CN212206470U - Pointer type pressure gauge intelligent verification system - Google Patents
Pointer type pressure gauge intelligent verification system Download PDFInfo
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- CN212206470U CN212206470U CN202020743946.8U CN202020743946U CN212206470U CN 212206470 U CN212206470 U CN 212206470U CN 202020743946 U CN202020743946 U CN 202020743946U CN 212206470 U CN212206470 U CN 212206470U
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Abstract
The utility model relates to a pointer-type manometer intelligence verification system, intelligence verification system includes: the device comprises an image acquisition unit, a knocking mechanism, a moving mechanism, a control unit, an automatic pressure regulating unit and a data processing and analyzing unit. The utility model discloses a machine vision and image processing technique realize the automatic reading of manometer dial plate ID number, precision, unit, full range value, realize effective management, inquiry, derivation etc. of manometer template, examination authority and examination result simultaneously, provide the basis for the follow-up tracking and the management of product. The automatic control of the fixed-point pressure value is completed through the proportional control valve and the PLC, the automation of the verification process is realized, and a rapid, accurate and reliable verification system is provided for the verification of the pointer instrument.
Description
Technical Field
The utility model belongs to the metrological verification field relates to a pointer-type manometer is intelligence verification system in batches.
Background
The pressure gauge is widely applied in scientific research and production departments and industrial and mining enterprises, and at present, a manual reading observation method is adopted no matter quality verification is carried out by pressure gauge manufacturers before the pressure gauge leaves a factory or the pressure gauge is periodically verified by a metrological verification department. The discrimination method is influenced by subjective factors of people such as observation angles, observation distances and the like, and is unstable and low in reliability. And the workload of later data processing is large, and the verification efficiency is low.
SUMMERY OF THE UTILITY MODEL
To the defect that exists among the prior art, the utility model aims to provide a pointer manometer intelligence verification system adopts machine vision and image processing technique, realizes pointer manometer automatic verification and result output, realizes the automation of verification process.
In order to achieve the above purpose, the utility model adopts the technical proposal that:
an intelligent verification system for a pointer pressure gauge comprises: the device comprises an image acquisition unit, a knocking mechanism, a moving mechanism, a control unit, an automatic pressure regulating unit and a data processing and analyzing unit;
the image acquisition unit comprises an industrial camera, a light source and a pneumatic light screen capable of ascending and descending; the number of the industrial cameras and the number of the light sources are equal;
the knocking mechanism comprises an electromagnet and is used for realizing knocking action on the shell of the pressure gauge;
the moving mechanism comprises 4 groups of sliding tables, each group of sliding tables is provided with a stepping motor and a driver, one side of each sliding table is provided with an auxiliary guide rail, 2 groups of sliding tables are used for enabling the image acquisition unit to move up and down front and back, and the other 2 groups of sliding tables are used for enabling the knocking mechanism to move up and down front and back;
the control unit comprises a PLC with 4 high-speed pulse ports, the PLC comprises 40 input interfaces and 40 output interfaces, and a 232 communication expansion module and an AD/DA module are simultaneously arranged; the control unit is used for controlling the starting, stopping, positioning and locking of a stepping motor of the sliding table, controlling the switching of a light source, controlling the adjustment of a proportional control valve and controlling the switching of a main-path electromagnetic valve and a branch-path electromagnetic valve;
the automatic pressure regulating unit is used for regulating the pressure value in the whole pipeline and comprises a main circuit manual valve, a pressure transmitter, a main circuit electromagnetic valve, a proportional control valve and a pressure relief valve on a main circuit, a high-precision pressure transmitter for reading a pressure standard value and a branch electromagnetic valve on a branch of a detected meter; the main-path manual valve is used for controlling the on-off of an air source; the pressure transmitter on the main road is used for detecting the pressure in the main road pipeline; the main path electromagnetic valve is used for controlling the on-off of gas on the main path, the proportional control valve is used for controlling the pressure of the pipeline in the processes of pressure increasing, pressure maintaining and pressure reducing, and the pressure relief valve is used for relieving the pressure of the pipeline in an emergency; the high-precision pressure transmitter is used as a standard device of the verification system, and the pressure value converted by reading the electric signal of the high-precision pressure transmitter is used as a pressure standard value; branch electromagnetic valves on the branches of the checked meter are used for controlling the on-off of each branch gas;
the data processing and analyzing unit comprises an upper computer, and the upper computer is used for indirectly controlling the sliding table to move, the electromagnetic valve to be switched on and switched off and the proportional valve to increase and decrease the pressure through a PLC (programmable logic controller); the upper computer communicates with the high-precision pressure transmitter and the pressure transmitter of the main road through a Modbus pressure transmitter communication protocol, and acquires corresponding pressure values;
the image acquisition unit is connected to an upper computer network interface of the data processing and analyzing unit; the knocking mechanism is connected to an I/O port of a PLC of the control unit through a relay; the sliding table is connected with a high-speed pulse port of the control unit PLC; the PLC of the control unit is connected with a serial port of the upper computer through a 232-to-422 adapter; the pressure transmitter and the high-precision pressure transmitter in the automatic pressure regulating unit are connected to the serial port of the upper computer of the data processing and analyzing unit through 232-to-485 adapter connectors, the branch electromagnetic valve, the main electromagnetic valve and the pressure release valve in the automatic pressure regulating unit are connected to the I/O port of the PLC of the control unit, and the proportional control valve of the automatic pressure regulating unit is connected to the AD/DA module of the PLC of the control unit.
