JP2013096879A - Rotary machine gap measurement device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To save labor and time of a maintenance worker in a confirmation work by a visual inspection when directly measuring a gap by image processing or detecting an abnormality.SOLUTION: A gap 14 of a rotary machine illuminated by a lighting apparatus 2 is photographed by a camera 1, the photographed image data is converted from an electric signal to an optical signal by an image transmitter 4, and the optical signal is passed through an optical cable 8 and is transmitted to an image transmitter 5 in an information device board 6. The transmitted optical signal is converted into an electric signal again in the image transmitter 5 and the electric signal is transmitted from the image transmitter 5 to an image analyzer 7. In the image analyzer 7, the gap 14 is measured on the basis of the image data transmitted from the image transmitter 5 and the measured information is transmitted to a monitoring device 13b at a remote place via a network 13a. Accordingly, the measured information can be confirmed by the monitoring device 13b.

Description

  The present invention relates to an apparatus for measuring a gap that is a gap between a stator and a rotor of a rotating machine by image processing, and more particularly to a rotating machine gap measuring apparatus that measures a gap of a rotating machine used as a wind power generator. Is.

  A rotating machine used as a wind power generator is a device that generates power using wind power as a power source. A rotating machine is composed of a stator and a rotor, and when the windmill receives wind, the rotor rotates to generate electricity.

  The gap, which is the gap between the stator and the rotor, has a width of about several millimeters. If the stator and the rotor come into contact with each other due to some abnormality, a serious accident will occur. For this reason, for the safe operation of wind power generators, the minimum gap width that can ensure safety must be used as a reference, and the gap must always be kept above this reference value.

  However, since the rotating machine used as a wind power generator is installed on a tower with a height of several tens of meters, it is made light, but it is slightly rigid and easily distorted. Further, many have a cantilever structure in which only the windmill side of the rotating shaft is fixed by a bearing, and the shaft is likely to shake due to the force of the wind hitting the windmill. Therefore, it is necessary to provide a device for measuring the gap of the rotating machine.

  As a device for measuring the gap of a general rotating machine, not limited to a wind power generator, the gap itself is not directly measured, but instead of measuring the gap by measuring the axial position of the rotor. A device has been proposed.

  For example, in order to detect an abnormal shaft system of a vertical shaft rotating machine of a hydroelectric power plant, there is a device that measures the position of a rotating shaft with a gap sensor and detects an abnormal center position (see Patent Document 1).

  There is also an apparatus that detects the amount of shaft swing by installing a magnetic substance on the rotating shaft of a rotating machine and detecting it with a magnetic sensor (see Patent Document 2).

Japanese Patent Laid-Open No. 5-60544 JP-A-8-254402

  However, in the apparatus as described above, the gap state can be estimated by measuring the position of the rotating shaft of the rotating machine, but the gap cannot be measured directly.

  Therefore, when using the above-mentioned equipment for wind power generators, if a gap abnormality is detected, the maintenance worker goes to the site, climbs on a tower of several tens of meters, and visually confirms the state of the gap. It needs to be done and takes a lot of work.

  In addition, wind power generators are typically installed in large areas without shielding. For this reason, the machine room in which the rotating machine of the wind power generator is housed is always exposed to direct sunlight, and the inside of the nacelle is hot and humid.

  The object of the present invention is to measure the gap directly by image processing in order to solve the above-mentioned problems, and when an abnormality is detected, the image and data of the abnormal part are transmitted to a remote place to maintain the gap. It is an object of the present invention to provide a rotating machine gap measuring apparatus that can save the labor of visual confirmation by an operator and that can withstand high temperature and high humidity in a wind power generator nacelle.

A rotating machine gap measuring apparatus according to a first invention for solving the above-mentioned problems is as follows.
A camera that shoots around the gap between the rotor and the rotor of the rotating machine,
An image taken by the camera is input as an input image, and from the input image, an actual size gap width that is an actual gap width is measured, and an image analysis device that determines the presence or absence of an abnormality,
A network for transmitting the actual size gap width, the presence / absence of abnormality, and the input image as gap measurement information.

A rotating machine gap measuring apparatus according to a second invention for solving the above-mentioned problems is as follows.
In the rotating machine gap measuring apparatus according to the first invention,
An imaging device box having a hermetically sealed structure and a cooling function, which is installed in a plurality of locations in a machine room that houses the rotating machine, and that has illumination means for illuminating the camera and the imaging location of the camera inside.
An information device board that is installed outside the machine room and houses the image analysis device connected to the camera by an optical cable;
And a monitoring device that receives the gap measurement information transmitted by the network at a remote location.

