CN115283659A - Fixed point casting system based on artificial intelligence - Google Patents
Fixed point casting system based on artificial intelligence Download PDFInfo
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- CN115283659A CN115283659A CN202210942853.1A CN202210942853A CN115283659A CN 115283659 A CN115283659 A CN 115283659A CN 202210942853 A CN202210942853 A CN 202210942853A CN 115283659 A CN115283659 A CN 115283659A
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- 238000005266 casting Methods 0.000 title claims abstract description 131
- 238000013473 artificial intelligence Methods 0.000 title description 5
- 239000007788 liquid Substances 0.000 claims abstract description 42
- 238000012937 correction Methods 0.000 claims abstract description 29
- 238000012544 monitoring process Methods 0.000 claims abstract description 29
- 238000005516 engineering process Methods 0.000 claims abstract description 10
- 238000011156 evaluation Methods 0.000 claims description 33
- 238000012806 monitoring device Methods 0.000 claims description 19
- 238000000034 method Methods 0.000 claims description 15
- 238000012545 processing Methods 0.000 claims description 12
- 238000004458 analytical method Methods 0.000 claims description 4
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- 230000003542 behavioural effect Effects 0.000 claims description 2
- 239000002184 metal Substances 0.000 abstract description 7
- 230000009471 action Effects 0.000 abstract description 5
- 230000006399 behavior Effects 0.000 description 24
- 238000004519 manufacturing process Methods 0.000 description 4
- 238000011161 development Methods 0.000 description 3
- 238000005058 metal casting Methods 0.000 description 3
- 238000010586 diagram Methods 0.000 description 2
- 238000003708 edge detection Methods 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
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- 230000001079 digestive effect Effects 0.000 description 1
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- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000008569 process Effects 0.000 description 1
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- 239000010959 steel Substances 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D46/00—Controlling, supervising, not restricted to casting covered by a single main group, e.g. for safety reasons
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D35/00—Equipment for conveying molten metal into beds or moulds
- B22D35/04—Equipment for conveying molten metal into beds or moulds into moulds, e.g. base plates, runners
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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 application discloses fixed point casting system based on machine vision includes: the system comprises an image acquisition module, a safety monitoring module and a control module; the image acquisition module is used for acquiring image information at the gate to obtain gate position information, position correction parameters and gate liquid level information; the safety monitoring module is used for acquiring behavior video information and working environment temperature information of workers and sending a braking signal; the control module is used for controlling the casting platform to move based on the pouring gate position information and the position correction parameter, controlling the furnace body inclination angle and the pouring time based on the position correction parameter and the pouring gate liquid level information, and performing emergency braking based on the braking signal. The automatic casting device solves the mechanization and automation problems of fixed-point casting of the molten metal of the casting enterprise through the image recognition technology, meanwhile, the safety of the action of workers is evaluated through the action capturing technology, emergency braking can be carried out at any time when the potential safety hazard occurs, and the life safety and the equipment safety of the workers are guaranteed.
Description
Technical Field
The application relates to the field of metal casting, in particular to a fixed-point casting system based on artificial intelligence.
Background
Metal casting is one of the main methods for obtaining mechanical product blanks, is an important basic process in the mechanical industry, and occupies an important position in national economy. In recent years, the performance of the casting industry in China is obvious, the technical level of matched products such as large castings, key basic parts and the like is greatly broken through, and the industrial development foundation is tamped; depending on national key construction projects, major technical equipment autonomy work is carried out on a large scale; the method combines the insist of autonomous development and the introduction of digestive absorption, and provides large-scale and high-end key castings for national pillar industries such as energy, electric power, steel, ships, rail traffic, machine tools, aerospace, automobiles and the like by increasing the technical transformation investment; the development direction of the casting enterprises is to give full play to the combined advantages of production, science and research, advocate the creation of an industrial strategy alliance, overcome key technical difficulties, promote the autonomous research and development capability and further improve the localization level of the automatic production line of the casting enterprises.
However, metal casting enterprises, particularly small and medium-sized casting enterprises still need to manually operate to cast the blank in the metal melting and casting links, so that the production efficiency is low, and greater potential safety production hazards exist.