5 branch electromagnetic valves in the automatic pressure regulating unit correspond to 5 pressure gauges; 5 industrial cameras and 5 light sources in the image acquisition unit respectively; the knocking mechanism comprises 5 sets of electromagnets.
The industrial camera is a 500 ten thousand pixel gigabit network interface, and the lens is an electric control lens with variable focus, variable magnification and variable aperture; the light source is a red monochromatic dome light source with the outer diameter of 232 mm.
The number of the high-precision pressure transmitters is three, and each high-precision pressure transmitter is connected with the main circuit through an overflow valve and a manual valve.
The PLC adopts FX3U-80PLC and is provided with an FX3U-232BD communication module, an FX3U-4AD input module and an FX3U-4DA output module; the upper computer communicates with the FX3U-232BD communication module through a Mitsubishi special PLC communication protocol.
An intelligent calibration method for a pointer type pressure gauge comprises the following steps:
(1) a checker logs in the verification system and the system is initialized;
(2) manually performing table-on-table, wherein the pressure gauge model requirements of each batch of detection are consistent, after an inspector selects the pressure gauge model on an operation interface, an intelligent verification system automatically completes pressure gauge configuration parameter setting according to the pressure gauge model, an upper computer issues a sliding table motion command to a PLC (programmable logic controller) through an FX3U-232BD (file format converter) communication module according to the sliding table Y, Z axis position information in the pressure gauge configuration parameters, the PLC controls corresponding sliding table motion to enable an image acquisition unit and a knocking mechanism to move to a preset position set by the sliding table Y, Z axis position information, and a high-precision pressure transmitter with a corresponding range is manually configured to start detection;
(3) opening an industrial camera and a light source, acquiring images of the zero point position of a pointer type pressure gauge according to camera parameters in pressure gauge configuration parameters, transmitting the images to an upper computer after the images are acquired, automatically identifying whether a pressure gauge to be detected exists on each branch by the upper computer, automatically closing an electromagnetic valve and an image acquisition function on a branch without the pressure gauge to be detected, identifying the ID number, the precision, the unit, the full-scale value and the zero point pointer position in the acquired pressure gauge dial image for the branch to be detected, calculating a zero point error and displaying the identification result in an operation interface;
(4) boosting and fixed-point detection: according to the pressure gauge fixed-point detection value of the model in the pressure gauge configuration parameters, the upper computer controls the proportional control valve through the PLC to enable the pressure value in the pipeline to reach the first pressure gauge fixed-point detection value, the upper computer automatically reads the pressure value of the high-precision pressure transmitter to serve as a standard value, meanwhile, the image acquisition unit acquires images of the pressure gauge to be detected, the acquired images are transmitted to the upper computer to automatically read the pressure value and calculate basic errors, and the results are displayed on an operation interface. After the PLC controls the automatic knocking mechanism to knock the dial plate, the image acquisition unit acquires an image of the pressure gauge to be detected, the acquired image is transmitted to the upper computer to automatically read a pressure value, calculate a basic error and knock displacement, and display a result on an operation interface. In the boosting fixed-point detection process, if the calculated basic error at a certain pressure gauge fixed-point detection value exceeds 2 times of the allowed maximum error, closing the branch electromagnetic valve corresponding to the pressure gauge, and recording the branch corresponding to the pressure gauge and the corresponding pressure gauge fixed-point detection value so as to open the corresponding branch electromagnetic valve when the pressure is reduced to the pressure gauge fixed-point detection value;
(5) sequentially boosting the pressure to each pressure gauge fixed point detection value according to the step 4 until the pressure gauge fixed point detection value is a full-scale value, closing each branch solenoid valve of the pressure gauge to be detected to perform pressure maintaining after calculating a basic error and a knocking displacement, acquiring an image of the pressure gauge before pressure maintaining, wherein the pressure maintaining time is selected pressure maintaining time set in detection parameter setting, acquiring images after pressure maintaining, acquiring images before pressure maintaining and after pressure maintaining, comparing a pressure value after pressure maintaining with a pressure value before pressure maintaining, and recording whether the pressure gauge leaks or not;
(6) after the pressure maintaining is finished, the branch electromagnetic valve corresponding to the pressure gauge without the problem of overlarge basic error is opened, and the pressure reduction fixed-point detection is started. The voltage reduction fixed-point detection process is the same as the voltage boosting fixed-point detection process until the zero point, and the voltage reduction process is added with return error calculation. If the basic error is overlarge in the boosting process, closing the pressure gauge of the corresponding branch electromagnetic valve, and opening the corresponding branch electromagnetic valve when the pressure is reduced to the recorded fixed-point detection value of the pressure gauge;
(7) the system is enabled to continuously increase and reduce the pressure, the pressure value of the high-precision pressure transmitter is continuously read, one image is collected every one fiftieth of the full-scale value of the pressure gauge to be detected, and the deflection stability of the pointer of the pressure gauge to be detected is analyzed. Closing the camera, the light source and the branch electromagnetic valves after the verification is finished;
(8) and (4) outputting a verification result: and storing the verification result in an Excel format in a verification report form, and sending the verification result to a specified folder. The verification report content comprises the name, specification and allowable error of a verification pressure gauge, the name, specification, precision and error of a high-precision pressure transmitter, the verification point, basic error, return error, tapping displacement, pointer deflection stability, instrument appearance and verification conclusion of the verification pressure gauge.