A rotating machine gap measuring apparatus according to a third invention for solving the above-described problems is
In the rotating machine gap measuring apparatus according to the first or second invention,
The camera
A plurality of positions are installed in the machine room at an angle such that the horizontal axis direction of the image passing through the optical axis is on the radiation from the rotation axis of the rotor,
The image analysis device includes:
The input image is binarized to create a binary image, and the binary image is scanned in the vertical direction to measure the width of the black portion as the gap width on the image. A function for converting the gap width on the image into the actual size gap width from a parameter, comparing the actual size gap width of the input images from all the cameras with a preset reference value, and determining the presence or absence of an abnormality. It is characterized by providing.

A rotating machine gap measuring apparatus according to a fourth invention for solving the above-mentioned problems is
In the rotating machine gap measuring apparatus according to the third aspect,
The image analysis device includes:
Each processing parameter includes a binarization threshold that is a threshold of brightness when binarizing the input image, the camera parameter, a distance from the camera to the gap portion of the rotating machine, and the reference value. A process setting unit to set as
An image input unit for inputting an image captured by the camera as the input image;
An image binarization unit that binarizes the input image based on the binarization threshold and creates the binary image;
Measuring the gap width on the image, and further, based on the camera parameters, a gap width measurement unit for creating gap width data in which the gap width on the image is converted into the actual gap width;
An abnormality determination unit that compares the actual size gap width of the input images by all the cameras and the reference value, and determines whether there is an abnormality,
A gap measurement information creating unit for creating the gap measurement information;
A storage unit for storing the input image, the processing parameters, the binary image, the gap width data, a record of the presence or absence of abnormality, and the gap measurement information;
And a data output unit for outputting the gap measurement information to the outside.

A rotating machine gap measuring apparatus according to a fifth invention for solving the above-described problems is
In the rotating machine gap measuring apparatus according to the third invention,
The image analysis device includes:
When scanning the binary image in the vertical direction, an edge portion that changes from black to white is detected in the left-right direction of the scanning line from the gap center line set in advance in the gap, and the detected interval between the left and right edges is determined. It is measured as a gap width on an image.

A rotating machine gap measuring apparatus according to a sixth invention for solving the above-mentioned problems is as follows.
In the rotating machine gap measuring apparatus according to the fifth aspect,
The image analysis device includes:
A binarization threshold that is a threshold for brightness when binarizing the input image, the camera parameter, a distance from the camera to the gap portion of the rotating machine, the reference value, and the gap center line Are set as each processing parameter,
An image input unit for inputting an image captured by the camera as the input image;
An image binarization unit that binarizes the input image based on the binarization threshold and creates the binary image;
Measuring the gap width on the image, and further, based on the camera parameters, a gap width measurement unit for creating gap width data in which the gap width on the image is converted into the actual gap width;
An abnormality determination unit that compares the actual size gap width of the input images by all the cameras and the reference value, and determines whether there is an abnormality,
A gap measurement information creating unit for creating the gap measurement information;
A storage unit for storing the input image, the processing parameters, the binary image, the gap width data, a record of the presence or absence of abnormality, and the gap measurement information;
And a data output unit for outputting the gap measurement information to the outside.

  According to the rotating machine gap measuring device according to the first to sixth inventions, it is possible to determine the presence or absence of abnormality by directly measuring the gap itself of the rotating machine used as a wind power generator from an image. . In addition, when an abnormality is detected, gap measurement information can be transmitted to a remote location, so that the situation can be grasped from a remote location. This saves you the trouble of climbing and checking directly with your eyes.

  According to the rotating machine gap measuring apparatus according to the second aspect of the present invention, the wind turbine generator is further provided by installing the camera and the image transmitter in the closed structure photographing apparatus box and providing a cooling function in the box. The influence of high temperature and humidity in the machine room can be prevented.

  According to the rotating machine gap measuring apparatus according to the third to sixth inventions, it is possible to further determine whether or not there is an abnormality in the gap width by scanning a binary image.

  According to the rotating machine gap measuring apparatus according to the fifth and sixth inventions, when the gap center line is set in the input image to binarize the image and scan the binary image in the vertical direction, scanning is performed. In the line, by detecting the edge part that changes from black to white in the left-right direction from the gap center line, and measuring the gap between the detected left and right edges as the gap width on the image, the surface of the stator and rotor is uneven, Accurate measurement can be performed even when there is discoloration and dirt.

  According to the rotating machine gap measuring apparatus according to the fourth and sixth inventions, an image at the time of occurrence of an abnormality can be further recorded as a record in the storage unit of the image analyzing apparatus.