Disclosure of Invention
Based on above industrial application, this application provides a fixed point casting system based on machine vision, adopts artificial intelligence technique to upgrade the artifical casting operation of inefficiency and reforms transform into automation mechanized operation, confirms the position and the casting gate liquid level height of casting gate through image recognition technology, simultaneously through the security of video monitoring personnel's action, when the potential safety hazard appears, can carry out emergency braking in order to guarantee the safety of personnel and equipment.
In order to achieve the above purpose, the present application provides the following solutions:
a machine vision-based, point-cast system, comprising: the system comprises an image acquisition module, a safety monitoring module and a control module;
the image acquisition module is connected with the control module and is used for acquiring image information at the casting opening to obtain casting opening position information, position correction parameters and casting opening liquid level information;
the safety monitoring module is connected with the control module and is used for acquiring behavior video information and working environment temperature information of workers and sending a braking signal;
the control module is used for controlling the casting platform to move based on the casting opening position information and the position correction parameter, and is also used for controlling the furnace body pouring angle and pouring time based on the position correction parameter and the casting opening liquid level information, and the control module is also used for carrying out emergency braking based on the braking signal.
Preferably, the image of the sprue gate comprises: a blank mold image and a sprue gate level image.
Preferably, the image acquisition module includes: the casting gate positioning device, the casting gate liquid level monitoring device and the first processor are arranged on the casting gate;
the casting opening positioning device is connected with the first processor and is used for acquiring blank mold images;
the casting port liquid level monitoring device is connected with the first processor and is used for acquiring a casting port liquid level image;
the first processor is connected with the control module and used for receiving and processing the blank mold image and the casting gate liquid level image to obtain the casting gate position information, the position correction parameter and the casting gate liquid level information.
Preferably, the working method of the image acquisition module comprises:
acquiring the blank mold image, and determining the casting gate position through an image recognition technology to obtain the casting gate position information and the position correction parameter;
and acquiring the liquid level image of the casting port, and monitoring the liquid level information of the casting port in real time through an image recognition technology.
Preferably, the safety monitoring module includes: the system comprises a personnel behavior monitoring device, a temperature monitoring device and a second processor;
the personnel behavior monitoring device is connected with the second processing unit and is used for acquiring behavior video information of the workers;
the temperature monitoring device is connected with the second processing device and used for monitoring the temperature of the working environment to obtain temperature information;
the second processor is connected with the control module, and is used for analyzing and evaluating the personnel behavior safety based on the behavior video information to obtain a behavior safety evaluation result, receiving and processing the temperature information to obtain a temperature evaluation result, and sending the braking signal based on the behavior safety evaluation result and the temperature evaluation result.
Preferably, the working method of the safety monitoring module comprises the following steps:
acquiring behavior video information of the staff, and performing safety evaluation analysis in real time by using a motion capture method to obtain a behavior safety evaluation result;
acquiring the temperature information, and evaluating in real time to obtain a temperature evaluation result;
issuing the braking signal based on the behavioral safety evaluation result and the temperature evaluation result.
Preferably, the control module includes: the device comprises an emergency braking device, a casting platform control device and a furnace body control device;
the emergency braking device is respectively connected with the safety monitoring module, the furnace body control device and the casting platform control device, and is used for carrying out emergency braking based on the braking signal;
the casting platform control device is also connected with the image acquisition module and is used for controlling the casting platform to move to a specified position based on the casting port position information and the position correction parameter;
the furnace body control device is also connected with the image acquisition module and is used for controlling the pouring angle and the pouring time of the furnace body based on the position correction parameters and the liquid level information of the casting gate.
Preferably, the control module operating method includes:
controlling the casting platform to move to a specified position based on the casting opening position information and the position correction parameters;
controlling the pouring angle and the pouring time of the furnace body based on the position correction parameter and the liquid level information of the casting gate;
and performing emergency braking when the braking signal is received.
The beneficial effect of this application does:
this application adopts artificial intelligence technique to upgrade the manual casting operation of inefficiency and reforms transform into automation mechanized operation, solves the mechanization and the automation problem of casting enterprise's molten metal fixed point casting through image recognition technology, simultaneously through the security of action capture technique evaluation staff's action, can carry out emergency braking at any time when the potential safety hazard appears, has guaranteed personnel's life safety and equipment safety.
