CN115417067A - Belt deviation monitoring system and method based on binocular line laser camera - Google Patents

Belt deviation monitoring system and method based on binocular line laser camera Download PDF

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Publication number
CN115417067A
CN115417067A CN202211233871.9A CN202211233871A CN115417067A CN 115417067 A CN115417067 A CN 115417067A CN 202211233871 A CN202211233871 A CN 202211233871A CN 115417067 A CN115417067 A CN 115417067A
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China
Prior art keywords
belt
deviation
edge
line laser
point
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Inventor
王胜利
郑旭
朱守明
李正强
黄志强
张绪祥
包嘉伟
李铮
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Ningxia Guangtianxia Electronics Technology Co ltd
Shaanxi Xunyi Qinggangping Mining Co Ltd
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Ningxia Guangtianxia Electronics Technology Co ltd
Shaanxi Xunyi Qinggangping Mining Co Ltd
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Priority to CN202211233871.9A priority Critical patent/CN115417067A/en
Publication of CN115417067A publication Critical patent/CN115417067A/en
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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
    • B65G15/60—Arrangements for supporting or guiding belts, e.g. by fluid jets
    • B65G15/64—Arrangements for supporting or guiding belts, e.g. by fluid jets for automatically maintaining the position of the belts
    • 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
    • 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
    • B65G2203/00—Indexing code relating to control or detection of the articles or the load carriers during conveying
    • B65G2203/02—Control or detection
    • B65G2203/0266—Control or detection relating to the load carrier(s)
    • B65G2203/0283—Position of the load carrier
    • 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
    • B65G2203/00—Indexing code relating to control or detection of the articles or the load carriers during conveying
    • B65G2203/04—Detection means
    • B65G2203/041—Camera

Abstract

The application provides a belt deviation monitoring system and method based on a binocular line laser camera, which relate to the technical field of coal mining automation, and the belt deviation monitoring system based on the binocular line laser camera comprises a data acquisition module and a rear-end processor; the data acquisition module at least comprises a binocular line laser camera, the binocular line laser camera is installed above the target belt and used for acquiring point cloud data on the upper portion of the target belt when the target belt runs, the rear-end processor at least comprises a data processing module, and the data processing module is used for acquiring the point cloud data on the upper portion of the target belt and carrying out deviation calculation. According to the deviation detection method and device, deviation detection precision is improved, and the requirements for real-time performance and accuracy of detection are met.

