Conveyer belt tears monitoring devices and has transfer chain that tears monitoring devices
Technical Field
The utility model belongs to the technical field of the conveyer belt detects, concretely relates to monitoring devices is torn to the conveyer belt and has transfer chain of tearing monitoring devices.
Background
The belt conveying mode is an important mode for transporting materials in ports, steel plants and other related enterprises, and due to the fact that complicated industrial and mining conditions and abnormally transported materials can cause longitudinal tearing accidents of the conveying belt under unexpected conditions, if the materials are found out untimely, the whole belt can be torn and damaged, and huge economic loss is caused. In order to solve the technical problem, a plurality of methods are proposed at home and abroad for tear-resistant detection of the conveyer belt, such as an ultrasonic method (detecting ultrasonic wave propagation in a belt medium), abnormal bearing roller stress detection (analyzing abnormal states of bearing roller stress), a piezoresistor method (detecting leakage below the belt), machine vision (extracting characteristics of belt tearing and judging according to an intelligent algorithm) and the like.
The machine vision mode is a detection means proposed in recent years, and has the advantages of non-contact mode, no need of modifying conveying belt equipment and convenience in installation. However, due to the complexity of the image processing algorithm, the operation requirement of online real-time detection cannot be met, and meanwhile, the display of the image is inaccurate due to many influence factors of visible light, such as dust, fog and the like, and the whole detection result is inaccurate from the source. Even the influence factor of environment has been solved, it is also not enough to be can be timely tear the damage to the conveyer belt and report to the police to rely on infrared or visible light alone, and the conveyer belt is torn or the damage is the proruption incident, simultaneously because monitoring facilities's mounted position leads to only tearing when taking place and run through the belt at the conveyer belt indulges, could monitored by monitoring facilities monitor. Finally, the machine vision type detection method in the prior art cannot accurately detect the tear on the conveying line in an all-around and high-efficiency manner, so that the conveying efficiency of the conveying line is also affected.
SUMMERY OF THE UTILITY MODEL
To the not enough of above-mentioned prior art, the utility model provides a monitoring devices is torn to conveyer belt, the purpose is that tearing on the transfer chain can't all-round, high-efficiently detect accurately in order to solve the machine vision mode detection mode among the prior art, therefore the technical problem of the influence that has also produced the conveying efficiency of transfer chain. Furthermore, the utility model also provides a transfer chain and monitoring method with tear monitoring devices.
The utility model provides a monitoring devices is torn to conveyer belt, concrete technical scheme as follows:
monitoring devices is torn to conveyer belt, including installed part, infrared detection mechanism and degree of depth detection mechanism, the installed part is installed on the frame of conveyer belt, infrared detection mechanism with degree of depth detection mechanism orientation the conveyer belt, infrared detection mechanism with degree of depth detection mechanism all installs on the installed part.
In some embodiments, the infrared detection mechanism is a thermal imaging camera and the depth detection mechanism is a depth camera.
In some embodiments, the device further comprises a high-speed image capturing mechanism, wherein the high-speed image capturing mechanism is mounted on the mounting member and faces the conveying belt.
In some embodiments, the high-speed image capturing mechanism is a high-speed camera.
By adopting an infrared detection and optical depth detection technology, the influence of the field working condition environment on image acquisition can be reduced through the principle of thermal imaging, the non-contact characteristic is realized, and the defects that infrared detection or visible light detection cannot timely alarm the tearing and damage of the conveying belt and the detection result is inaccurate can be overcome.
The utility model also provides a transfer chain with tear monitoring devices, tear monitoring devices including frame, conveyer belt, power device, tensioning part and at least one foretell conveyer belt, the conveyer belt is connected power device with tensioning part is striden and is established on the frame, the conveyer belt is torn monitoring devices and is installed on the support body of frame, just monitoring devices's detection direction orientation upper strata is torn to the conveyer belt the back and the upper strata of conveyer belt the front of conveyer belt.