It is a schematic diagram of the whole rotary machine gap measuring device. (A) is the AA arrow directional view of the rotary machine in FIG. (B) is an enlarged view of an image obtained by photographing a photographing location B surrounded by a one-dot chain line in (a) with a camera. It is a schematic diagram of a binary image. It is a schematic diagram of the on-image gap width measurement according to the first embodiment of the present invention. (A) shows a state in which a binary image is scanned in the vertical direction, and (b) shows a state of measurement of an on-image gap width in a scanning line. It is a flowchart of the gap measurement by an image analyzer. It is a block diagram of an image analysis apparatus. It is a schematic diagram of an image when there are unevenness, discoloration, and dirt on the surface around the gap between the stator and the rotor. It is a schematic diagram of a binary image when there are unevenness, discoloration, and dirt on the surface around the gap between the stator and the rotor. It is the schematic diagram of the image which set the gap centerline based on Example 2 of this invention. It is a schematic diagram of the on-image gap width measurement according to the second embodiment of the present invention. (A) shows a state in which a binary image is scanned in the vertical direction, and (b) shows a state of measurement of an on-image gap width in a scanning line.

  Hereinafter, a rotating machine gap measuring apparatus according to the present invention will be described with reference to the drawings by way of examples.

  As shown in FIG. 1, the rotating machine gap measuring apparatus according to the first embodiment of the present invention includes a camera 1, a lighting fixture 2, an imaging device box 3, image transmitters 4 and 5, an information device panel 6, an image analysis device 7, An optical cable 8 and a monitoring device 13b are provided.

  The above-described camera 1 is housed in a photographing device box 3 installed in a machine room (hereinafter referred to as a nacelle 11) in which a rotating machine of a wind power generator is housed. The periphery of the gap 14 of the rotor 10 is photographed.

  FIG. 2A is a view taken along the line AA in FIG. In FIG. 2A, B surrounded by an alternate long and short dash line is a shooting location by the camera 1. As can be seen from this, the horizontal axis direction of the image passing through the optical axis of the camera 1 is that of the rotor 10. It is installed at an angle that is above the radiation from the rotation axis.

  When the camera 1 is installed as described above, as shown in FIG. 2B, the stator 9 portion, the rotor 10 portion, and the gap 14 of the rotating machine are photographed so as to be aligned vertically in the photographed image 20a. Gap measurement by processing is simplified (detailed description of the gap measuring means will be described later).

  The above-described lighting fixture 2 is installed outside the lens of the camera 1 and illuminates the rotating machine, so that the light of the stator 9 and the rotor 10 is reflected and brightened, and the light of the gap 14 is reflected. Since the dark state is maintained, the brightness and darkness of the captured image 20a is further emphasized.

  The above-described photographing apparatus box 3 is installed at a position where the gap 14 of the rotating machine in the nacelle 11 can be seen, and houses the camera 1, the luminaire 2, and the image transmitter 4. The box container has a shape that can be hermetically sealed with a transparent material to block moisture from entering inside. Further, the camera 1 and the image transmitter 4 are prevented from becoming hot by providing a cooling function such as installing a heat sink and an air cooling fan outside or circulating cold water.

  As shown in FIG. 2A, the photographing device box 3 is installed at a plurality of positions at an angle such that the horizontal axis direction of the image passing through the optical axis of the camera 1 is on the radiation from the rotation axis of the rotor 10. ing.

  The above-mentioned image transmitter 4 is installed in the photographing apparatus box 3 and receives an electrical signal of image data photographed by the camera 1 and converts it into an optical signal.

  The above-mentioned image transmitter 5 is installed in the information device panel 6, converts an optical signal of image data into an electrical signal, and outputs the electrical signal to the image analysis device 7.

  The optical cable 8 is connected to the image transmitter 4 in the photographing apparatus box 3 and the image transmitter 5 in the information operation panel 6, and transmits an optical signal of image data from the image transmitter 4 to the image transmitter 5. It becomes a route to do.

  The information device panel 6 described above is installed in the vicinity of the tower of the wind power generator, and houses the image transmitter 5 and the image analysis device 7.

  The image analysis device 7 measures the gap based on the image data sent from the image transmitter 5. The measured information is transmitted to the remote monitoring device 13b via the network 13a.