Description

Belt deviation monitoring system and method based on binocular line laser camera
Technical Field
The application relates to the field of coal mining automation, in particular to a belt deviation monitoring system and method based on a binocular line laser camera.
Background
The belt conveyor is more and more widely applied to coal mines, and the early warning and protection measures for the belt are more and more important. The belt deviation is the most frequently encountered phenomenon in the running process of the belt conveyor, and when the belt deviation reaches a certain degree, the belt conveyor counter deflector can be triggered, so that the belt conveyor cannot run normally, and the normal production efficiency and process are influenced. The main parts of the equipment are damaged, the axial force borne by the roller and the carrier roller is increased after the belt deviates, the roller changes the shaft, and the carrier roller bearing is damaged. The material can be sprinkled on the return belt by the deviation, the abnormal abrasion between the belt and the roller is caused, and the service life of the roller and the belt is shortened. Therefore, it is very important to take corresponding measures to process the deviation of the belt conveyor.
In view of the above, the present invention is particularly proposed.
Disclosure of Invention
In order to overcome the defects of the prior art, the embodiment of the application provides a belt deviation monitoring system and method based on a binocular line laser camera, and deviation detection precision and real-time performance are improved.
In a first aspect, a technical solution adopted by the embodiments of the present application to solve the technical problem is: a belt deviation monitoring system based on a binocular line laser camera comprises a data acquisition module and a rear-end processor;
the data acquisition module at least comprises a binocular line laser camera which is arranged above a target belt and is used for acquiring point cloud data on the upper part of the target belt when the target belt runs;
the back-end processor at least comprises a data processing module, and the data processing module is used for acquiring point cloud data on the upper part of the target belt and carrying out deviation calculation.
Further, the point cloud data is specifically constructed by adopting a sliding window idea, edge detection is carried out on the point cloud in unit time, all edge points are extracted, the edge points of the head and the tail are removed, only edge point sets on two sides of the belt are left, and deviation calculation is carried out according to the point cloud edge point sets.
Further, the extraction of the edge points comprises the steps of extracting X values of a first line and a last line, extracting a Y value range of the point cloud, and removing points of which the abscissa values are X-cut ordinate values in the Y value range.
Further, the deviation calculating method includes: a. recording three-dimensional coordinate information of a belt edge of a laser at a belt position, b, calculating an included angle between an initial belt edge and a camera central point, c, calculating an included angle between the initial belt edge and the camera central point through a calculated real-time belt edge point set, and d, calculating a deviation angle through the included angle between the initial belt edge and the camera central point and the included angle between the real-time belt edge point calculation and the camera central point.
Furthermore, the system also comprises a back-end control unit;
and the input end of the rear-end control unit is connected with the output end of the data processing module.
Furthermore, the output end of the rear-end control unit is connected with an audible and visual alarm, and the audible and visual alarm is used for executing audible and visual alarm operation according to the received audible and visual alarm instruction.
In a second aspect, a method of a belt deviation monitoring system based on a binocular line laser camera is characterized by comprising the following steps:
s1, point cloud data of the upper portion of a target belt are obtained; the point cloud data is acquired by a binocular line laser camera arranged above a target belt;
s2, constructing point clouds in unit time by using a sliding window idea, carrying out edge detection on the point clouds in the unit time, and extracting edge points to form an edge point set;
s3, calculating a deviation angle of the target belt based on the point cloud edge point set, comparing the deviation angle with a set threshold value, judging whether the deviation exists, judging whether the deviation is larger than the set threshold value according to the calculated deviation angle, if so, determining that the belt deviates, further performing alarm linkage processing, and if not, determining that the belt is normal.
The technical effect of this application is:
1. identifying point cloud data of binocular line laser projected on the upper part of a target belt in real time on line through a point cloud processing technology; secondly, performing edge detection on the point cloud data in unit time, and extracting edge points to form an edge point set; and then calculating the belt deviation angle based on the point cloud boundary. Compared with images and single-channel linear laser, the double-eye line laser improves the deviation detection accuracy.
2. The method has low complexity, can be operated in the field analysis and decision of the mine intrinsically safe embedded equipment, does not need to transmit data to an upper computer, avoids time delay, and meets the requirements of real-time performance and accuracy of detection.
The foregoing description is only an overview of the technical solutions of the present invention, and in order to make the technical means of the present invention more clearly understood and to be implemented in accordance with the content of the description, the following detailed description is given with reference to the preferred embodiments of the present invention and the accompanying drawings.
Drawings
Fig. 1 is a block diagram of a belt deviation monitoring system based on a binocular line laser camera according to an embodiment of the present disclosure;
fig. 2 is a flowchart of a method of a belt deviation monitoring system based on a binocular line laser camera according to an embodiment of the present application.
Detailed Description
The invention aims to provide a belt deviation monitoring system and method based on a binocular line laser camera, which mainly detect belt deviation by using a binocular ranging technology and a point cloud processing technology. The method specifically comprises the following steps: the method comprises the steps of acquiring point cloud data of the upper portion of a belt in real time by using a binocular line laser camera, carrying out edge detection on the point cloud data in unit time, extracting edge points to form an edge point set, calculating a belt deviation angle based on a point cloud boundary, comparing the belt deviation angle with a set threshold value, and judging whether deviation occurs. The invention can carry out deviation detection and deviation angle calculation on the belt in real time and output alarm information, and has great application value on intelligent detection and protection of the belt.
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, the present invention is described in detail with reference to the accompanying drawings and the detailed description thereof.
Example one
As shown in fig. 1, a belt deviation monitoring system based on a binocular line laser camera provided by the embodiment of the present invention mainly includes a data acquisition module and a back-end processor.