In some embodiments, the mounting member includes an upper mounting portion and a lower mounting portion, the upper mounting portion is located on the upper layer above the conveyer belt, the lower mounting portion is arranged between the conveyer belts, the infrared detection mechanism is mounted on the upper mounting portion, a detection direction of the infrared detection mechanism faces the upper layer, a back face of the conveyer belt, the depth detection mechanism is mounted on the lower mounting portion, and a detection direction of the depth detection mechanism faces the upper layer, a front face of the conveyer belt.
In some embodiments, the device further comprises a high-speed image capturing mechanism, the high-speed image capturing mechanism is mounted on the upper mounting portion, and a detection direction of the high-speed image capturing mechanism faces the back surface of the upper layer of the conveying belt.
In some embodiments, the tensioning section comprises a tensioning roller and a tensioning frame, the tensioning roller being mounted on the tensioning frame; the power device comprises a motor and a transmission roller, and the motor drives the transmission roller to rotate; the frame is also provided with a plurality of lifting rollers.
By adopting the infrared detection and optical depth detection technology, the influence of the field working condition environment on image acquisition can be reduced through the principle of thermal imaging, the non-contact characteristic is achieved, the defects that infrared detection or visible light detection cannot timely alarm the tearing damage of the conveying belt and the detection result is inaccurate can be overcome, and therefore the conveying efficiency of the conveying line is improved. In addition, not only has realized the detection to the tearing of conveyer belt through the degree of depth detection mechanism that is located upper conveyer belt top, can also in time acquire the goods information that causes the tearing of conveyer belt to adjust the parameter of transfer chain, and then guaranteed the operation stability of transfer chain.
In addition, the monitoring method for the tearing of the conveyer belt of the conveying line with the tearing monitoring device comprises the following steps:
step S1: an infrared detection mechanism collects heat infrared images on the conveying belt;
step S2: graying the thermal infrared image obtained in the step S1 to obtain a grayscale image;
step S3: carrying out binarization processing on the gray level image of the step S2 to obtain a binarized image;
step S4: the depth detection mechanism collects a depth 3D image of the conveying belt;
step S5: performing depth image processing on the depth 3D map of the step S4 to obtain a depth map;
step S6: performing image morphology processing on the binarized image of the step S3 and the depth map of the step S5 to respectively obtain a highlight difference map and a depth difference map;
step S7: comparing the image similarity of the highlight difference image and the depth difference image in the step S6 with the images in the sample library, and comparing the relative temperature of the temperature data acquired by the infrared detection mechanism;
step S8: if the highlight difference graph reaches the similarity threshold, the step S9 is carried out; if the depth difference map reaches the similarity threshold, the process proceeds to step S12; the highlight difference image and the depth difference image do not reach a similarity threshold value, and if the temperature data do not reach the temperature threshold value, information data collected by the conveyor belt tearing monitoring device are removed;
step S9: carrying out quantity statistics on the highlight difference graphs entering the step;
step S10: judging the length and the width of the highlight difference image,
step S11: step S12 is carried out if the length and width value of the highlight difference map exceeds the preset length and width parameter, and the information data collected by the conveyor belt tearing monitoring device are removed if the length and width value of the highlight difference map is within the preset length and width parameter;
step S12: and storing the highlight difference image and the depth difference image into a sample library, and sending a tearing alarm signal.
The utility model discloses an infrared detection allies oneself with uses optics degree of depth detection technique can compensate infrared detection missing judgement, improves accuracy and the high efficiency of tearing the monitoring to the conveyer belt, in addition, through the sample storehouse that constantly increases, increases the learning ability of the system of self, also can increase the analytical ability of system simultaneously.
