CN115984162A - Wire breakage detection method for steel wire rope - Google Patents
Wire breakage detection method for steel wire rope Download PDFInfo
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- CN115984162A CN115984162A CN202211272294.4A CN202211272294A CN115984162A CN 115984162 A CN115984162 A CN 115984162A CN 202211272294 A CN202211272294 A CN 202211272294A CN 115984162 A CN115984162 A CN 115984162A
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Abstract
The invention relates to a wire breakage detection method for a steel wire rope, which comprises the following steps: s1, sleeving an oil wiper on a starting detection point of a steel wire rope, and arranging a plurality of shooting devices on one side of the oil wiper, which outputs clean steel wire rope, at regular intervals in a spiral shape around the steel wire rope; s2, starting each shooting device to continuously shoot the moving steel wire rope, synchronously comparing an image shot by the shooting device close to the oil scraper with the image data of the specific posture of the steel wire rope by the image processing device, counting once by the counter when the comparison is matched each time, controlling each shooting device to shoot synchronously, and processing and comparing the shot images by the image processing device; and S3, if the number of counting is N times, comparing a picture with obvious difference in similarity, judging the suspected wire breakage position, and calculating the distance S from the suspected wire breakage position to the initial detection point of the steel wire rope according to the N value. The method has the advantages that the broken wire condition of the steel wire rope can be relatively quickly and accurately determined, and the distance between the broken wire position and the initial detection point is conveniently positioned.
Description
Technical Field
The invention relates to the field of monitoring of use safety of a steel wire rope, in particular to a method for detecting wire breakage of the steel wire rope.
Background
The steel wire rope is generally a flexible rope twisted by a plurality of or a plurality of strands of thin steel wires, has the characteristics of high strength, light dead weight, large bearing capacity, difficult fracture, high safety factor and the like, and is widely applied to mines, shipbuilding, metallurgy, ports, shipping and the like. When the steel wire rope is used, the steel wire rope is easy to break due to corrosion, abrasion or fatigue and the like, the strength is reduced, and the steel wire rope is in a risk of breaking when the steel wire rope is seriously broken.
In order to avoid the accident that the steel wire rope is suddenly disconnected in the using process, the steel wire rope needs to be subjected to flaw detection regularly. The current steel wire rope flaw detection comprises manual visual inspection, electromagnetic detection and machine vision detection: the manual visual inspection has the defects of large workload, high labor intensity, easy fatigue, strong subjectivity and the like; the electromagnetic detection needs to magnetize the steel wire rope and then detect magnetic leakage, and has the disadvantages of complex equipment, high cost and easy distortion caused by external interference; machine vision is the most widely applied wire rope broken wire detection method at present, but the current detection method needs to shoot a standard wire rope without broken wire and broken strand to obtain a reference picture, and during reference, the shooting positions of the detected wire rope and the standard wire rope are also required to be the same, otherwise, the detection result is difficult to obtain through comparison, and the on-line detection is difficult to realize, specifically refer to CN104063716a. In actual use, dust and grease can be deposited on the surface of the steel wire rope, and even if no broken wire exists, the steel wire rope covered by the dust and the grease at the same position has a large difference with a standard steel wire rope; in addition, in the current machine vision detection method, after a suspected broken wire is judged in a video or an image, because the steel wire rope is in constant motion, the broken wire is still difficult to find quickly and accurately in the later period, and the reason is that the constant speed is difficult to ensure due to the slippage phenomenon during the transmission of the steel wire rope, and accumulated errors exist. Based on the above problems, there is a need to provide a new system and method for detecting broken steel wire rope based on machine vision method.
Disclosure of Invention
The invention provides a method for detecting broken steel wire ropes, and aims to overcome the defects in the prior art.
The technical scheme for solving the technical problems is as follows: a wire breakage detection method for a steel wire rope comprises the following steps:
s1, sleeving an oil wiper on a starting detection point of a steel wire rope, spirally and uniformly arranging a plurality of shooting devices which are opposite to the steel wire rope for shooting at intervals on one side of the steel wire rope, where the oil wiper outputs a clean steel wire rope, wherein the distance between every two adjacent shooting devices in the axial direction of the steel wire rope is n times of the lay length L of the steel wire rope, n is an integer not less than 1, and the distance between the shooting device close to the oil wiper and the starting detection point of the steel wire rope is s;
s2, one end of the steel wire rope is pulled by a traction device to move relative to an oil wiper, each shooting device is started to continuously shoot the moving steel wire rope cleaned by the oil wiper, an image processing device synchronously compares an image shot by the shooting device close to the oil wiper with picture data of a specific posture of the steel wire rope, when the comparison is matched each time, a counter counts once and simultaneously controls each shooting device to synchronously shoot and collect the picture of the steel wire rope at the position opposite to each shooting device at the moment, and the shot pictures are processed by the image processing device and compared in similarity;
and S3, if the number is N times, comparing to obtain a picture with obvious difference in similarity, judging that the picture is an abnormal picture and the corresponding position is a suspected wire breakage position of the steel wire rope, extracting the N value at the moment as an early warning data record, calculating the distance S between the suspected wire breakage position and the initial detection point of the steel wire rope according to the N value, wherein S = (N-1 + lambda x N) xL + S, lambda is the number value of a shooting device for shooting the abnormal picture, the number value of the shooting device adjacent to the oil scraper is 0, the number value of the subsequent shooting device is 1, and then sequentially increasing the number.
