CN116142727B - Conveyor belt tearing detection method and system based on laser stripe defect identification - Google Patents
Conveyor belt tearing detection method and system based on laser stripe defect identification Download PDFInfo
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- CN116142727B CN116142727B CN202310398850.0A CN202310398850A CN116142727B CN 116142727 B CN116142727 B CN 116142727B CN 202310398850 A CN202310398850 A CN 202310398850A CN 116142727 B CN116142727 B CN 116142727B
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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
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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
- 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)
- B65G2203/0275—Damage on the load carrier
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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
- B65G2203/00—Indexing code relating to control or detection of the articles or the load carriers during conveying
- B65G2203/04—Detection means
- B65G2203/042—Sensors
- B65G2203/044—Optical
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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
- Y02P90/30—Computing systems specially adapted for manufacturing
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- Mechanical Engineering (AREA)
- Length Measuring Devices By Optical Means (AREA)
Abstract
The invention belongs to the technical field of conveyor belt detection, and particularly relates to a conveyor belt tearing detection method and system based on laser stripe defect identification. The method comprises the following steps: extracting a central line of the laser line area; correcting the center line; inquiring the position information of a central point on a central line, performing central point trending, and acquiring a trending peak value extraction result; the tear depth and tear width are calculated from the peak extraction results. The system comprises an extraction module, a correction module, a trending module and a calculation module. The invention can accurately identify the tearing fault of the conveyor belt and can shield the problem of disordered laser stripe characteristics caused by the reasons of dirt, paint, belt repairing and the like at the bottom of the conveyor belt.
Description
Technical Field
The invention belongs to the technical field of conveyor belt detection, and particularly relates to a conveyor belt tearing detection method and system based on laser stripe defect identification.
Background
The belt conveyor system has the advantages of simple structure, high conveying efficiency and the like in the aspect of long-distance continuous material conveying in the process industry, is important equipment for industrial coal, ore and the like transportation, and is the most critical fault type influencing the operation of the conveyor during the operation process of the conveyor. Because the conveyor runs at a fast speed and over a long distance, if the tearing accident is not detected timely, the belt can be damaged by tens of meters or even hundreds of meters. Repairing the belt is time-consuming and labor-consuming, and can affect normal production, thereby causing direct and indirect economic losses for enterprises.
The detection method commonly adopted by the current belt conveying systems in various enterprises is a scheme of periodic manual inspection, has poor real-time performance and depends on responsibility of workers. In the aspect of the overall system, the problems of operation and maintenance prevention, numerous potential safety hazards and the like are lacked, so that on-line monitoring and intelligent operation and maintenance are necessary.
The current mainstream implementation on-line monitoring technical scheme mainly comprises two technical routes, one is to carry out image acquisition and image analysis through a line scanning camera so as to determine the form and position of a fault, and the fault detection device is represented by a fault detector developed by Tianjin industrial university team and Tianjin constant technology, and can detect faults to a certain extent through combining a plurality of line scanning cameras with image fusion and image detection technologies, but because the line scanning camera acquisition needs stable speed feedback to control shooting, the fault detection device is not suitable for being used in a severe environment.
The other technical scheme is that fault detection is carried out by a line laser auxiliary line matched with an area array camera and a triangulation principle. The representative products are fault detectors of Shanxian corporation and Yan Shanda school team, belt longitudinal tearing detection equipment for Shanxi measurement and control, and the like. It is worth mentioning that detection and measurement systems based on laser triangulation are a large class, e.g. line laser profile scanners, structured light flaw detectors, etc. are all done using this principle. The laser triangulation principle is as shown in fig. 1, when a laser irradiates vertically downwards, and a camera shoots with a certain included angle, different longitudinal depths can enable laser points to be reflected on different positions imaged by the camera, depth information of the laser point positions can be effectively obtained through analyzing light bars and light spots of the laser, faults can be effectively detected by utilizing the laser triangulation principle, a plurality of false detection signals can be generated due to more dirt at the bottom of a conveyor belt, and due to short acquisition time, camera exposure is very low, and manual assistance is difficult to distinguish whether the faults are true tearing faults or not during manual inspection.
In order to solve the above problems, a method and a system for detecting tearing of a conveyor belt based on laser stripe defect recognition are needed.
Disclosure of Invention
In view of the above problems, the present invention provides a method for detecting tearing of a conveyor belt based on identification of defects of laser stripes, the method comprising:
extracting a central line of the laser line area;
correcting the center line;
inquiring the position information of a central point on a central line, performing central point trending, and acquiring a trending peak value extraction result;
the tear depth and tear width are calculated from the peak extraction results.