The data acquisition module at least comprises a binocular line laser camera; the binocular line laser camera is arranged on the upper part of a target belt; the binocular line laser camera is used for acquiring point cloud data of the upper part of the target belt when the target belt runs; the binocular line laser camera operates at a fixed frequency.
The back-end processor comprises at least one data processing module. The data processing module is configured to:
firstly, point cloud data of the upper part of the target belt are obtained; secondly, performing edge detection on the point cloud in unit time, removing edge points of the head and the tail of the point cloud, and only leaving edge point sets on two sides of the belt; and finally, carrying out deviation calculation according to the point cloud edge point set, judging whether the calculated deviation angle is larger than a set threshold value, if so, determining that the belt is deviated, and further carrying out alarm linkage processing, otherwise, determining that the belt is normal.
The hardware structure of the data processing module is a Hi3559 development board.
Further, the back-end processor further includes an auxiliary analog input module, an auxiliary analog output module, a DC12V input module, a DC12V output module, and a system management module (the system management module is used to set various parameters of the back-end processor).
And a related application algorithm and an interactive interface are transplanted in the data processing module to complete the extraction of point cloud data, the deviation detection processing and the algorithm result expression. The algorithm result expression comprises analog quantity output and is compatible with common network communication output of Modbustcp, TCP and a database.
Preferentially, the system also comprises a back-end control unit;
the input end of the rear-end control unit is connected with the output end of the data processing module, the output end of the rear-end control unit is connected with the audible and visual alarm, and the audible and visual alarm is used for executing audible and visual alarm operation according to the received audible and visual alarm instruction.
Preferably, the back end control unit is a PLC or other devices.
The analog quantity signal output by the back-end processor is sent to a back-end control unit for linkage control or alarm output. The linkage control comprises belt shutdown control and audible and visual alarm control, once the algorithm detects that the belt deviates and reaches the relevant set alarm limit, audible and visual alarm is immediately carried out, and the belt is shut down, so that the larger loss is avoided.
Further, the back-end processor is connected with the back-end control unit through an electric cable or an optical cable.
Example two
In order to achieve the above object, the present invention further provides a method for monitoring belt deviation based on a binocular line laser camera, as shown in fig. 2, the method includes:
s1: acquiring point cloud data of the upper part of a target belt; the point cloud data is acquired by a binocular line laser camera arranged above a target belt;
s2: and carrying out edge detection on the point cloud data in unit time and extracting edge points to form an edge point set. The method comprises the following steps of constructing point clouds in unit time by utilizing a sliding window idea, carrying out edge detection on the point clouds in the unit time, and judging a point cloud P edge point set in the following steps:
a) For any point O in the point cloud O i Setting a search radius R, and recording the region points in the search radius R as a set N (O) i ) I.e. N (O) i )＝{O j |O j ∈O，||O i -O j ||＜R}。
b) The curved surface equation ax + by + cz = d (d is more than or equal to 0), a 2 +b 2 +c 2 =1, take O i Corresponding set N (O) i ) Calculating N (O) i ) Distance d to curved surface i = ax + by + cz-d |, solving
Figure RE-GDA0003926006600000051
The feature vector corresponding to the minimum is the normal vector n of the point change.
c) According to O i And a normal vector N of the point is taken as a tangent plane omega of the point, and a set N (O) is formed i ) The inner point is projected on the tangent plane omega and is marked as N (O) i '). In N (O) i ') take a point O j ' to
Figure RE-GDA0003926006600000052
Is u-axis, n is w-axis, u x w is v-axis, and O is i Constructing a local coordinate system for the coordinate center, denoted as (O) i ，u，v，w)。
d) Separately compute the set N (O) i ) Other point of n To point O i Vector O of i O n Clockwise angle to the coordinate axis u
Figure BDA0003882815180000053
Making difference between two adjacent included angles to obtain included angle set
Figure BDA0003882815180000061
Wherein:
ε n-1 ′＝ε n -ε n-1
Figure BDA0003882815180000062
for the angle between two adjacent vectors, assemble
Figure BDA0003882815180000063
The elements in the list are arranged in descending order to find out the maximum included angle epsilon max ', when ∈ max When' is larger than a threshold value (generally pi/2), the point is considered as an edge point.
After all the edge points are extracted, removing the edge points at the head and the tail, and only leaving edge point sets at two sides of the belt, wherein the specific steps are as follows:
a) The X values of the first line and the last line are extracted.
b) And extracting the Y value range of the point cloud.
c) The points with X-cut ordinate in the Y value range are removed from the horizontal coordinate value.
S3: calculating the deviation angle of the target belt based on the point cloud boundary and comparing the deviation angle with a set threshold value to determine whether the target belt deviates, wherein the method comprises the following steps:
a) And recording three-dimensional coordinate information of the belt edge of the laser at the belt position.
b) The angle between the initial belt edge and the camera center point is calculated.
c) And calculating an included angle between the calculated real-time belt edge point set and the central point of the camera.
d) And calculating the deviation angle through an included angle between the initial belt edge and the central point of the camera and an included angle between the real-time belt edge point calculation and the central point of the camera.
e) And judging whether the calculated deviation angle is larger than a set threshold value or not according to the calculated deviation angle, if so, determining that the belt deviates, and further performing alarm linkage processing, otherwise, determining that the belt is normal.
Compared with the prior art, the invention has the following advantages:
the laser equipment can set the density and the number of the collected point clouds according to the precision and the timeliness, and can realize the belt deviation detection by matching with the idea of concurrent blocking treatment, the detection speed can be realized within 200ms, the deviation angle detection accuracy rate reaches 98%, and the false alarm rate is less than 2%.
The core algorithm is realized and deployed on a Hi3559 board of the edge-end equipment, the equipment is mining intrinsic safety equipment, the system stability is good, the fault tolerance rate is high, and the electromagnetic environment interference of the environment is avoided; the embedded algorithm is transplanted, edge calculation is supported, the operation pressure of the central server can be greatly reduced, normal work can still be kept when the underground looped network has problems, and the stability of the system is improved.
Finally, it should be noted that: it should be understood that the above examples are only for clearly illustrating the present invention and are not intended to limit the embodiments. Other variations and modifications of the present invention will be apparent to those of ordinary skill in the art in light of the above teachings. And are neither required nor exhaustive of all embodiments. And obvious variations or modifications of the invention may be made without departing from the scope of the invention.