Drawings
FIG. 1 is a conveyor line with a tear monitoring device provided by the present invention;
fig. 2 is a schematic plan view of embodiment 1 of the present invention;
fig. 3 is a flowchart of a method for monitoring tearing of a conveyor belt according to embodiment 2 of the present invention;
fig. 4 is a thermal infrared image of a normal and intact conveyer belt in the conveyer belt tearing monitoring method provided in embodiment 2 of the present invention;
fig. 5 is a thermal infrared image of an un-torn conveyer belt in the conveyer belt tearing monitoring method provided in embodiment 2 of the present invention;
FIG. 6 is a highlight disparity map of FIG. 5 after processing;
fig. 7 is a thermal infrared image of a torn conveyer belt in the method for monitoring tearing of a conveyer belt according to embodiment 2 of the present invention;
FIG. 8 is a highlight disparity map of FIG. 7 after processing;
fig. 9 is a thermal infrared image of a torn conveyer belt in the method for monitoring tearing of a conveyer belt according to embodiment 2 of the present invention;
FIG. 10 is a highlight disparity map of FIG. 9 after processing.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention will be described in further detail below with reference to specific embodiments 1 to 10, and with reference to the accompanying drawings.
Example 1
As shown in fig. 2, the conveyer belt tearing monitoring device provided by this embodiment has the following specific technical solutions:
monitoring devices is torn to conveyer belt, including installed part, infrared detection mechanism 4 and degree of depth detection mechanism 2, the installed part is installed on the frame 9 of conveyer belt, and infrared detection mechanism 4 and degree of depth detection mechanism 2 are all installed on the installed part towards the conveyer belt, infrared detection mechanism 4 and degree of depth detection mechanism 2. Through the setting of infrared detection mechanism 4, the phenomenon of generating heat of the local production of conveyer belt before taking place to tear has been guaranteed to the conveyer belt can be acquireed and the perception to can early warning the tearing condition of conveyer belt in advance, utilize degree of depth detection mechanism 2 to detect the tearing degree of depth of conveyer belt, tear the damage and report to the police to the conveyer belt with remedying infrared detection or visible light detection can't be timely, and the inaccurate not enough of testing result.
Specifically, the infrared detection mechanism 4 is a thermal imaging camera, and the depth detection mechanism 2 is a depth camera.
In some embodiments, the device further comprises a high-speed image capturing mechanism 5, wherein the high-speed image capturing mechanism 5 is mounted on the mounting member, and the high-speed image capturing mechanism 5 faces the conveying belt. The high-speed image capturing mechanism 5 is used for performing image capturing recording on the running process of the conveying belt, is convenient for review and re-coiling, and inspects the reason for tearing the conveying belt.
Specifically, the high-speed image capturing mechanism 5 is a high-speed camera.
Example 2
As shown in fig. 1, the conveyor line with the tear monitoring device provided in this embodiment includes a frame 9, conveyor belts (an upper conveyor belt 3 and a lower conveyor belt 7), a power device 10, a tensioning portion 8, and at least one conveyor belt tear monitoring device of embodiment 1, the conveyor belt connects the power device 10 and the tensioning portion 8 and spans over the frame 9, the conveyor belt tear monitoring device is installed on a frame body of the frame 9, and a detection direction of the conveyor belt tear monitoring device faces a back surface of the upper conveyor belt 3 and a front surface of the upper conveyor belt 3. So all have all-round and efficient control to the back and the front of upper conveyer belt 3, in time acquire the goods information that causes the conveyer belt to tear simultaneously to adjust the parameter of transfer chain, and then guaranteed the operation stability of transfer chain.
Further, the installed part includes installation department 1 and lower installation department 6, and installation department 1 is located the top of upper conveyer belt 3 on going up, and lower installation department 6 is arranged in between the conveyer belt, and infrared detection mechanism 4 installs on installation department 1, and infrared detection mechanism 4's direction of detection is towards the back of upper conveyer belt 3, and degree of depth detection mechanism 2 installs in lower installation department 6, and degree of depth detection mechanism 2's direction of detection is towards the front of upper conveyer belt 3. The last installation department 1 and the lower installation department 6 of installed part all have all-round and efficient control to provide the structure basis for realizing the back and the front of upper conveyer belt 3.
Further, the device also comprises a high-speed image capturing mechanism 5, wherein the high-speed image capturing mechanism 5 is mounted on the upper mounting part 1, and the detection direction of the high-speed image capturing mechanism 5 faces the back surface of the upper-layer conveying belt 3. The high-speed image capturing mechanism 5 is used for capturing images of the whole running process of the conveying belt at a high speed, so that not only is comprehensive monitoring realized, but also the reason for tearing the conveying belt is conveniently checked.