On the basis of the technical scheme, the invention can further specifically select as follows.
Specifically, when the image processing device processes the shot pictures and performs similarity comparison in S2, the processed and compared pictures are two adjacent pictures shot by the same shooting device, and the pictures shot by each shooting device are processed and compared.
Specifically, when the shooting devices in S1 are spirally distributed near the steel wire rope, the staggered angle of two adjacent shooting devices in the circumferential direction of the steel wire rope needs to be adjusted to ensure that the postures of the steel wire rope photos shot by the shooting devices at any moment are the same, and the steel wire rope photos shot by all the shooting devices cover all the angles of the steel wire rope in one circle, at this time, when the image processing device in S2 processes the shot photos and compares the similarities, the processed and compared photos are the photos shot by all the shooting devices at the same time.
Specifically, in the step S1, two shooting devices are provided, and the two shooting devices are staggered by an angle of 180 degrees in the circumferential direction of the steel wire rope.
Specifically, in the step S1, the number of the shooting devices is three, and the staggered angles of any two shooting devices in the circumferential direction of the steel wire rope are 120 degrees.
Specifically, the shooting device in S1 is a digital camera or a video camera.
Specifically, the picture of the specific posture of the steel wire rope in S2 is a picture of the steel wire rope which is clean and has not broken, and the picture data of the specific posture is a specific angle and a starting point of a surface line of the steel wire rope, which is extracted after the picture of the picture taken in advance is processed.
Specifically, the obvious difference in comparison of the pictures in S2 means that the similarity data of the two pictures after comparison by the picture similarity comparison software is below 95%.
Compared with the prior art, the invention has the beneficial effects that:
the invention originally cleans the steel wire rope by the oil scraper, then spirally distributes a plurality of shooting devices near the steel wire rope after oil scraping cleaning, the shooting devices are staggered in the circumferential direction of the steel wire rope and are spaced at the distance of integral multiple of the lay length in the axial direction, thus, the shooting devices do not influence each other when shooting and taking pictures for the steel wire rope, and the posture of the steel wire rope is completely consistent with the current posture after spacing the distance of integral multiple of the lay length, although the shooting devices do not aim at the shooting of each angle in the circumferential direction at the same position of the steel wire rope, the shooting devices continuously move along with the steel wire rope, the comprehensive effect can be equal to the complete shooting of one circle at the same position, and the steel wire rope is comprehensively detected when detecting broken wires. According to the method, the shooting and the shooting are carried out by utilizing the image comparison method to detect the broken wire, when the suspected broken wire position of the steel wire rope is compared in the detection process, the distance from the broken wire position to the detection starting point of the steel wire rope can be calculated according to the counted corresponding shooting times N, the broken wire condition of the steel wire rope can be rapidly and accurately determined by video playback and actual observation of the steel wire rope condition at the corresponding distance position of the steel wire rope, and the method is high in efficiency and good in accuracy.
Drawings
FIG. 1 is a flow chart of the present invention for detecting a wire breakage in a steel wire rope;
fig. 2 is a schematic diagram of a positional distribution relationship between three photographing devices in the method for detecting a broken wire of a steel wire rope and an oil wiper.
Fig. 3 is a schematic view of a picture of a specific posture of a steel wire rope, which is shot by a shooting device in the wire breakage detection method provided by the invention;
fig. 4 is a schematic diagram of an abnormal photo of a suspected wire breakage of a steel wire rope, which is shot by a shooting device in the wire breakage detection method provided by the invention.
In the drawings, the reference numbers indicate the following list of parts:
1. a photographing device; 2. a wire rope; 3. an oil wiper.
Detailed Description
The principles of the present invention will be described in further detail below with reference to the accompanying drawings and specific embodiments, which are provided for illustration only and are not intended to limit the scope of the invention.