Claims (7)

1. A belt deviation monitoring system based on a binocular line laser camera is characterized by comprising a data acquisition module and a rear-end processor;
the data acquisition module at least comprises a binocular line laser camera which is arranged above the target belt and used for acquiring point cloud data on the upper part of the target belt when the target belt runs;
the back-end processor at least comprises a data processing module, and the data processing module is used for acquiring point cloud data on the upper part of the target belt and carrying out deviation calculation.
2. The binocular line laser camera-based belt deviation monitoring system of claim 1, wherein the point cloud data is constructed by adopting a sliding window idea, edge detection is performed on the point cloud in unit time, all edge points are extracted, the edge points of the head and the tail are removed, only edge point sets on two sides of the belt are left, and deviation calculation is performed according to the point cloud edge point sets.
3. The binocular line laser camera based belt deviation monitoring system of claim 2, wherein the extraction of the edge points includes extracting X values of a first line and a last line, extracting a Y value range of the point cloud, and removing points having X-cut ordinate and Y-cut ordinate in the Y value range as abscissa values.
4. The binocular line laser camera-based belt deviation monitoring system of claim 3, wherein the deviation calculation mode comprises: a. recording three-dimensional coordinate information of the belt edge of the laser at the belt position, b, calculating an included angle between the initial belt edge and a camera central point, c, calculating an included angle between the initial belt edge and the camera central point through a calculated real-time belt edge point set, and d, calculating a deviation angle through the included angle between the initial belt edge and the camera central point and the included angle between the real-time belt edge point calculation and the camera central point.
5. The binocular line laser camera-based belt deviation monitoring system of claim 1, further comprising a rear end control unit;
and the input end of the rear-end control unit is connected with the output end of the data processing module.
6. The belt deviation monitoring system based on the binocular line laser cameras as claimed in claim 5, wherein an audible and visual alarm is connected to an output end of the rear end control unit and is used for executing audible and visual alarm operation according to the received audible and visual alarm instruction.
7. A method of a belt deviation monitoring system based on a binocular line laser camera is characterized by comprising the following steps of:
s1, point cloud data of the upper part of a target belt are obtained; the point cloud data is acquired by a binocular line laser camera arranged above a target belt;
s2, constructing point clouds in unit time by using a sliding window idea, carrying out edge detection on the point clouds in the unit time, and extracting edge points to form an edge point set;
and S3, calculating a deviation angle of the target belt based on the point cloud edge point set, comparing the deviation angle with a set threshold value, judging whether the deviation is caused, judging whether the deviation is larger than the set threshold value according to the calculated deviation angle, if so, determining that the belt is deviated, further performing alarm linkage processing, and if not, determining that the belt is normal.
CN202211233871.9A 2022-10-10 2022-10-10 Belt deviation monitoring system and method based on binocular line laser camera Pending CN115417067A (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN116135744A (en) * 2023-03-20 2023-05-19 北京众驰自动化设备有限公司 Method and device for detecting abrasion of conveying belt of belt conveyor

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN116135744A (en) * 2023-03-20 2023-05-19 北京众驰自动化设备有限公司 Method and device for detecting abrasion of conveying belt of belt conveyor
CN116135744B (en) * 2023-03-20 2023-12-15 北京众驰自动化设备有限公司 Method and device for detecting abrasion of conveying belt of belt conveyor

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