In the verification process, the upper computer performs data processing and analysis, and the data processing and analysis comprise: system management, data analysis and processing, result storage and query.
The system management comprises pressure gauge configuration parameter setting, detection parameter setting and user management; the pressure gauge configuration parameters comprise position information of a sliding table Y, Z shaft for a pressure gauge image acquisition unit, camera parameters, position information of a sliding table Y, Z shaft for a knocking mechanism, a pressure gauge fixed point detection value, a precision level, an allowed maximum error, a maximum return stroke difference and a maximum knocking displacement; the detection parameter setting comprises knocking times setting, pressure maintaining time setting and identification result remaining effective digit setting; user management includes user addition, user deletion, and password modification.
The analysis processing of the data comprises image processing and analysis and data calculation in the verification process. The image processing and analysis comprises: reading zero dial information and automatically identifying fixed point scale values, wherein the reading and the automatic identification are realized through Halcon software.
The zero dial information comprises a content ID number, precision, unit and full range value; the zero dial information reading process is as follows:
(1) preprocessing a pressure gauge image acquired at a zero point, including image scaling, rotation and mean value filtering;
(2) performing edge detection on the pressure gauge image through a Canny operator to obtain a pressure gauge edge contour curve, wherein the extracted pressure gauge edge contour curve comprises a plurality of similar circular contour curves; firstly, counting the lengths of all edge contour curves, setting a threshold value according to the lengths, screening out contour curves with contour lengths meeting requirements, firstly calculating the radiuses of all quasi-circular contours in the screened contour curves, then finding out the quasi-circular contour with the smallest radius, finally intercepting from an original image along the quasi-circular contour with the smallest radius to obtain a dial image, and segmenting the dial image from a background;
(3) accurately positioning the information of the extracted dial plate image, and searching X, Y-direction character areas to segment the areas to be extracted according to the position information of the information to be extracted on the input image;
(4) using an OCR model Industrial _ NoRej in Halcon software to identify the ID number, the precision, the unit and the full-scale value on the dial;
the automatic reading of the fixed-point scale value comprises: polar coordinate transformation, primary extraction of scale lines and pointers, scale line acquisition, pointer positioning and geometric calculation;
(1) and (3) polar coordinate transformation: the polar coordinate transformation is to convert the scale marks of the circular instrument into the horizontal direction, and the interchange formula between the rectangular coordinate system and the polar coordinate system is as follows:
p (x, y) is any point in a rectangular coordinate system, rho is the polar diameter of a point P in polar coordinates, and theta is the polar angle of the point P in polar coordinates;
the polar coordinate transformation operator polar _ trans _ image _ ext () is called in Halcon software to realize the conversion of the pressure gauge dial; when the polar _ trans _ image _ ext () operator is called, the circle center coordinates and the radius of the dial acquired in the step (2) in the zero dial information reading process are used as parameters of the polar _ trans _ image _ ext () operator, so that the parameters only depend on the image information of a pressure gauge; shearing the transformed image according to the position characteristics of the dial scale mark distribution, and only keeping the scale mark and the scale value;
(2) preliminarily extracting scale marks and pointers: extracting scale marks and pointers by adopting a method of combining mean filtering and local threshold segmentation; carrying out mean filtering on the cut image by adopting 5 multiplied by 5, then carrying out difference operation on the cut image and the mean filtered image, setting the gray value of the pixel as 0 when the gray value difference is greater than a set threshold value, and setting the gray value of the pixel as 255 when the gray value difference is less than or equal to the set threshold value;
(3) acquiring scale marks: firstly, calling an area arrangement operator in Halcon software, and sequencing the scale marks in sequence according to a column sequencing method from left to right to enable the index value of the first scale mark on the left to be 1; then checking the missing condition of the scale marks of the whole dial, and performing scale mark supplementing treatment according to the unit distance of the scale marks of the dial; the right scale mark is extended according to the unit distance of the dial scale mark, and the right scale mark is extended by 10 unit distances;
(4) pointer positioning: obtaining the region of the key part of the pointer by using an open operator open _ circle (), extracting a proper pointer region according to the area characteristic, and finally obtaining the barycentric coordinate (R) of the pointer by using an operator area _ center ()3，C3)；
(5) And (3) geometric calculation: the center of gravity coordinate of the pointer is used for obtaining a fitted straight line of the sheared middle pointer, the deviation value of the fitted straight line of the pointer and a scale mark with a scale value adjacent to the left side is calculated, the reading of the pointer is obtained by combining the reading of the scale mark adjacent to the left side and the related scale value of a unit, and the expression is as follows:
s is the reading of the pointer; leftvalue is the reading of the adjacent scale line on the left side of the pointer; clColumn coordinates for the left hand side of the pointer adjacent to the tick mark: crThe column coordinate of the right side of the pointer adjacent to the scale mark; cPFitting a linear coordinate for the pointer; unitvalue is a unit scale value.