Further, the tensioning part 8 comprises a tensioning roller and a tensioning frame, and the tensioning roller is mounted on the tensioning frame; the power device 10 comprises a motor and a transmission roller, and the motor drives the transmission roller to rotate; a plurality of lifting rollers are also arranged on the frame 9. The conveying line is also provided with a feeding part 11 and a discharging part 12, the feeding part 11 is erected on the frame 9 and is arranged on one side close to the tensioning part 8, and the discharging part 12 is arranged at one end of the power device 10.
The monitoring method for the tearing of the conveying belt of the conveying line with the tearing monitoring device applied to the embodiment comprises the following steps of:
step S1: the infrared detection mechanism 4 collects heat infrared images on the conveying belt;
step S2: graying the thermal infrared image obtained in the step S1 to obtain a grayscale image;
step S3: carrying out binarization processing on the gray level image of the step S2 to obtain a binarized image;
step S4: the depth detection mechanism 2 collects a depth 3D image of the conveying belt;
step S5: performing depth image processing on the depth 3D map of the step S4 to obtain a depth map;
step S6: performing image morphology processing on the binarized image of the step S3 and the depth map of the step S5 to respectively obtain a highlight difference map and a depth difference map;
step S7: comparing the image similarity of the highlight difference image and the depth difference image in the step S6 with the images in the sample library, and comparing the relative temperature of the temperature data acquired by the infrared detection mechanism 4;
step S8: if the highlight difference graph reaches the similarity threshold, the step S9 is executed; if the depth difference map reaches the similarity threshold, the process proceeds to step S12; if the highlight difference image and the depth difference image do not reach the similarity threshold value and the temperature data do not reach the temperature threshold value, removing the information data collected by the conveyor belt tearing monitoring device;
step S9: carrying out quantity statistics on the highlight difference graphs entering the step;
step S10: the length and the width of the highlight difference image are judged,
step S11: if the length and width values of the highlight difference map exceed the preset length and width parameters, the step S12 is carried out, and if the length and width values of the highlight difference map are within the preset length and width parameters, the information data collected by the conveyor belt tearing monitoring device are removed;
step S12: storing the highlight difference image and the depth difference image into a sample library, and sending a tearing alarm signal.
Judging abnormal temperature display according to a real-time change curve of the surface temperature of the conveying belt and then according to a temperature characterization algorithm model, if abnormal temperature exists, performing characteristic processing on a thermal imaging graph and a depth graph, wherein the thermal imaging graph shows a strip-shaped high-brightness area (shown in figures 4-10) after being processed, and finally performing similarity comparison with a defect sample library in a tearing monitoring system, wherein the similarity is more than 70%, and the system is primarily judged to be torn. And then, reading the depth of the initially determined tearing area by using a depth 3D image, wherein the depth difference between the area and other areas reaches a certain degree, the depth difference area is also in a strip shape, the area can be determined as longitudinal tearing, the abnormal pushing reminding of the surface of the conveying belt is carried out, meanwhile, the thermal imaging image and the depth image are pushed to a terminal, and the system carries out the alarm of the tearing of the surface of the conveying belt. Meanwhile, the depth detection mechanism 2 not only realizes the detection of the tearing of the conveying belt, but also can timely acquire the cargo depth information causing the tearing of the conveying belt, timely adjusts the detailed transportation parameters of the cargo causing the tearing of the conveying belt, and guarantees the transportation efficiency. In addition, the abnormal images can be recorded in the defect sample library at the same time, so that the sample library is continuously abundant. As the running time increases and more systems are deployed, a sample library can be networked and shared among a plurality of tearing systems, and tearing accidents and conveyor belt surface anomalies can be detected more quickly.
The above-mentioned only the utility model discloses the feasible embodiment of preferred is not right the utility model discloses a restriction, the utility model discloses also not be limited to the above-mentioned example, technical field's technical personnel the utility model discloses an in the essential scope, change, modification, interpolation or replacement made also should belong to the utility model discloses a protection scope.