  In the apparatus according to the first embodiment of the present invention, with the apparatus configuration as described above, first, the camera 14 captures the gap 14 of the rotating machine illuminated by the lighting fixture 2, and the captured image data is the image transmitter 4. Thus, the electrical signal is converted into an optical signal and transmitted through the optical cable 8 to the image transmitter 5 in the information device board 6. The transmitted optical signal is converted again into an electrical signal in the image transmitter 5 and transmitted from the image transmitter 5 to the image analysis device 7. The image analysis device 7 measures the gap 14 based on the image data transmitted from the image transmitter 5, and the measured information is transmitted to the remote monitoring device 13b via the network 13a.

  Next, the image analysis device 7 for measuring the gap of the rotating machine as described above will be described in detail.

  As shown in FIG. 6, the image analysis apparatus 7 includes a process setting unit 21, an image input unit 22, an image binarization unit 23, a gap measurement part 24, an abnormality determination unit 25, a gap measurement information creation unit 26, a storage unit 27, and A data output unit 28 is provided.

  In the image input unit 22 described above, the captured image 20a captured by the camera 1 is input as an input image.

  In the processing setting unit 21 described above, a threshold value of brightness when the input image is binarized (hereinafter referred to as a binarization threshold value), a lens focal length of the camera 1 and a CCD size (hereinafter referred to as camera parameters). Description), each processing parameter of the distance from the camera 1 to the gap 14 portion of the rotating machine and the reference value of the gap width that determines the presence or absence of abnormality is set.

  The above-described image binarization unit 23 binarizes the input image based on the binarization threshold value to create a binary image 20b.

  In the gap width measurement unit 24 described above, the scanning line 16 is moved in the vertical direction of the binary image 20b as shown in FIG. 4A, and the width of the black portion (hereinafter referred to as the image upper side) as shown in FIG. Measure the gap width). Further, based on the camera parameters, gap width data is created by converting the on-image gap width into an actual gap width (hereinafter referred to as an actual gap width).

  The above-described abnormality determination unit 25 compares the gap width data for all installed cameras for one camera and the reference value of the gap width to determine whether there is an abnormality.

  The above-described gap measurement information creation unit 26 creates gap measurement information in which the actual gap width, presence / absence of abnormality, and the input image are arranged.

  The storage unit 27 stores an input image, each processing parameter, a binary image 20b, gap width data, a record of presence / absence of abnormality, and gap measurement information.

  The data output unit 28 outputs gap measurement information to the outside.

  Hereinafter, the procedure of gap measurement by the image analysis device 7 will be described with reference to FIG.

  In step S <b> 1, image data of the captured image 20 a captured by the camera 1 is input as an input image from the image transmitter 5 by the image input unit 22.

  In step S2, the image binarization unit 23 binarizes the input image to create a binary image 20b as shown in FIG. The binarization threshold used for binarization is set in advance by the process setting unit 21.

  In step S3, the gap width measuring unit 24 measures the on-image gap width as described above.

  In step S4, the gap width measurement unit 24 converts the on-image gap width into an actual size gap width based on the camera parameters set by the process setting unit 21.

  In step S5, the abnormality determination unit 25 determines whether there is an abnormality. All the actual size gap widths photographed by all the cameras 1 are compared with a reference value of the gap width, and when the actual size gap width is less than the reference value, it is determined as abnormal.

  The result of the presence / absence of abnormality is organized together with the input image and gap width data in the gap measurement information creation unit 26, and is transmitted as gap measurement information from the data output unit 28 to the remote monitoring device 13b through the network 13a. Is done. Further, in order to reduce the load on the network 13a, the input image may be included in the gap measurement information only when there is an abnormality.

  Incidentally, in the above-described steps S1 to S5, each image data and each processing parameter is stored in the storage unit 27 each time.

  In the apparatus according to the first embodiment of the present invention, the gap itself of the rotating machine used for the wind power generator can be directly measured by an image, and the image at the time of occurrence of abnormality is confirmed by the remote monitoring device 13b. As a result, maintenance workers can go to the site to check for abnormalities, and then go up to a tower of several tens of meters to check the gap of the rotating machine.

  As shown in FIG. 7, the stator 9 and the rotor 10 of the rotating machine have irregularities 17 on the surface. Further, discoloration 18 and dirt 19 due to aging also occur. For this reason, when the periphery of the gap 14 of the rotating machine is photographed, the unevenness 17, the color change 18 and the dirt 19 are also photographed.

  When these portions appear dark in the photographed image 20a, when this image is binarized, these portions also become black as the gap 14 as in the binarized image 20b of FIG.

  When the gap width on the image is measured from the binary image 20b in this state, it cannot be measured accurately only by scanning the binary image 20b in the vertical direction and obtaining the width of the black portion.

