motion driving module, a pulley block and a charging bin; the motion driving module drives the pulley block to roll on the track 11; the elastic element of the pulley block is arranged to ensure that the vehicle body stably runs; the charging bin has the functions of cleaning and charging.
The real-time monitoring and obstacle removing device for the belt conveyor and the carrier roller temperature monitoring system have information interaction, the carrier roller temperature monitoring system is a carrier roller temperature monitoring module based on infrared thermal image, and the plurality of groups of carrier roller temperature monitoring systems are uniformly distributed on a carrier roller frame (not shown in the figure). The support roller temperature monitoring module collects infrared images by using a thermal infrared imager, processes the collected infrared images of the belt conveyor, analyzes temperature information of a support roller area, carries out fault early warning, and simultaneously transmits acquired information to the main control unit and the remote control center of the real-time monitoring and obstacle removing device of the belt conveyor.
The carrier roller temperature monitoring module collects infrared images of the transport equipment by using a thermal infrared imager and processes the collected infrared images of the belt conveyor: intercepting the area where the carrier roller is located by utilizing vertical and horizontal projections; filtering the image edges by adopting the long-short axis ratio and the area information based on the connected components, eliminating the false edges formed by edge detection of the intercepted images and keeping the real edges of the carrier rollers; connecting the edge gaps of the carrier roller by using morphological closed operation, obtaining the closed contour of the carrier roller through boundary tracking and filling a seed region, thereby realizing automatic division of the carrier roller region; and finally, analyzing the temperature information of the carrier roller area and carrying out fault early warning.
Further, the pulley block comprises a first driving wheel 12 and a second stabilizing pulley 10. The first drive wheel 12 is mounted on a housing of the vehicle body unit, and the driving module is controlled by the control center to drive the first drive wheel 12. The housing comprises circular groove rails 7 with the circumferential sides opened, and the housing is shaped like Jiong so as to avoid interference with a supporting structure of the running track 11 in the running process. The body unit can run on rails 11 wrapped therein. The second set of stabilizing sheaves 10 comprises two opposing second stabilizing sheaves 10. The second stable pulley 10 is fixedly connected with one end of a spring 9, and the other end of the spring 9 is fixedly connected to the inner side of the shell; the second stabilizing pulley 10 group and the two sides of the track 11 are in rolling friction, and the spring 9 compresses the second stabilizing pulley 10 group and keeps close contact with the side surface of the track 11.
Further, the detection component comprises a detection module and a sliding block 6, the detection module is in sliding connection with the sliding block 6, the sliding block 6 slides in the circular groove rail 7, and the sliding of the sliding block and the sliding of the relative sliding block of the detection module are increased to the detection range of the detection module. The inner side of the sliding block 6 is meshed with a driving gear, the driving gears are arranged in the shell at intervals, the driving module drives the driving gear set 8, and the driving gear set 8 drives the sliding block 6 to slide on the groove rail 7 in a relay mode. The 8 intervals of drive gear group are less than 6 arc angles of sliding block can. Preferably, the driving gear set 8 is spaced by 1/5 arcs, and the angle of the arc of the sliding block 6 is 120 °. The shell further comprises a section of linear guide rail 13 tangent to the circular groove rail 7, and the detection module can continuously slide at the joint of the sliding block 6 and the linear guide rail 13 and further move on the linear guide rail 13. The sliding of the sliding block 6 and the sliding of the detection module relative to the sliding block 6 and the linear guide 13 increase the detection range of the detection module.
Further, track 11 is I-shaped 4# angle steel, and pipe belt machine overall structure is complicated, in order to detect more comprehensively, need arrange track 11 in pipe belt machine both sides equipartition, and track 11 is the circularity promptly, sets up a set of on the ring rail 11 the robot, the opposition is gone, monitors the both sides of same section belt simultaneously.
Further, a plurality of groups of detection shifting pieces are symmetrically arranged at two ends of the track 11, and when the robot passes through the detection shifting pieces, the detection shifting pieces send real-time signals to the main control unit to judge the synchronism of the pair of robots.
Further, 11 ends of the track are provided with charging piles, the robot monitors the electric quantity condition and the current position in real time and the distance between the charging piles, and according to an autonomous recharging strategy, the robot autonomously navigates to the charging piles and automatically starts charging with the communication of the charging piles.