Drawings
In order to more clearly illustrate the technical solutions of the present application, the drawings required to be used in the embodiments are briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present application, and it is obvious for those skilled in the art that other drawings can be obtained according to these drawings without inventive labor.
FIG. 1 is a schematic structural diagram of a machine vision-based point-casting system according to the present application;
FIG. 2 is a schematic structural view of a sprue gate positioning device according to an embodiment of the present disclosure;
fig. 3 is a schematic structural diagram of a casting platform control device and a furnace body control device according to an embodiment of the present application.
Description of reference numerals:
1. the first layer is linked with three cameras; 2. the second layer is linked with three cameras; 3. a casting opening; 4. a blank mold; 5. finely adjusting the base; 6. a hydraulic lifting rod; 7. a hydraulic lifting platform; 8. a furnace body.
Detailed Description
The technical solutions in the embodiments of the present application will be described clearly and completely with reference to the drawings in the embodiments of the present application, and it is obvious that the described embodiments are only some embodiments of the present application, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present application.
In order to make the aforementioned objects, features and advantages of the present application more comprehensible, the present application is described in further detail with reference to the accompanying drawings and the detailed description.
Example one
In the first embodiment, a machine vision-based fixed-point casting system, as shown in fig. 1, includes: the device comprises an image acquisition module, a safety monitoring module and a control module.
The image acquisition module includes: the casting gate positioning device, the casting gate liquid level monitoring device and the first processor are arranged on the casting gate; pouring gate positioner is connected with first treater, and pouring gate positioner is as shown in fig. 2, chooses for use three camera linkage positioner in bilayer, includes: the system comprises a first layer of linkage three cameras 1 and a second layer of linkage three cameras 2, wherein the cameras are 4K high-definition self-cleaning cameras, and the upper and lower layers of planes are slightly inclined in a differentiation manner and are used for acquiring images of a blank mold 4 and transmitting the images of the blank mold to a first processor; the casting gate liquid level monitoring device is connected with the first processor, is used for monitoring the liquid level height of the casting gate 3 to obtain a casting gate liquid level image and transmitting the casting gate liquid level image to the first processor, and can also be used for acquiring the liquid level infrared image of the casting gate 3 and assisting the monitoring work of the visible light camera; the first processor is connected with the control module and used for receiving and processing the blank mold image and the casting opening liquid level image to obtain casting opening position information and casting opening liquid level information.
The working method of the image acquisition module comprises the following steps: the three cameras on the same layer in the double-layer three-camera linkage positioning device form two eyes in pairs, the horizontal positions of the three cameras are in certain dislocation rotation, images of the blank mold 4 are respectively collected, the central position of the collected blank mold images is obtained through an edge detection algorithm, the average value of the obtained central positions is obtained, accurate blank mold images are obtained, image recognition is carried out on the accurate blank mold images to determine the position of a casting gate, and casting gate position information and position correction parameters are obtained; and acquiring a casting port liquid level image, and monitoring the casting port liquid level height in real time through an image recognition technology to obtain casting port liquid level information.
The safety monitoring module includes: the system comprises a personnel behavior monitoring device, a temperature monitoring device and a second processor; the personnel behavior monitoring device is connected with the second processing unit and used for acquiring behavior video information of workers; the temperature monitoring device is connected with the second processing device and can adopt an infrared temperature monitor, and the temperature monitoring device is used for monitoring the temperature of the working environment to obtain temperature information; the second processor is connected with the control module and used for analyzing and evaluating the safety of personnel behaviors based on the behavior video information to obtain a behavior safety evaluation result, the second processor is also used for receiving and processing the temperature information to obtain a temperature evaluation result, and the second processor is also used for sending a braking signal based on the behavior safety evaluation result and the temperature evaluation result, wherein the braking signal comprises a furnace body braking control signal and a casting platform braking control signal, and the furnace body braking is the highest control priority for ensuring the life safety of the personnel.
The working method of the safety monitoring module comprises the following steps: acquiring behavior video information of the staff, and performing safety evaluation analysis in real time by using a motion capture method to obtain a behavior safety evaluation result; acquiring the temperature information, and evaluating in real time to obtain a temperature evaluation result; and sending a braking signal based on the behavior safety evaluation result and the temperature evaluation result, wherein the braking signal comprises a furnace body braking control signal and a casting platform braking control signal.