The result storage and query comprise storage of verification results and query of historical verification records. The storage of the verification result is to store the data in the verification process in a database. The query condition of the historical verification records is set as a checker or time or a pressure gauge ID number, and all verification records of the pressure gauge can be queried.
The utility model has the advantages that: the utility model discloses a pointer-type manometer intelligence verification system adopts machine vision and image processing technique, realizes the automatic reading of manometer dial plate ID number, precision, unit, full range value, realizes effective management, inquiry, derivation etc. of manometer template, examination authority and examination result simultaneously through the database, provides the basis for the follow-up tracking and the management of production enterprise's product. The automatic control of the fixed-point pressure value is completed through the proportional control valve and the PLC, the automation of the verification process is realized, and a rapid, accurate and reliable verification system is provided for the verification of the pointer instrument.
Drawings
The utility model discloses there is following figure:
FIG. 1 is a schematic diagram of an intelligent calibration system for a pointer pressure gauge;
FIG. 2 is a flow chart of an intelligent calibration method for a pointer pressure gauge.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings.
FIG. 1 shows that pointer-type pressure gauge intelligence verification system schematic diagram, pointer-type pressure gauge intelligence verification system includes: the device comprises an image acquisition unit, a knocking mechanism, a moving mechanism, a control unit, an automatic pressure regulating unit and a data processing and analyzing unit. The image acquisition unit is connected to the upper computer network interface of the data processing and analyzing unit. The knocking mechanism is connected to an I/O port of a PLC of the control unit through a relay. The sliding table is connected with a high-speed pulse port of the control unit PLC. The PLC of the control unit is connected with the serial port of the upper computer through a 232-422 conversion joint. Pressure transmitter and 3 high accuracy pressure transmitter in the automatic pressure regulating unit all connect at data processing and analysis unit's host computer serial ports through 232 commentaries on classics 485 crossover subs, and 5 branch road solenoid valves, main road solenoid valve and relief valve in the automatic pressure regulating unit are connected at the IO mouth of the PLC of the control unit, and the proportional control valve of the automatic pressure regulating unit is connected on the AD DA module of the PLC of the control unit. The intelligent verification system has two login identities, namely an administrator and a checker. Different identity login systems have different functions, an administrator has all administration and operation authorities, and a checker only has the authority to verify operation.
The image acquisition unit comprises an industrial camera, a light source and a pneumatic shading plate. The number of the industrial cameras and the number of the light sources are respectively 5, the industrial cameras are 500 ten thousand pixel gigabit network interfaces, and the lenses are three variable (zooming, zooming and iris diaphragm) electrically controlled lenses so as to adapt to pressure gauges of different models. The light source is a red monochromatic dome light source with the outer diameter of 232 mm. The pneumatic light screen can rise and descend, and the light screen descends to the set position under the control of host computer software before the manometer detects the flow and begins, covers the light of dome light source, reduces the harm of light source to inspector's eyes, closes the light source after the detection finishes, and the light screen rises to the set position, makes things convenient for inspector to unload and go up the table.
The knocking mechanism comprises 5 sets of electromagnets and is used for realizing knocking action of the pressure gauge shell.
The moving mechanism comprises 4 groups of sliding tables, each group of sliding tables is provided with a stepping motor and a driver, one side of each sliding table is provided with an auxiliary guide rail, 2 groups of sliding tables are used for enabling the image acquisition unit to move up and down front and back, and the other 2 groups of sliding tables are used for enabling the knocking mechanism to move up and down front and back. The image acquisition unit moves up and down and back to meet the object distance of pressure gauges of different models; the centers of the pressure gauges of different models are adjusted to be coaxial with the focus of the industrial camera, so that dial images of the pressure gauges of different models can be completely in the field of view of the industrial camera and the whole screen can be filled as far as possible. The knocking mechanism moves up and down and back and forth so as to realize automatic knocking on pressure gauges of different models.
The control unit mainly comprises a PLC with 4 high-speed pulse ports, and comprises 40 input interfaces, 40 output interfaces, 232 communication expansion modules and AD/DA modules. The main functions are to control the start, stop, positioning and locking of the stepping motor of the sliding table, control the on and off of the light source, control the adjustment of the proportional control valve and control the on and off of the main path electromagnetic valve and the branch path electromagnetic valve. The utility model discloses select for use FX3U-80PLC of Mitsubishi company to be equipped with FX3U-232BD communication module, FX3U-4AD input module and FX3U-4DA output module.