The robot energy module is wireless charging and discharging device, the energy module is arranged on the upper portion of the shell and forms a charging bin with the upper surface of the shape like the Chinese character 'Jiong', and the charging bin can be used for charging and supplying energy to the detection module which slides to the charging bin.
The battery capacity is 7AH, and the wireless module that charges adopts 100W magnetic resonance principle module, and the time of charging is 3H. The functions of charging distance sensing detection, load change self-adjustment and the like can be realized. When the robot patrols and examines and finishes and need charge, can trigger the switch that targets in place when getting back to and fill electric pile, can send the signal of opening the charging to filling electric pile after confirming the position, fill electric pile this moment and open and charge, after patrolling and examining the robot and being full of the electricity, can send the signal that stops charging to filling electric pile.
Further, the detection module comprises an industrial camera and at least one of a camera, a temperature sensor, a humidity sensor, smoke, a dust sensor, an AI camera and an oxygen content sensor.
Further, the internal surface of upper end of the charging bin is provided with an automatic cleaning device, when the detection module comprises a camera, the sliding block 6 slides to the upper end of the shell under the driving of the driving gear set 8, and the automatic cleaning device cleans the camera. Preferably, cleaning device is including the superfine fiber lens cloth of parcel elasticity filler, works as the camera is in sliding block 6 drives, slides extremely during the automatic cleaning device below, because the thickness of filler, lens cloth height is less than the camera, elasticity drives down lens cloth and cleans the camera of process, realizes simple self-cleaning effect.
Further, the robot also comprises a fire extinguisher, and the fire extinguisher is fixed on the robot body.
Furthermore, each car body unit is provided with at least one pulley block, each pulley block comprises two second stable pulleys 10 distributed on two sides of the track 11, at least one of the pulley blocks is a first driving wheel 12, the pulley block is hung on the upper surface of the robot running track 11, and the interval of the three pulleys in each pulley block is smaller than the width of the track 11.
Further, the master control unit includes a safeguard system, including:
the foreign matter identification system is used for detecting a conveyed object by sliding the detection module of the real-time monitoring and obstacle removing device for the belt conveyor to the uppermost end of the linear guide rail under the condition of loading of the belt conveyor, and carrying out image denoising and image enhancement preprocessing by using a bilateral filtering and piecewise linear transformation algorithm by using an anchor rod foreign matter existing in a belt image acquired by an industrial camera; carrying out image binarization processing by adopting a generation-selection self-adaptive read value segmentation method; identifying the shape of the anchor rod foreign matter based on the length-width ratio of the rectangle circumscribed by the connected components to complete the detection and identification of the anchor rod foreign matter target;
the detection module of the real-time monitoring and obstacle-removing device for the belt conveyor slides to the uppermost end of the linear guide rail to detect conveyed objects, a profile of the upper cross section of the coal flow is obtained through a two-dimensional laser radar, speed information is measured through a speed sensor, and then the coal flow is obtained through the integration of the cross section area of the coal flow and the speed information;
the belt monitoring system is used for monitoring the lower-layer conveying belt in real time by utilizing the belt damage monitoring system when the abnormal information detected by the carrier roller temperature monitoring module is received under the condition that the belt conveyor is under a load, and the detection module of the real-time monitoring and obstacle removing device for the belt conveyor slides onto the sliding block; when the belt conveyor is stopped or is in an unloaded detection condition, the detection module of the real-time monitoring and obstacle removing device for the belt conveyor slides to the uppermost end of the linear guide rail to detect the belt, and the belt of the belt conveyor is detected by using a belt damage monitoring system.
Under the condition of loading of a belt conveyor, the belt damage online monitoring system based on machine vision information utilizes cracks in belt images acquired by an industrial camera to respectively perform image filtering and image enhancement preprocessing by adopting bilateral filtering and histogram equalization; carrying out image binarization processing by adopting a generation-selection self-adaptive read value segmentation method; removing small-area noise based on morphological region characteristics of the connected components to complete detection and identification of the crack target;
the belt damage online monitoring system based on the machine vision information utilizes the line structure light image acquisition system to read the light image of the conveying belt line structure under the condition that the belt conveyor is stopped or in no load, cuts and grays the image, extracts the light center line of the line structure, divides the image communication domain of the center line after the center line is calculated and optimized in a fitting mode, determines whether a belt crack occurs or not according to the obtained communication domain and the number of the communication domains, and meanwhile determines the accurate position of the belt crack.