As shown in fig. 1, the invention provides a method for detecting a wire breakage of a steel wire rope, which comprises the following steps:
s1, sleeving an oil wiper on a starting detection point of a steel wire rope, and spirally and uniformly arranging a plurality of shooting devices (three shooting devices, namely cameras, shown in figure 2) which are opposite to the steel wire rope for shooting at intervals near the steel wire rope on one side of the steel wire rope, which is output by the oil wiper and cleaned by the oil wiper, wherein the distance between every two adjacent shooting devices in the axial direction of the steel wire rope is n times of the lay length L of the steel wire rope, n is an integer not less than 1, and the distance between the shooting devices close to the oil wiper and the starting detection point of the steel wire rope is s;
s2, pulling one end of the steel wire rope to move relative to the oil wiper through the traction device, starting each shooting device to continuously shoot the moving steel wire rope cleaned by the oil wiper, synchronously comparing an image shot by the shooting device close to the oil wiper with picture data of a specific posture of the steel wire rope through the image processing device, counting once through a counter when the comparison is matched every time, simultaneously controlling each shooting device to synchronously shoot and collect a steel wire rope picture at the moment, processing the shot picture through the image processing device, and carrying out similarity comparison;
and S3, if the number is N times, comparing to obtain a picture with obvious difference in similarity, judging that the picture is an abnormal picture (shown in figure 4) and the corresponding position is a suspected wire breakage position of the steel wire rope, extracting the N value at the moment as an early warning data record, calculating the distance S between the suspected wire breakage position and the initial detection point of the steel wire rope according to the N value, wherein S = (N-1 + lambda x N) x L + S, lambda is the number value of a shooting device for shooting the abnormal picture, the number value of the shooting device adjacent to the oil scraper is 0, the number values of the subsequent shooting devices are 1, and then sequentially increasing.
It should be noted that, after the oil wiper cleans the steel wire rope, the steel wire rope has a clean rope surface, and a better image processing effect can be obtained.
In an embodiment of the present invention, when the image processing device processes the captured photos and performs similarity comparison in S2, the processed and compared photos are two adjacent photos captured by the same capturing device, and the photos captured by each capturing device are processed and compared. It should be noted that, in the initial stage of this method, because the spiral distribution of the shooting device, a section of the steel wire rope in a small range at the starting end cannot be shot, so that it is impossible to compare images to determine whether there is a broken wire, and in order to avoid missing detection, it is necessary to manually check the steel wire rope in a small range at the starting end (starting detection point), and because only a small section of the steel wire rope is used, the workload of manual checking is not large. Of course, in this embodiment, the comparison is performed between two adjacent steel wire images captured by the same capturing device, so the comparison amount is large, and the image processing device is required to have a strong processing capability. When the processing capability of the image processing apparatus is difficult to satisfy the requirement, the method provided in the next embodiment may be used, and the image comparison workload may be reduced by half.
In another embodiment of the present invention, when the shooting devices in S1 are spirally distributed near the wire rope, the staggered angle of two adjacent shooting devices in the circumferential direction of the wire rope needs to be adjusted to ensure that the postures of the wire rope photos shot by the shooting devices at any time are the same, and the wire rope photos shot by all the shooting devices cover all angles of one circle of the wire rope, at this time, when the image processing device in S2 processes the shot photos and performs similarity comparison, the processed and compared photos are photos shot by all the shooting devices at the same time. By utilizing the structural characteristic that the steel wire rope is twisted into one strand by a plurality of or a plurality of strands of thin steel wires, the posture images of the steel wire rope at the integral multiple lay length in front are completely the same, so when the side wall around a certain position of the steel wire rope needs to be photographed, in order to avoid mutual interference among photographing devices, photographing can be carried out on the steel wire rope at each angle at intervals of the integral multiple lay length without mutual interference. In addition, due to the characteristic that the steel wire ropes are twisted into one strand, after the steel wire ropes rotate at the same point and are staggered by a certain angle, the shot attitude images of the steel wire ropes are also the same.
In one embodiment of the invention, in S1, there are two cameras, and the two cameras are staggered by an angle of 180 degrees in the circumferential direction of the steel wire rope.
In another embodiment of the present invention, as shown in fig. 2, in S1, there are three cameras, and any two of the cameras are staggered by 120 degrees in the circumferential direction of the steel wire rope.
In the above embodiments, the photographing device in S1 is a digital camera or a video camera.
In the above embodiments, the picture (as shown in fig. 3) of the specific posture of the wire rope in S2 refers to a picture taken by a camera in advance of the clean and unbroken wire rope, and the picture data of the specific posture refers to the specific angle and the starting point of the surface line of the wire rope extracted after image processing is performed on the picture taken in advance.