The automatic pressure regulating unit is mainly used for regulating the pressure value in the whole pipeline according to requirements and comprises a main-circuit manual valve, a pressure transmitter, a main-circuit electromagnetic valve, a proportional control valve, a pressure release valve, a high-precision pressure transmitter and a branch electromagnetic valve, wherein the main-circuit manual valve, the pressure transmitter, the main-circuit electromagnetic valve, the proportional control valve and the pressure release valve are arranged on a main circuit, the high-precision pressure transmitter is used for reading. Three high-precision pressure transmitters are provided, and each high-precision pressure transmitter is connected with the main circuit through an overflow valve and a manual valve; the main-path manual valve is used for controlling the on-off of an air source; the pressure transmitter on the main road is used for detecting the pressure in the main road pipeline and ensuring that the pressure is in a specified range; the main circuit electromagnetic valve is used for controlling the on-off of gas on the main circuit, the proportional control valve is used for controlling the pressure of a pipeline in the processes of boosting, pressure maintaining and pressure reducing, the pressure relief valve is used for relieving the pressure of the pipeline in emergency situations, the high-precision pressure transmitter is used as a standard device of the verification system, the pressure value converted by reading an electric signal of the high-precision pressure transmitter is used as a pressure standard value, a plurality of or one pressure transmitter with different measuring ranges and different precisions can be automatically selected according to verification requirements, and the branch electromagnetic valves on the branches of the tested meter are used.
The pressure control of the automatic pressure regulating unit is divided into three stages: boosting pressure, maintaining pressure and reducing pressure. And (3) boosting process control: the model of the pressure gauge is selected on the operation interface, and all fixed points of the pressure gauge of the model are sequentially detected according to the requirements in the configuration parameters of the pressure gauge. The upper computer issues a fixed-point detection pressure value to the PLC through the FX3U-232BD communication module, the PLC adjusts the main path pressure value to a fixed-point pressure value through the opening and closing angle of the proportional control valve timely adjusted through the FX3U-4DA module, meanwhile, the PLC obtains the current system pressure value from the proportional control valve in real time through the FX3U-4AD module, data are transmitted to upper computer software through the FX3U-232BD communication module, then the upper computer reads the pressure value of the high-precision pressure transmitter through a serial port connected with the high-precision pressure transmitter to serve as a record, and meanwhile, the industrial camera shoots a pressure gauge image. And then the system boosts the pressure to the next fixed-point detection value of the pressure gauge, and the process is repeated until the maximum measuring range of the pressure gauge is reached. Pressure maintaining: and the branch electromagnetic valves of all the branches are closed for a certain time, and the industrial camera shoots images before and after pressure maintaining of the pressure gauge. The pressure reduction process is the same as the pressure boosting process.
The data processing and analyzing unit mainly comprises an industrial personal computer, namely an upper computer which is a core part of the intelligent verification system, the upper computer is communicated with an FX3U-232BD communication module in the PLC through a Mitsubishi special PLC communication protocol, and the upper computer indirectly controls mechanical actions such as sliding table movement, electromagnetic valve switching and the like, and the proportional valve is used for increasing and decreasing pressure. And the upper computer communicates with the high-precision pressure transmitter and the pressure transmitter of the main road through a Modbus pressure transmitter communication protocol to acquire corresponding pressure values.
As shown in fig. 2, an intelligent calibration method for a pointer pressure gauge includes the following steps:
(1) a checker logs in the verification system and the system is initialized;
(2) manually performing table-on-table, wherein the pressure gauge model requirements of each batch of detection are consistent, after an inspector selects the pressure gauge model on an operation interface, an intelligent verification system automatically completes pressure gauge configuration parameter setting according to the pressure gauge model, an upper computer issues a sliding table motion command to a PLC (programmable logic controller) through an FX3U-232BD (file format converter) communication module according to the sliding table Y, Z axis position information in the pressure gauge configuration parameters, the PLC controls corresponding sliding table motion to enable an image acquisition unit and a knocking mechanism to move to a preset position set by the sliding table Y, Z axis position information, and a high-precision pressure transmitter with a corresponding range is manually configured to start detection;
(3) opening an industrial camera and a light source, acquiring images of the zero point position of a pointer type pressure gauge according to camera parameters in pressure gauge configuration parameters, transmitting the images to an upper computer after the images are acquired, automatically identifying whether a pressure gauge to be detected exists on each branch by the upper computer, automatically closing an electromagnetic valve and an image acquisition function on a branch without the pressure gauge to be detected, identifying the ID number, the precision, the unit, the full-scale value and the zero point pointer position in the acquired pressure gauge dial image for the branch to be detected, calculating a zero point error and displaying the identification result in an operation interface;
(4) boosting and fixed-point detection: according to the pressure gauge fixed-point detection value of the model in the pressure gauge configuration parameters, the upper computer controls the proportional control valve through the PLC to enable the pressure value in the pipeline to reach the first pressure gauge fixed-point detection value, the upper computer automatically reads the pressure value of the high-precision pressure transmitter to serve as a standard value, meanwhile, the image acquisition unit acquires images of the pressure gauge to be detected, the acquired images are transmitted to the upper computer to automatically read the pressure value and calculate basic errors, and the results are displayed on an operation interface. After the PLC controls the automatic knocking mechanism to knock the dial plate, the image acquisition unit acquires an image of the pressure gauge to be detected, the acquired image is transmitted to the upper computer to automatically read a pressure value, calculate a basic error and knock displacement, and display a result on an operation interface. In the boosting fixed-point detection process, if the calculated basic error at a certain pressure gauge fixed-point detection value exceeds 2 times of the allowed maximum error, closing the branch electromagnetic valve corresponding to the pressure gauge, and recording the branch corresponding to the pressure gauge and the corresponding pressure gauge fixed-point detection value so as to open the corresponding branch electromagnetic valve when the pressure is reduced to the pressure gauge fixed-point detection value;
(5) sequentially boosting the pressure to each pressure gauge fixed point detection value according to the step 4 until the pressure gauge fixed point detection value is a full-scale value, closing each branch solenoid valve of the pressure gauge to be detected to perform pressure maintaining after calculating a basic error and a knocking displacement, acquiring an image of the pressure gauge before pressure maintaining, wherein the pressure maintaining time is the pressure maintaining time set in the detection parameter setting, acquiring an image after pressure maintaining is finished, comparing the pressure value after pressure maintaining with the pressure value before pressure maintaining, and recording whether the pressure gauge leaks or not;
(6) after the pressure maintaining is finished, the branch electromagnetic valve corresponding to the pressure gauge without the problem of overlarge basic error is opened, and the pressure reduction fixed-point detection is started. The voltage reduction fixed-point detection process is the same as the voltage boosting fixed-point detection process until the zero point, and the voltage reduction process is added with return error calculation. And if the basic error is overlarge in the boosting process, closing the pressure gauge of the corresponding branch electromagnetic valve, and opening the corresponding branch electromagnetic valve when the pressure is reduced to the recorded fixed-point detection value of the pressure gauge.