Preferably, before the real-time signal collected by the robot 1 is transmitted to a remote control center through the wireless communication module, the main control unit compares and analyzes the collected information. Optionally, the information obtained by the two robots is compared, and when the monitored information acquired by the working assemblies 3 in symmetric arrangement and the deviation of the monitored information of the environment monitoring at the two sides are greater than a preset threshold value and/or when the monitored information acquired by the working assemblies 3 in symmetric arrangement and the deviation of the monitored information of the environment monitoring at the two sides and a preset standard value are greater than a preset threshold value, the working condition of the current monitoring section is determined to be abnormal.
As shown in fig. 1 to 2, the main functions implemented by the present invention are: the real-time monitoring and troubleshooting device for the belt conveyor and the carrier roller temperature monitoring system have information interaction, detect equipment and environment near the track 11 in real time, and transmit the detected information to a remote control center through the wireless communication module. The staff can know the specific conditions of equipment and its surrounding environment in real time at control center to can send the instruction to the robot, control its concrete operation action, for example according to monitoring operating mode, charge and clean the needs adjust to the position of sliding block 6, detection module position, according to monitoring section needs to carry out the rail running drive to the automobile body unit.
The real-time monitoring and obstacle removing device for the belt conveyor and the carrier roller temperature monitoring system are in information interaction, the carrier roller temperature monitoring system is a carrier roller temperature monitoring module based on infrared thermal imagery, and the plurality of groups of carrier roller temperature monitoring systems are uniformly distributed on a carrier roller frame (not shown in the figure). The carrier roller temperature monitoring module collects infrared images by using a thermal infrared imager, processes the collected infrared images of the belt conveyor, analyzes temperature information of a carrier roller area, carries out fault early warning, and simultaneously transmits acquired information to the main control unit and the remote control center of the real-time monitoring and obstacle removing device for the belt conveyor.
The invention adopts a classification detection idea. Firstly, the dust in the working area of the coal mine belt conveyor is much, the illumination change is violent and random, and the influence on the detection method for carrying out threshold value based on geometric characteristics and illumination correction is great. The detection method based on the line structure light image reduces the influence of severe environment to a certain extent, and obviously improves the reliability of the detection method;
secondly, since the difference of heat generated by friction on the conveyor belt is relatively small, the occurrence of significant difference of monitoring data during transportation needs to be emphasized. Therefore, the equipment under the load condition needs to be monitored in real time through infrared detection, and once obvious data abnormal change is detected, a more accurate detection mode is adopted for further judgment, so that the detection reliability is improved, the shutdown/no-load working condition caused by detection or faults is reduced to the maximum extent, and the production efficiency is improved.
The operation of the real-time monitoring and obstacle-removing device for a belt conveyor is described below:
when the belt conveyor is under a load condition, information interaction exists between the real-time monitoring and obstacle removing device for the belt conveyor and the carrier roller temperature monitoring system.
A detection module slides to for belt conveyor's real time monitoring and troubleshooting device linear guide topmost, carries out foreign matter discernment and coal flow monitoring to equipment.
The foreign matter identification system detects the conveyed objects, and performs image denoising and image enhancement preprocessing by using anchor rod foreign matters in belt images acquired by an industrial camera and adopting bilateral filtering and piecewise linear transformation algorithms respectively; carrying out image binarization processing by adopting a generation-selection self-adaptive read value segmentation method; identifying the shape of the anchor rod foreign matter based on the length-width ratio of the connected component circumscribed rectangle to complete the detection and identification of the anchor rod foreign matter target;
the coal flow monitoring system obtains the profile of the upper cross section of the coal flow through a two-dimensional laser radar, speed information is measured through a speed sensor, and then the coal flow is obtained through the coal flow cross section area and the speed information integration.