The control module includes: the device comprises an emergency braking device, a casting platform control device and a furnace body control device; the casting platform control device and the furnace body control device are shown in fig. 3, the emergency brake device is respectively connected with the safety monitoring module, the furnace body control device and the casting platform control device, the emergency brake device is used for automatically performing emergency braking based on a brake signal, firstly, the furnace body 8 is directly controlled to stop toppling and quickly restore to an initial position based on the furnace body brake control signal, then, the casting platform is directly controlled to restore to the original position based on the casting platform brake control signal, and the emergency brake device can also perform emergency braking manually by a worker; the casting platform control device is also connected with the image acquisition module, and comprises a fine adjustment base 5 for controlling the casting platform to move to a specified position based on the casting opening position information and performing fine adjustment based on position correction parameters; the furnace body control device includes: and the hydraulic lifting rod 6 and the hydraulic lifting platform 7 are connected with the image acquisition module, and the furnace body control device is used for controlling the pouring angle and the pouring time of the furnace body 8 based on the casting gate liquid level information and the position correction parameter.
The control module working method comprises the following steps: controlling the casting table to move to a specified position based on the casting opening position information, and then carrying out Y-axis direction fine adjustment on the casting opening based on the position correction parameter; controlling the pouring angle of the furnace body 8 based on the position correction parameter, namely controlling the positions of the pouring gate in the X-axis and Z-axis directions to ensure that the molten metal solution can be accurately and accurately poured into the pouring gate, and simultaneously controlling the pouring time based on the liquid level information of the pouring gate to ensure that the molten metal solution cannot overflow; when a braking signal is received, the furnace body 8 is directly controlled to stop dumping and quickly restore to an initial position based on a furnace body braking control signal, the casting table is directly controlled to restore to an original position based on a casting table braking control signal, and emergency braking can be performed manually by a safety worker when dangerous behaviors of the safety monitoring module cannot be identified occur.
Example two
In the second embodiment, the work flow of the machine vision-based fixed-point casting system of the present application is described in detail;
the three cameras on the same layer in the double-layer three-camera linkage positioning device form two eyes pairwise, slightly differential inclination is carried out between two layers of planes, certain dislocation rotation is carried out at the horizontal position, blank mold images are respectively collected, the central position of the collected blank mold images is obtained through an edge detection algorithm, the obtained central position is averaged to obtain an accurate blank mold image, image recognition is carried out on the accurate blank mold image to determine the position of a casting gate, and casting gate position information and position correction parameters are obtained; and acquiring a casting port liquid level image, and monitoring the casting port liquid level height in real time through an image recognition technology to obtain casting port liquid level information. Controlling the casting table to move to a specified position based on the casting opening position information, and then carrying out Y-axis direction fine adjustment on the casting opening based on the position correction parameter; the pouring angle of the furnace body 8 is controlled based on the position correction parameter, namely the positions of the pouring gate in the X-axis and Z-axis directions are controlled to ensure that the molten metal solution can be accurately and accurately poured into the pouring gate, and meanwhile, the pouring time is controlled based on the liquid level information of the pouring gate to ensure that the molten metal solution cannot overflow.
In order to ensure the life safety and equipment safety of workers, the safety monitoring module is further arranged, the behavior video information of the workers is collected in real time, and the safety evaluation analysis is carried out in real time through a motion capture method to obtain a behavior safety evaluation result; and acquiring the temperature information, and evaluating in real time to obtain a temperature evaluation result. When the safety evaluation result or the temperature evaluation result is dangerous, a braking signal is sent, firstly, the furnace body 8 is directly controlled to stop pouring and quickly restore to the initial position based on a furnace body braking control signal, and then the casting platform is directly controlled to restore to the original position based on a casting platform braking control signal; when dangerous behaviors of people which cannot be identified by the safety monitoring module occur, emergency braking can be performed manually by a safety worker.
The above-mentioned embodiments are merely illustrative of the preferred embodiments of the present application, and do not limit the scope of the present application, and various modifications and improvements made to the technical solutions of the present application by those skilled in the art without departing from the spirit of the present application should fall within the protection scope defined by the claims of the present application.