(7) The system is enabled to continuously increase and reduce the pressure, the pressure value of the high-precision pressure transmitter is continuously read, one image is collected every one fiftieth of the full-scale value of the pressure gauge to be detected, and the deflection stability of the pointer of the pressure gauge to be detected is analyzed. Closing the camera, the light source and the branch electromagnetic valves after the verification is finished;
(8) and (6) outputting the verification result. And storing the verification result in an Excel format in a verification report form, and sending the verification result to a specified folder. The verification report content comprises the name, specification and allowable error of a verification pressure gauge, the name, specification, precision and error of a high-precision pressure transmitter, the verification point, basic error, return error, tapping displacement, pointer deflection stability, instrument appearance and verification conclusion of the verification pressure gauge.
In the verification process, the upper computer performs data processing and analysis, and the data processing and analysis comprise: system management, data analysis and processing, result storage and query.
The system management comprises pressure gauge configuration parameter setting, detection parameter setting and user management. The pressure gauge configuration parameters comprise position information of a sliding table Y (front and back) and Z (up and down) axes and camera parameters (including a camera focal length and an amplification ratio) of the pressure gauge image acquisition unit, position information of the sliding table Y (front and back) and Z (up and down) axes of the knocking mechanism, a fixed point detection value of the pressure gauge, a precision level, an allowed maximum error, a maximum return stroke difference and a maximum knocking displacement. The user with the pressure gauge configuration parameter authority can create, modify or delete the pressure gauge configuration parameters according to the pressure gauge model. The detection parameter setting comprises knocking times setting, pressure maintaining time setting and identification result remaining effective digit setting. User management includes user addition, user deletion, and password modification.
The analysis and processing of the data comprise image processing and analysis and calculation of various data in the verification process. The core of the method is image processing and analysis, which comprises the following steps: reading zero dial information and automatically identifying fixed point scale values, wherein the reading and the automatic identification are realized through Halcon software.
The zero dial information includes content ID number, accuracy, unit, full scale value. The zero dial information reading process:
(1) and preprocessing the pressure gauge image acquired at the zero point, including image scaling, rotation and mean value filtering. Because the installation of industrial camera and manometer has mechanical error, and there is the difference in the manometer image that five industrial cameras shoot, so through the image zoom to preset size and rotate to preset angle guarantee five image's uniformity. The purpose of the mean filtering is to suppress noise and make the effective area of the image clearer.
(2) The edge detection is carried out on the pressure gauge image through a Canny operator to obtain a pressure gauge edge contour curve, and the acquired pressure gauge image is provided with a dial plate and a shell, so that the extracted pressure gauge edge contour curve is provided with a plurality of similar circular contour curves. The utility model discloses a method is according to the size characteristics and the shape characteristics of zooming back dial plate come the accurate dial plate profile of selecting. Firstly, the lengths of all edge contour curves obtained by edge detection of a table through a Canny operator are counted, contour curves with contour lengths meeting requirements are screened out according to the lengths by setting a threshold, and a quasi-circular contour closest to the center of a circle is found out from the screened contour curves. Because the radius of the quasi-circular outline closest to the center of the circle is the minimum, the radius of all quasi-circular outlines is calculated first, and then the quasi-circular outline with the minimum radius is found. And finally, a dial image is obtained by intercepting the original image along the circular outline, namely the dial image is segmented from the background.
(3) And carrying out information accurate positioning on the extracted dial plate image. The character region in the direction of X, Y is searched for to segment the region to be extracted through the position information of the information to be extracted on the input image.
(4) And using an OCR model Industrial _ NoRej in Halcon software to identify the ID number, the precision, the unit and the full-scale value on the dial.