The carrier roller temperature monitoring module collects infrared images of the transport equipment by using a thermal infrared imager and processes the collected infrared images of the belt conveyor: intercepting the area where the carrier roller is located by utilizing vertical and horizontal projections; filtering the image edges by adopting the long-short axis ratio and the area information based on the connected components, eliminating the false edges formed by edge detection of the intercepted images and keeping the real edges of the carrier rollers; connecting a gap at the edge of the carrier roller by using morphological closed operation, obtaining a carrier roller closed contour through boundary tracking, filling a seed region, and realizing automatic segmentation of the carrier roller region; and finally, analyzing the temperature information of the carrier roller area and carrying out fault early warning.
The fault early warning judgment step comprises the following steps:
within a certain time threshold, when only one group of carrier roller temperature monitoring modules monitors: if the temperature data difference value of the left and right carrier rollers 3 in the same group is larger than a first threshold value, the monitored carrier rollers 3 are judged to have faults, the carrier roller temperature monitoring module sends interactive information to the main control unit, the main control unit controls a pair of real-time monitoring and obstacle removing devices for the belt conveyor to move to the carrier rollers of the problem section, and the detection module slides to appropriate positions on the two sides of the left and right carrier rollers 3 under the abnormal working condition to perform detection and identification. When the asymmetry of the stations of the left and right carrier rollers 3 or the difference of rolling rates is identified, the fault of the carrier roller is judged, and the remote control center controls the emergency shutdown and alarms to inform the working personnel of maintenance operation after receiving fault information; when the temperature data difference value of the left and right side carrier rollers 3 in the same group is larger than a second threshold value, judging that the monitored side carrier rollers 3 have faults, sending fault signals to a remote control center, and carrying out emergency shutdown (the time threshold value, the first threshold value and the second threshold value are adaptively set according to actual working conditions, and the first threshold value is smaller than the second threshold value);
within a certain time threshold, when only one group of carrier roller temperature monitoring modules monitors: the temperature data of the left and right side carrier rollers 3 or the main carrier rollers 4 in the same group is larger than a third threshold value and a fourth threshold value corresponding to a preset standard temperature difference value, the monitored side carrier rollers 3 or the monitored main carrier rollers 4 are judged to have faults, the carrier roller temperature monitoring module sends interactive information to the main control unit, the main control unit controls a pair of real-time monitoring and obstacle removing devices for the belt conveyor to move to the problem section carrier rollers, and the detection module slides to appropriate positions on two sides of the carrier rollers under abnormal working conditions to perform detection and identification. When the carrier roller posture difference or the rolling speed difference between the carrier roller and the upstream and downstream carrier rollers is recognized, the carrier roller fault is judged, and the remote control center controls the emergency shutdown and alarms to inform the working personnel to carry out maintenance operation after receiving the fault information; if the temperature data of the left and right side carrier rollers 3 or the main carrier rollers 4 in the same group is larger than a fifth threshold and a sixth threshold corresponding to a preset standard temperature difference value, judging that the monitored side carrier rollers 3 or the main carrier rollers 4 have a fault, and sending a fault signal to a remote control center for emergency shutdown (the preset standard temperature, the third threshold, the fourth threshold, the fifth threshold and the sixth threshold are adaptively set according to actual working conditions, the preset standard temperature is a corresponding temperature mean value under normal working conditions under normal conditions, the third threshold is less than the fifth threshold, and the fourth threshold is less than the sixth threshold);
and within a certain time threshold, when the abnormal monitoring information is collected by the upstream and downstream carrier rollers in sequence, and the difference value between the abnormal monitoring information and the preset standard temperature is greater than a seventh threshold, the tearing/deviation fault of the belt is judged. The roller temperature monitoring module sends interactive information to the main control unit, the main control unit controls a pair of real-time monitoring and obstacle removing devices for the belt conveyor to move to a problem section roller, the detection module slides to the sliding block, and a belt damage monitoring system is used for monitoring the lower layer conveying belt in real time. The belt damage online monitoring system based on machine vision information utilizes a crack in an image of a lower conveying belt 5' acquired by an industrial camera to respectively perform image filtering and image enhancement preprocessing by adopting bilateral filtering and histogram equalization under the condition of loading of a belt conveyor; carrying out image binarization processing by adopting a generation-selection self-adaptive read value segmentation method; and removing small-area noise based on the morphological region characteristics of the connected components, and completing the detection and identification of the crack target. When the lower conveying belt 5' is identified to be torn, the remote control center controls the emergency shutdown and alarms to inform the staff of maintenance operation after receiving the fault information; and when the abnormal monitoring information is collected in sequence by the upstream and downstream carrier rollers, and the difference value between the abnormal monitoring information and the preset standard temperature is greater than an eighth threshold value, judging that the belt has tearing/deviation fault, sending a fault signal to a remote control center, and carrying out emergency shutdown (the seventh threshold value and the eighth threshold value are adaptively set according to the actual working conditions, and the seventh threshold value is less than the eighth threshold value).