In each of the above embodiments, the obvious difference in the comparison of the photos in S2 means that the similarity data of the two photos after comparison by the photo similarity comparison software is below 95%. It can be understood that, in order to improve the detection accuracy, the 95% may be adjusted to be 90% or less, and once an abnormal photo is detected, the possibility of filament breakage is very high, so the detection is more accurate; in order to avoid missing detection, some fine broken filaments may not be enough to make the similarity data reach below 95%, at this time, the above 95% can be adjusted to 98%, so that more abnormal photos are detected, and missing detection can be avoided, but the workload of manual subsequent video playback or on-site investigation and confirmation is increased.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.
Claims (8)
1. A wire breakage detection method for a steel wire rope is characterized by comprising the following steps:
s1, sleeving an oil wiper on a starting detection point of a steel wire rope, spirally and uniformly arranging a plurality of shooting devices which are opposite to the steel wire rope for shooting at intervals on one side of the steel wire rope, where the oil wiper outputs a clean steel wire rope, wherein the distance between every two adjacent shooting devices in the axial direction of the steel wire rope is n times of the lay length L of the steel wire rope, n is an integer not less than 1, and the distance between the shooting device close to the oil wiper and the starting detection point of the steel wire rope is s;
s2, one end of the steel wire rope is pulled by a traction device to move relative to an oil wiper, each shooting device is started to continuously shoot the moving steel wire rope cleaned by the oil wiper, an image processing device synchronously compares an image shot by the shooting device close to the oil wiper with picture data of a specific posture of the steel wire rope, when the comparison is matched each time, a counter counts once and simultaneously controls each shooting device to synchronously shoot and collect the picture of the steel wire rope at the position opposite to each shooting device at the moment, and the shot pictures are processed by the image processing device and compared in similarity;
and S3, if the number is N times, comparing to obtain a picture with obvious difference in similarity, judging that the picture is an abnormal picture and the corresponding position is a suspected wire breakage position of the steel wire rope, extracting the N value at the moment as an early warning data record, calculating the distance S between the suspected wire breakage position and the initial detection point of the steel wire rope according to the N value, wherein S = (N-1 + lambda x N) xL + S, lambda is the number value of a shooting device for shooting the abnormal picture, the number value of the shooting device adjacent to the oil scraper is 0, the number value of the subsequent shooting device is 1, and the number values are sequentially increased.
2. The method for detecting the broken wire of the steel wire rope according to claim 1, wherein when the image processing device processes the shot pictures and compares the similarity, the processed and compared pictures are the pictures shot by the same shooting device in two adjacent times, and the pictures shot by each shooting device are processed and compared.
3. The method for detecting the broken wire of the steel wire rope according to claim 1, wherein in the step S1, when the shooting devices are spirally distributed near the steel wire rope, the staggered angle of the two adjacent shooting devices in the circumferential direction of the steel wire rope needs to be adjusted to ensure that the postures of the steel wire rope photos shot by the shooting devices at any moment are the same, and the steel wire rope photos shot by all the shooting devices cover all angles of the circumference of the steel wire rope, at the moment, when the image processing device in the step S2 processes the shot photos and compares the similarities, the pictures processed and compared are the photos shot by the shooting devices at the same time.
4. The method for detecting the breakage of the steel wire rope according to claim 1, wherein two shooting devices are arranged in S1, and the two shooting devices are staggered by an angle of 180 degrees in the circumferential direction of the steel wire rope.
5. The method for detecting the broken wire of the steel wire rope according to claim 1, wherein the number of the shooting devices in S1 is three, and the staggering angle of any two shooting devices in the circumferential direction of the steel wire rope is 120 degrees.
6. The method for detecting the breakage of the steel wire rope according to claim 1, wherein a shooting device in the step S1 is a digital camera or a camera.
7. The method for detecting the breakage of the steel wire rope according to claim 1, wherein the picture of the specific posture of the steel wire rope in the S2 is a picture of the steel wire rope which is clean and has not broken, and the picture data of the specific posture is a specific angle and a starting point of a surface line of the steel wire rope, which are extracted after the picture of the picture taken in advance is processed.
8. The method for detecting the breakage of the steel wire rope according to any one of claims 1 to 7, wherein the obvious difference in comparison of the pictures in S2 means that the similarity data of the two pictures after comparison by the picture similarity comparison software is below 95%.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202211272294.4A CN115984162A (en) | 2022-10-18 | 2022-10-18 | Wire breakage detection method for steel wire rope |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202211272294.4A CN115984162A (en) | 2022-10-18 | 2022-10-18 | Wire breakage detection method for steel wire rope |
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| CN115984162A true CN115984162A (en) | 2023-04-18 |
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| CN202211272294.4A Pending CN115984162A (en) | 2022-10-18 | 2022-10-18 | Wire breakage detection method for steel wire rope |
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- 2022-10-18 CN CN202211272294.4A patent/CN115984162A/en active Pending
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