The automatic reading of the fixed point scale value mainly comprises the following steps: polar coordinate transformation, initial extraction of scale lines and pointers, scale line acquisition, pointer positioning and geometric calculation.
(1) And (5) polar coordinate transformation. The polar coordinate transformation is to convert the scale lines of the circular instrument into the horizontal direction. The interchange formula between the rectangular coordinate system and the polar coordinate system is as follows:
p (x, y) is any point in a rectangular coordinate system, ρ is the polar diameter of the point P in polar coordinates, and θ is the polar angle of the point P in polar coordinates.
The polar coordinate transformation operator polar _ trans _ image _ ext () is called in the Halcon software to realize the conversion of the pressure meter dial. When the polar _ trans _ image _ ext () operator is called, the circle center coordinates and the radius of the dial acquired in the step 2 in the zero dial information reading process are used as parameters of the polar _ trans _ image _ ext () operator, so that the polar _ trans _ image _ ext () operator only depends on the image information of the pressure gauge, and the polar _ trans _ image _ ext () operator is suitable for various different pointer pressure gauges. The scale value of the pointer type pressure gauge is automatically read mainly by determining the position of the pointer, the position of the scale mark and the position relation between the pointer and the scale mark, so that the converted image is cut according to the distributed position characteristics of the scale mark of the dial plate, and only the scale mark and the scale value are reserved.
(2) And preliminarily extracting scale marks and pointers. And extracting scale marks and pointers by adopting a method of combining mean filtering and local threshold segmentation. And performing mean filtering on the sheared image by adopting 5 multiplied by 5, performing difference operation on the sheared image and the mean filtered image, setting the gray value of the pixel as 0 when the gray value difference is greater than a set threshold, and setting the gray value of the pixel as 255 when the gray value difference is less than or equal to the set threshold, so that the local threshold segmentation of the sheared image is realized.
(3) And acquiring scale marks. Firstly, calling an area arrangement operator in Halcon software, and sequencing the scale marks in sequence according to a column sequencing method from left to right to enable the index value of the first scale mark on the left to be 1; and then checking the missing condition of the scale marks of the whole dial, and performing scale mark supplementing treatment according to the unit distance of the scale marks of the dial. Because the system has certain error in automatic pressure regulation, and an overpressure condition exists at a full-scale point during constant pressure detection, in order to automatically read a pressure value exceeding the full-scale, the right scale mark (subsequent to the full-scale value) needs to be extended according to the unit distance of the scale mark of the dial. The utility model discloses the scale mark extension of the right is 10 unit distances.
(4) And positioning the pointer. Obtaining the region of the key part of the pointer by using an open operator open _ circle (), extracting a proper pointer region according to the area characteristic, and finally obtaining the barycentric coordinate (R) of the pointer by using an operator area _ center ()3，C3)。
(5) And (4) geometric calculation. The center of gravity coordinate of the pointer is used for obtaining a fitted straight line of the sheared middle pointer, the deviation value of the fitted straight line of the pointer and a scale mark with a scale value adjacent to the left side is calculated, the reading of the pointer is obtained by combining the reading of the scale mark adjacent to the left side and the related scale value of a unit, and the expression is as follows:
s is the reading of the pointer; leftvalue is the reading of the adjacent scale line on the left side of the pointer; clColumn coordinates for the left hand side of the pointer adjacent to the tick mark: crThe column coordinate of the right side of the pointer adjacent to the scale mark; cPFitting a linear coordinate for the pointer; unitvalue is a unit scale value.
The result storage and query mainly comprise the storage of the verification result and the query of the historical verification record. The storage of the verification result is mainly to store the data in the verification process in a database. The query condition of the historical verification record is set as a checker or time or a pressure gauge ID number, and all verification records of the pressure gauge can be queried, so that relevant personnel can know the overall situation in the verification process of the pressure gauge and provide reference for later use.
The above embodiments are only used for illustrating the present invention, and are not intended to limit the present invention, and those skilled in the relevant art can make various changes and modifications without departing from the spirit and scope of the present invention, and therefore all equivalent technical solutions also belong to the protection scope of the present invention.
Those not described in detail in this specification are within the skill of the art.