When the belt conveyor is in a stop/no-load condition, the real-time monitoring and obstacle removing device 1 for the belt conveyor is symmetrically arranged on the rails 11 on two sides, and the detection module slides to the uppermost end of the linear guide rail 13. The method comprises the steps of reading a light image of a conveying belt line structure by using a line structure light image acquisition system, cutting and graying the image, extracting a line structure light center line, calculating and optimizing a center line in a fitting manner, dividing a center line image communication domain, determining whether a belt crack occurs according to the obtained communication domain and the number of the communication domains, and determining the accurate position of the belt crack. And transmitting the acquired information to the main control unit and the remote control center of the real-time monitoring and obstacle removing device for the belt conveyor.
The method comprises the steps that various data information of a belt conveyor in operation is collected in real time by using a machine vision sensor, a computer processes relevant data information through a certain algorithm, common problems of giant foreign matters, coal flow overload, roller damage, belt damage and the like are judged and analyzed, finally a judgment basis of a fault type of the belt conveyor is formulated, and when the belt conveyor has characteristic faults, the computer formulates a corresponding safety guarantee control decision for a driving motor according to the fault type of the belt conveyor, so that the safety production of the belt conveyor is guaranteed; the classification detection judgment idea further improves the detection reliability, and simultaneously reduces the halt/no-load working condition caused by detection or faults to the maximum extent, and improves the production efficiency.
All technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.
The above description is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, several modifications and variations can be made without departing from the technical principle of the present invention, and these modifications and variations should also be regarded as the protection scope of the present invention.
Claims (8)
1. A real-time monitoring and obstacle removing device for a belt conveyor is characterized by comprising a robot body, a main control unit, an energy module, a detection assembly for detecting equipment and the surrounding environment and a wireless communication module for exchanging data with a remote control center, wherein the detection assembly comprises a detection module; the real-time monitoring and obstacle removing device for the belt conveyor and the carrier roller temperature monitoring system have information interaction.
2. The real-time monitoring and troubleshooting apparatus for a belt conveyor of claim 1 wherein there is an information interaction between the real-time monitoring and troubleshooting apparatus for a belt conveyor and the idler temperature monitoring system when the belt conveyor is under load.
3. The real-time monitoring and troubleshooting apparatus for a belt conveyor as claimed in claim 2, wherein said main control unit includes a safeguard system including a foreign object recognition system and a coal flow monitoring system.
4. The real-time monitoring and troubleshooting device for belt conveyors of claim 1, wherein said idler temperature monitoring system collects infrared images of the conveyor equipment with a thermal infrared imager when the belt conveyor is under load, processes the collected infrared images of the belt conveyor, and performs fault pre-warning by analyzing temperature information of the idler area.
5. The real-time monitoring and troubleshooting apparatus for a belt conveyor as claimed in claim 4, wherein said failure early warning step includes: within a certain time threshold, when only one group of carrier roller temperature monitoring modules monitors: if the temperature data difference value of the left and right side carrier rollers 3 in the same group is greater than a first threshold value, judging that the monitored side carrier rollers 3 have faults, and moving the real-time monitoring and obstacle removing device for the belt conveyor and the detection module to appropriate positions on two sides of the carrier rollers of the problem section for detection and identification; when fault information is identified, emergency shutdown and alarm processing are carried out; when the temperature data difference value of the left and right side carrier rollers 3 in the same group is larger than a second threshold value, the monitored side carrier rollers 3 are judged to have faults, fault signals are sent to a remote control center, and the emergency shutdown is carried out.