Preferably, the method for extracting the laser line area comprises the steps of setting a self-detection belt mask and black plug matrix analysis.
Preferably, the method for extracting the center line of the laser line region comprises a gray-scale gravity center method;
the gray level gravity center method comprises the following steps:
defining a point to be measured and a neighborhood, wherein the neighborhood is a point adjacent to the point to be measured;
judging whether the neighborhood in the laser line area meets the deletion condition.
Preferably, the neighborhood of the center line center includes an intersection point, an end point, and an on-line point.
Preferably, the correcting the center line includes:
calculating the distance from the adjacent point of each end point to the nearest black pixel outside the laser line area;
and deleting the error crossing point caused by the burr according to the calculation result.
Preferably, the trending method includes extracting trending elements by a second order fitting method;
the method for obtaining the peak value extraction result comprises the step of obtaining the peak value extraction result by differencing the trending element and the original data element.
Preferably, the tearing depth and tearing width are obtained by calculation of the width and depth of the peak extraction result, respectively.
Preferably, the method further comprises the steps of:
and setting a threshold value to filter the peak value extraction result.
The invention also provides a conveyor belt tearing detection system based on laser stripe defect recognition, which comprises an extraction module, a correction module, a trending removal module and a calculation module;
the extraction module is used for extracting the laser line area and the central line of the laser line area;
the correction module is used for correcting the center line;
the trending module is used for inquiring the position information of the central point on the central line, carrying out trending on the central point and obtaining a trending peak value extraction result;
and the calculation module is used for calculating the tearing depth and the tearing width according to the peak value extraction result.
Preferably, the system further comprises a filtration module;
the filtering module is used for setting a threshold value to filter the peak value extraction result.
Preferably, the extraction module extracts the center line of the laser line area through a gray level gravity center method;
the gray level gravity center method comprises the following steps:
defining a point to be measured and a neighborhood, wherein the neighborhood is a point adjacent to the point to be measured;
judging whether the neighborhood in the laser line area meets the deletion condition.
Preferably, the correction module is configured to correct a center line, and includes:
the correction module is used for calculating the distance from the adjacent point of each end point to the nearest black pixel outside the laser line area;
and deleting the error crossing point caused by the burr according to the calculation result.
The invention has the following beneficial effects:
the invention can accurately identify the tearing fault of the conveyor belt and can shield the problem of disordered laser stripe characteristics caused by the reasons of dirt, paint, belt repairing and the like at the bottom of the conveyor belt.
Additional features and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions of the prior art, the following description will briefly explain the drawings used in the embodiments or the description of the prior art, and it is obvious that the drawings in the following description are some embodiments of the present invention, and other drawings can be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 shows a laser triangulation schematic;
FIG. 2 illustrates a belt tear detection system installation measurement schematic;
FIG. 3 is a diagram showing a method for detecting tearing of a conveyor belt based on laser stripe defect recognition in an embodiment of the present invention;
FIG. 4 is a view showing definition of gray centroid method in an embodiment of the present invention;
FIG. 5 illustrates a center-line center schematic diagram in an embodiment of the invention;
FIG. 6 is a schematic diagram showing the confirmation of points, intersections, and endpoints on a line in an embodiment of the invention;
FIG. 7 is a schematic diagram showing a graph of extracted center line valid points on an original image material in an embodiment of the present invention;
FIG. 8 is a graph showing a trending fit in an embodiment of the present invention;
FIG. 9 is a partial schematic view of a curve after center point detrending in an embodiment of the present invention;
FIG. 10 illustrates a schematic view of conveyor belt tear depth in an embodiment of the present invention;
FIG. 11 illustrates a schematic diagram of a tear width of a conveyor belt in an embodiment of the present invention;
FIG. 12 illustrates a schematic diagram of a conveyor belt failure depth and width filtered in an embodiment of the present invention;
FIG. 13 shows a schematic view of depth and width in an embodiment of the invention;
FIG. 14 is a diagram of a conveyor belt tear detection system based on laser stripe defect identification in an embodiment of the present invention.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the embodiments of the present invention more apparent, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is apparent that the described embodiments are some embodiments of the present invention, but not all embodiments of the present invention. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
The invention provides a conveyor belt tearing detection method based on laser stripe defect identification, wherein a conveyor belt tearing detection system installation measurement schematic diagram is shown in fig. 2, and a line laser-assisted belt longitudinal tearing detection system adopts triangulation to detect.