Claims (8)
1. A machine vision based spot casting system, comprising: the system comprises an image acquisition module, a safety monitoring module and a control module;
the image acquisition module is connected with the control module and is used for acquiring image information at the casting opening to obtain casting opening position information, position correction parameters and casting opening liquid level information;
the safety monitoring module is connected with the control module and is used for acquiring behavior video information and working environment temperature information of workers and sending a braking signal;
the control module is used for controlling the casting platform to move based on the casting opening position information and the position correction parameter, the control module is further used for controlling the furnace body pouring angle and pouring time based on the position correction parameter and the casting opening liquid level information, and the control module is further used for carrying out emergency braking based on the braking signal.
2. The machine-vision-based point-casting system of claim 1, wherein the sprue gate image comprises: a blank mold image and a sprue gate level image.
3. The machine-vision-based, point-cast system of claim 2, wherein the image acquisition module comprises: the device comprises a casting gate positioning device, a casting gate liquid level monitoring device and a first processor;
the casting opening positioning device is connected with the first processor and is used for acquiring blank mold images;
the casting port liquid level monitoring device is connected with the first processor and is used for acquiring a casting port liquid level image;
the first processor is connected with the control module and used for receiving and processing the blank mold image and the casting opening liquid level image to obtain the casting opening position information, the position correction parameter and the casting opening liquid level information.
4. The machine vision-based point casting system according to claim 3, wherein the image acquisition module operating method comprises:
collecting the blank mold image, and determining the casting gate position through an image recognition technology to obtain the casting gate position information and the position correction parameter;
and collecting the casting port liquid level image, and monitoring the casting port liquid level information in real time through an image recognition technology.
5. The machine-vision-based, point-casting system of claim 1, wherein the safety monitoring module comprises: the system comprises a personnel behavior monitoring device, a temperature monitoring device and a second processor;
the personnel behavior monitoring device is connected with the second processing unit and is used for acquiring behavior video information of the workers;
the temperature monitoring device is connected with the second processing device and used for monitoring the temperature of a working environment to obtain temperature information;
the second processor is connected with the control module, and is used for analyzing and evaluating the personnel behavior safety based on the behavior video information to obtain a behavior safety evaluation result, receiving and processing the temperature information to obtain a temperature evaluation result, and sending the braking signal based on the behavior safety evaluation result and the temperature evaluation result.
6. The machine vision-based cast-in-place casting system according to claim 5, wherein the safety monitoring module operating method comprises:
acquiring behavior video information of the staff, and performing safety evaluation analysis in real time by using a motion capture method to obtain a behavior safety evaluation result;
acquiring the temperature information, and evaluating in real time to obtain a temperature evaluation result;
issuing the braking signal based on the behavioral safety evaluation result and the temperature evaluation result.
7. The machine vision-based point casting system of claim 1, wherein the control module comprises: the device comprises an emergency braking device, a casting platform control device and a furnace body control device;
the emergency braking device is respectively connected with the safety monitoring module, the furnace body control device and the casting platform control device, and is used for carrying out emergency braking based on the braking signal;
the casting platform control device is also connected with the image acquisition module and is used for controlling the casting platform to move to a specified position based on the casting port position information and the position correction parameter;
the furnace body control device is also connected with the image acquisition module and is used for controlling the pouring angle and the pouring time of the furnace body based on the position correction parameters and the liquid level information of the casting gate.
8. The machine vision-based, point-casting system of claim 7, wherein the control module operating method comprises:
controlling the casting platform to move to a specified position based on the casting opening position information and the position correction parameter;
controlling the pouring angle and the pouring time of the furnace body based on the position correction parameter and the liquid level information of the casting gate;
and carrying out emergency braking when the braking signal is received.
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| CN204657459U (en) * | 2015-05-05 | 2015-09-23 | 埃博普感应系统（上海）有限公司 | Insulated pouring machine automatic positioning equipment |
| CN108705071A (en) * | 2018-05-28 | 2018-10-26 | 宁波中科毕普拉斯新材料科技有限公司 | A kind of aluminium alloy pouring procedure automatically controlling flow velocity |
| CN113770343A (en) * | 2021-08-26 | 2021-12-10 | 山东创新金属科技有限公司 | Casting automation control system of integrated early warning system |
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