6. The real-time monitoring and troubleshooting apparatus for a belt conveyor as claimed in claim 4, wherein said failure early warning step includes: within a certain time threshold, when only one group of carrier roller temperature monitoring modules monitors: the temperature data of the left and right side carrier rollers 3 or the main carrier rollers 4 in the same group is larger than a third threshold value and a fourth threshold value corresponding to a preset standard temperature difference value, the monitored side carrier rollers 3 or the main carrier rollers 4 are judged to have faults, and the real-time monitoring and obstacle removing device for the belt conveyor and the detection module move to appropriate positions on two sides of the carrier rollers of the problem section for detection and identification; when the carrier roller posture difference or the rolling speed difference between the carrier roller and the upstream and downstream carrier rollers is recognized, the carrier roller is judged to be in fault, and emergency shutdown and alarm processing are carried out; and if the temperature data of the left and right side carrier rollers 3 or the main carrier rollers 4 in the same group is larger than a fifth threshold and a sixth threshold corresponding to the preset standard temperature difference, judging that the monitored side carrier rollers 3 or the main carrier rollers 4 have faults, sending fault signals to a remote control center, and carrying out emergency shutdown.
7. A real-time monitoring and troubleshooting apparatus for a belt conveyor as claimed in claim 4 wherein said failure-early-warning step includes: within a certain time threshold, when the abnormal monitoring information is collected in sequence by the upstream and downstream carrier rollers, and the difference value between the abnormal monitoring information and the preset standard temperature is larger than a seventh threshold, the tearing/deviation fault of the belt is judged, and the real-time monitoring and obstacle removing device for the belt conveyor and the detection module move to the proper positions on the two sides of the carrier roller at the problem section for detection and identification; when the crack existing in the image of the lower conveying belt 5 'acquired by the industrial camera is identified, the lower conveying belt 5' is torn, the emergency machine is stopped and the alarm is given; and when the carrier rollers on the upstream and downstream collect abnormal monitoring information in sequence and the difference value between the abnormal monitoring information and the preset standard temperature is greater than an eighth threshold value, judging that the belt has a tearing/deviation fault, sending a fault signal to a remote control center, and carrying out emergency shutdown.
8. A real-time monitoring and obstacle-removing device for a belt conveyor as claimed in claim 3, wherein when the belt conveyor is in a stop/no-load condition, the real-time monitoring and obstacle-removing device for a belt conveyor 1 is symmetrically arranged on the rails 11 at both sides, and the detecting module is slid to the uppermost end of the linear guide rail 13; reading a light image of the conveyor belt line structure by using a line structure light image acquisition system, cutting and graying the image, extracting a line structure light center line, dividing a center line image connected domain after fitting, calculating and optimizing a center line, determining whether a belt crack occurs according to the obtained connected domain and the number of the connected domains, and determining the accurate position of the belt crack; and transmitting the acquired information to the main control unit and the remote control center of the real-time monitoring and obstacle removing device for the belt conveyor.
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|---|---|---|---|
| CN202210539883.8A CN115027903A (en) | 2022-05-17 | 2022-05-17 | Real-time monitoring and obstacle removing device for belt conveyor |
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| CN202210539883.8A CN115027903A (en) | 2022-05-17 | 2022-05-17 | Real-time monitoring and obstacle removing device for belt conveyor |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115128415A (en) * | 2022-08-26 | 2022-09-30 | 北京鼎诚鸿安科技发展有限公司 | Power distribution station room state testing platform and method |
| CN117245629A (en) * | 2023-11-10 | 2023-12-19 | 中煤科工机器人科技有限公司 | Colliery robot with belt trouble recognition function |
-
2022
- 2022-05-17 CN CN202210539883.8A patent/CN115027903A/en active Pending
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115128415A (en) * | 2022-08-26 | 2022-09-30 | 北京鼎诚鸿安科技发展有限公司 | Power distribution station room state testing platform and method |
| CN115128415B (en) * | 2022-08-26 | 2022-11-22 | 北京鼎诚鸿安科技发展有限公司 | Power distribution station room state testing platform and method |
| CN117245629A (en) * | 2023-11-10 | 2023-12-19 | 中煤科工机器人科技有限公司 | Colliery robot with belt trouble recognition function |
| CN117245629B (en) * | 2023-11-10 | 2024-02-06 | 中煤科工机器人科技有限公司 | Colliery robot with belt trouble recognition function |
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