After the line laser area is extracted by setting methods such as self-detection belt masking, black plug matrix analysis and the like, fault detection is carried out on laser stripe characteristics, and as shown in fig. 3, the specific steps of the conveyor belt tearing detection method based on laser stripe defect identification are as follows:
(1) Extracting a laser line region and a center line of the laser line region
The extraction method of the laser line area comprises the steps of setting a self-detection belt mask and a black plug Matrix Hessian Matrix analysis.
The central line extraction method of the laser line area comprises a gray level gravity center Zhang-sun method;
the gray-scale gravity center Zhang-sun method comprises the following steps: defining a point to be measured and a neighborhood, wherein the neighborhood is a point adjacent to the point to be measured; judging whether the neighborhood in the laser line area meets the deletion condition.
As shown in FIG. 4, the point to be measured is denoted as p1, and the neighborhood is denoted as p2-p9; the deletion conditions include a first condition and a second condition; wherein the first condition includes the following sub-conditions: 2.ltoreq.N (p 1). Ltoreq.6, N (x) being the number of black dots in the eight neighborhoods of x; a (p 1) =1, a (x) is the number (background color is 0) of pairs of values 0 and 1 between p2 and p8 in order; p2×p4×p6=0; p4×p6×p8=0; this point may be deleted (assigned a value of 0) if the above four conditions are met simultaneously.
The second condition includes the following sub-conditions: 2.ltoreq.N (p 1). Ltoreq.6, N (x) being the number of black dots in the eight neighborhoods of x; a (p 1) =1, a (x) is a logarithm (background color is 0) of 0 and 1 respectively before and after p2-p8 in order; p2×p4×p8=0; p2×p6×p8=0; this point may be deleted if the above four conditions are met simultaneously.
This is iterated until a refined image is obtained.
(2) Correction of centre line
The correcting the center line includes: calculating the distance from the adjacent point of each end point to the nearest black pixel outside the laser line area; and deleting the error crossing point caused by the burr according to the calculation result.
As shown in fig. 5, the neighborhood of the center line center includes the intersection point, the end point and the on-line point, and it is known from a priori knowledge that no abrupt change occurs in the width direction of the laser line, so that the distance from the on-line point near each intersection point to the black area is transformed once, that is, the distance from the point near each end point to the nearest black pixel outside the laser area is calculated by using the two-dimensional plane calculation formula of euclidean distance, and the erroneous intersection point caused by the burr is deleted. The confirmation modes of the points, the intersections and the endpoints on the line are as follows: as shown in fig. 6, for each point P, query it to traverse a neighborhood of 5*5 with one point as the center, define it as an on-line point if there are 2 non-adjacent non-zero points in its number 1-16 positions (if 2 non-zero points are adjacent, it is considered a point), cross point if there are more than 2, and end point if there are less than 2.
In order to solve the problem that the laser line is primarily segmented because of uneven laser intensity and halation of the material, burr-shaped error segmentation occurs at the edge of the segmented line due to the halation, for each extracted intersection point, in the method, the on-line point near each intersection point is calculated, and the distance from the black area in the primary segmented image area is not abrupt if the on-line point is a real on-line point. Since the thickness of the laser line does not become abrupt, the burr-like interference of the divided image can be removed by the above operation.
(3) Inquiring the position information of the central point on the central line, performing central point trending, and obtaining a trending peak value extraction result
The trending method comprises the steps of extracting trending elements through a second-order fitting method; the method for obtaining the peak extraction result comprises the steps of obtaining the peak extraction result by differencing the trending element and the original data element, wherein the abscissas and the ordinates in fig. 8-9 are all spatial distances as shown in fig. 7-9.
The method further comprises the following steps of: the peak extraction result is filtered by setting a threshold, as shown in fig. 10-11, and the non-obvious portion may be raised to achieve the filtering effect, as shown in fig. 12.
(4) Calculating the tearing depth and the tearing width according to the peak value extraction result
The tearing depth and the tearing width are obtained through the calculation of the width and the depth of the peak value extraction result respectively. When the depth threshold or width threshold is set to exceed the threshold, as shown in fig. 13, it is determined as a tear failure, and if it is lower than the threshold, no reaction is made, the alarm is filtered off unobvious, and the coordinates in fig. 13 are spatial coordinates.
The invention adopts the triangulation principle and the fitting strategy to carry out fault measurement, can accurately identify the tearing fault of the conveyor belt by the detection algorithm, and can shield the problem of disordered laser stripe characteristics caused by the reasons of dirt, paint, belt repairing and the like at the bottom of the conveyor belt.
As shown in fig. 14, the invention further provides a conveyor belt tearing detection system based on laser stripe defect recognition, which comprises an extraction module, a correction module, a trending module and a calculation module.