Claims (5)
1. The utility model provides a pointer manometer intelligence verification system which characterized in that includes: the device comprises an image acquisition unit, a knocking mechanism, a moving mechanism, a control unit, an automatic pressure regulating unit and a data processing and analyzing unit;
the image acquisition unit comprises an industrial camera, a light source and a pneumatic light screen capable of ascending and descending; the number of the industrial cameras and the number of the light sources are equal;
the knocking mechanism comprises an electromagnet and is used for realizing knocking action on the shell of the pressure gauge;
the moving mechanism comprises 4 groups of sliding tables, each group of sliding tables is provided with a stepping motor and a driver, one side of each sliding table is provided with an auxiliary guide rail, 2 groups of sliding tables are used for enabling the image acquisition unit to move up and down front and back, and the other 2 groups of sliding tables are used for enabling the knocking mechanism to move up and down front and back;
the control unit comprises a PLC with 4 high-speed pulse ports, the PLC comprises 40 input interfaces and 40 output interfaces, and a 232 communication expansion module and an AD/DA module are simultaneously arranged; the control unit is used for controlling the starting, stopping, positioning and locking of a stepping motor of the sliding table, controlling the switching of a light source, controlling the adjustment of a proportional control valve and controlling the switching of a main-path electromagnetic valve and a branch-path electromagnetic valve;
the automatic pressure regulating unit is used for regulating the pressure value in the whole pipeline and comprises a main circuit manual valve, a pressure transmitter, a main circuit electromagnetic valve, a proportional control valve and a pressure relief valve on a main circuit, a high-precision pressure transmitter for reading a pressure standard value and a branch electromagnetic valve on a branch of a detected meter; the main-path manual valve is used for controlling the on-off of an air source; the pressure transmitter on the main road is used for detecting the pressure in the main road pipeline; the main path electromagnetic valve is used for controlling the on-off of gas on the main path, the proportional control valve is used for controlling the pressure of the pipeline in the processes of pressure increasing, pressure maintaining and pressure reducing, and the pressure relief valve is used for relieving the pressure of the pipeline in an emergency; the high-precision pressure transmitter is used as a standard device of the verification system, and the pressure value converted by reading the electric signal of the high-precision pressure transmitter is used as a pressure standard value; branch electromagnetic valves on the branches of the checked meter are used for controlling the on-off of each branch gas;
the data processing and analyzing unit comprises an upper computer, and the upper computer is used for indirectly controlling the sliding table to move, the electromagnetic valve to be switched on and switched off and the proportional valve to increase and decrease the pressure through a PLC (programmable logic controller); the upper computer communicates with the high-precision pressure transmitter and the pressure transmitter of the main road through a Modbus pressure transmitter communication protocol, and acquires corresponding pressure values;
the image acquisition unit is connected to an upper computer network interface of the data processing and analyzing unit; the knocking mechanism is connected to an I/O port of a PLC of the control unit through a relay; the sliding table is connected with a high-speed pulse port of the control unit PLC; the PLC of the control unit is connected with a serial port of the upper computer through a 232-to-422 adapter; the pressure transmitter and the high-precision pressure transmitter in the automatic pressure regulating unit are connected to the serial port of the upper computer of the data processing and analyzing unit through 232-to-485 adapter connectors, the branch electromagnetic valve, the main electromagnetic valve and the pressure release valve in the automatic pressure regulating unit are connected to the I/O port of the PLC of the control unit, and the proportional control valve of the automatic pressure regulating unit is connected to the AD/DA module of the PLC of the control unit.
2. The intelligent verification system for pointer pressure gauges as claimed in claim 1, wherein: 5 branch electromagnetic valves in the automatic pressure regulating unit correspond to 5 pressure gauges; 5 industrial cameras and 5 light sources in the image acquisition unit respectively; the knocking mechanism comprises 5 sets of electromagnets.
3. The intelligent verification system for pointer pressure gauges as claimed in claim 1, wherein: the industrial camera is a 500 ten thousand pixel gigabit network interface, and the lens is an electric control lens with variable focus, variable magnification and variable aperture; the light source is a red monochromatic dome light source with the outer diameter of 232 mm.
4. The intelligent verification system for pointer pressure gauges as claimed in claim 1, wherein: the number of the high-precision pressure transmitters is three, and each high-precision pressure transmitter is connected with the main circuit through an overflow valve and a manual valve.
5. The intelligent verification system for pointer pressure gauges as claimed in claim 1, wherein: the PLC adopts FX3U-80PLC and is provided with an FX3U-232BD communication module, an FX3U-4AD input module and an FX3U-4DA output module; the upper computer communicates with the FX3U-232BD communication module through a Mitsubishi special PLC communication protocol.
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| CN111521321A (en) * | 2020-05-08 | 2020-08-11 | 北京京仪仪器仪表研究总院有限公司 | Intelligent verification system and method for pointer type pressure gauge |
| CN112633291A (en) * | 2020-12-24 | 2021-04-09 | 上海精密计量测试研究所 | Automatic calibrating device and calibrating method for pressure instrument |
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| CN114813031A (en) * | 2022-07-01 | 2022-07-29 | 中国航空工业集团公司沈阳空气动力研究所 | Wide-range high-precision pressure measuring device and method for wind tunnel test |
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| CN112633291A (en) * | 2020-12-24 | 2021-04-09 | 上海精密计量测试研究所 | Automatic calibrating device and calibrating method for pressure instrument |
| CN112798179A (en) * | 2020-12-24 | 2021-05-14 | 上海精密计量测试研究所 | Pressure instrument verification visual acquisition device |
| CN113063543A (en) * | 2021-03-15 | 2021-07-02 | 金仪计量科技(苏州)有限公司 | Pressure gauge calibration method and calibration system |
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| CN114264407A (en) * | 2021-12-29 | 2022-04-01 | 江南大学 | Method for detecting measurement accuracy of pointer type pressure gauge, computer medium and computer |
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| CN114813031B (en) * | 2022-07-01 | 2022-09-30 | 中国航空工业集团公司沈阳空气动力研究所 | Wide-range high-precision pressure measuring device and method for wind tunnel test |
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