The extraction module is used for extracting the laser line area and the central line of the laser line area; the extraction module extracts the central line of the laser line through a gray level gravity center method; the gray level gravity center method comprises the following steps: defining a point to be measured and a neighborhood, wherein the neighborhood is a point adjacent to the point to be measured; judging whether the neighborhood in the laser line area meets the deletion condition.
The correction module is used for correcting the center line and comprises: the correction module is used for calculating the distance from the adjacent point of each end point to the nearest black pixel outside the laser line area; and deleting the error crossing point caused by the burr according to the calculation result.
The trending module is used for inquiring the position information of the central point on the central line, carrying out trending on the central point and obtaining a trending peak value extraction result.
And the calculation module is used for calculating the tearing depth and the tearing width according to the peak value extraction result.
The system further comprises a filtration module; the filtering module is used for setting a threshold value to filter the peak value extraction result.
Those of ordinary skill in the art will appreciate that: although the invention has been described in detail with reference to the foregoing embodiments, it is to be understood that modifications may be made to the technical solutions described in the foregoing embodiments, or equivalents may be substituted for some of the technical features thereof; such modifications and substitutions do not depart from the spirit and scope of the technical solutions of the embodiments of the present invention.
Claims (11)
1. A method for detecting tearing of a conveyor belt based on laser stripe defect identification, the method comprising:
extracting a central line of the laser line area;
correcting the center line;
inquiring the position information of a central point on a central line, performing central point trending, and acquiring a trending peak value extraction result; the trending method comprises the steps of extracting trending elements through a second-order fitting method; the method for obtaining the peak value extraction result comprises the steps of carrying out difference between a trending element and an original data element to obtain the peak value extraction result;
the tear depth and tear width are calculated from the peak extraction results.
2. The method for detecting tearing of conveyor belt based on identification of laser stripe defect according to claim 1, wherein,
the extraction method of the laser line area comprises the steps of setting a self-detection belt mask and black plug matrix analysis.
3. The method for detecting tearing of conveyor belt based on identification of laser stripe defect according to claim 1, wherein,
the central line extraction method of the laser line area comprises a gray level gravity center method;
the gray level gravity center method comprises the following steps:
defining a point to be measured and a neighborhood, wherein the neighborhood is a point adjacent to the point to be measured;
judging whether the neighborhood in the laser line area meets the deletion condition.
4. A conveyor belt tear detection method based on laser stripe defect identification according to claim 3, wherein,
the neighborhood of the center line center includes an intersection point, an end point, and an on-line point.
5. A conveyor belt tear detection method based on laser stripe defect identification as in claim 4 wherein,
the correcting the center line includes:
calculating the distance from the adjacent point of each end point to the nearest black pixel outside the laser line area;
and deleting the error crossing point caused by the burr according to the calculation result.
6. The method for detecting tearing of conveyor belt based on identification of laser stripe defect according to claim 1, wherein,
the tearing depth and the tearing width are obtained through the calculation of the width and the depth of the peak value extraction result respectively.
7. The method for detecting tearing of conveyor belt based on identification of laser stripe defect according to claim 1, wherein,
the method further comprises the following steps of:
and setting a threshold value to filter the peak value extraction result.
8. The conveyor belt tearing detection system based on laser stripe defect identification is characterized by comprising an extraction module, a correction module, a trending module and a calculation module;
the extraction module is used for extracting the laser line area and the central line of the laser line area;
the correction module is used for correcting the center line;
the trending module is used for inquiring the position information of the central point on the central line, carrying out trending on the central point and obtaining a trending peak value extraction result; the trending method comprises the steps of extracting trending elements through a second-order fitting method; the method for obtaining the peak value extraction result comprises the steps of carrying out difference between a trending element and an original data element to obtain the peak value extraction result;
and the calculation module is used for calculating the tearing depth and the tearing width according to the peak value extraction result.
9. A conveyor belt tear detection system based on laser stripe defect identification as in claim 8 further comprising a filtration module;
the filtering module is used for setting a threshold value to filter the peak value extraction result.
10. The conveyor belt tear detection system based on laser stripe defect identification of claim 8 wherein,
the extraction module extracts the central line of the laser line area through a gray level gravity center method;
the gray level gravity center method comprises the following steps:
defining a point to be measured and a neighborhood, wherein the neighborhood is a point adjacent to the point to be measured;
judging whether the neighborhood in the laser line area meets the deletion condition.
11. The conveyor belt tear detection system based on laser stripe defect identification of claim 8 wherein,
the correction module is used for correcting the center line and comprises the following steps:
the correction module is used for calculating the distance from the adjacent point of each end point to the nearest black pixel outside the laser line area;
and deleting the error crossing point caused by the burr according to the calculation result.
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