  Therefore, the rotating machine gap measuring apparatus according to the second embodiment of the present invention has the same basic configuration as the apparatus according to the first embodiment of the present invention, but the setting and gap in the processing setting unit 21 of the image analysis apparatus 7. The function of the width measuring unit 24 is changed.

  Hereinafter, descriptions of the image analysis apparatus 7 other than the processing setting unit 21 and the gap width measuring unit 24 will be omitted, and only the processing setting unit 21 and the gap width measuring unit 24 will be described.

  In the processing setting unit 21, in addition to the binarization threshold value, the camera parameter, the distance from the camera 1 to the gap portion of the rotating machine, the reference value of the gap width, and the setting of each processing parameter, as shown in FIG. A gap center line 15 is set inside. In FIG. 9, the gap center line is set at the approximate center of the image, but actually the gap center line is not always set at the image center.

  The gap width measurement unit 24 scans in the vertical direction of the binary image 20b as shown in FIG. 10A. At this time, the gap center line 15 is included in the scanning line 16 as shown in FIG. The edge portion where the value of the binary image 20b changes from black to white in the left-right direction is detected, and the interval between the detected left and right edges is measured as the gap width on the image.

  Hereinafter, the measurement procedure of the rotating machine gap measuring apparatus according to the second embodiment of the present invention will be described with reference to FIG.

  In step S1, the image input unit 22 inputs image data of the captured image 20a captured by the camera 1 as an input image from the image transmitter 5, and the process setting unit 21 sets the gap center line 15 as shown in FIG. To do.

  In step S2, the image binarization unit 23 binarizes the input image in which the gap center line 15 is set to create a binary image 20b. The binarization threshold is set in advance by the process setting unit 21.

  In step S3, the gap width measuring unit 24 measures the on-image gap width as described above.

  In step S4, the gap width measurement unit 24 converts the on-image gap width into an actual size gap width based on the camera parameters set by the process setting unit 21.

  In step S5, the abnormality determination unit 25 determines whether there is an abnormality. All the actual size gap widths photographed by all the cameras 1 are compared with a reference value of the gap width, and when the actual size gap width is less than the reference value, it is determined as abnormal.

  The result of the presence / absence of abnormality is organized together with the input image and gap width data in the gap measurement information creation unit 26, and is transmitted as gap measurement information from the data output unit 28 to the remote monitoring device 13b through the network 13a. Is done. Further, in order to reduce the load on the network 13a, the input image may be included in the gap measurement information only when there is an abnormality.

  Incidentally, in the above-described steps S1 to S5, each image data and each processing parameter is stored in the storage unit 27 each time.

  In the apparatus according to the second embodiment of the present invention, in addition to the function of the apparatus according to the first embodiment of the present invention, the influence of unevenness, discoloration, and dirt on the surface of the rotating machine on the gap width measurement can be eliminated.

  The present invention is suitable as a rotating machine gap measuring device for measuring a gap of a rotating machine used as a wind power generator.

DESCRIPTION OF SYMBOLS 1 Camera 2 Lighting fixture 3 Imaging device box 4 Image transmitter 5 Image transmitter 6 Information apparatus board 7 Image analysis device 8 Optical cable 9 Stator 10 Rotor 11 Nacelle 12 Windmill 13a Network 13b Monitoring device 14 Gap 15 Gap center line 16 Scanning Line 17 Concavity and convexity 18 Discoloration 19 Dirt 20a Captured image 20b Binary image 21 Processing setting unit 22 Image input unit 23 Image binarization unit 24 Gap width measurement unit 25 Abnormality determination unit 26 Gap measurement information creation unit 27 Storage unit 28 Data output unit S1 Image input S2 Image binarization S3 Measurement of gap width on image S4 Conversion of gap width on image to actual gap width S5 Judgment of abnormality

Claims (6)

A camera that shoots around the gap between the rotor and the rotor of the rotating machine,
An image taken by the camera is input as an input image, and from the input image, an actual size gap width that is an actual gap width is measured, and an image analysis device that determines the presence or absence of an abnormality,
A rotating machine gap measuring device, comprising: the actual size gap width, presence / absence of abnormality, and a network that transmits the input image as gap measurement information. An imaging device box having a hermetically sealed structure and a cooling function, which is installed in a plurality of locations in a machine room that houses the rotating machine, and that has illumination means for illuminating the camera and the imaging location of the camera inside.
An information device board that is installed outside the machine room and houses the image analysis device connected to the camera by an optical cable;
The rotating machine gap measuring device according to claim 1, further comprising a monitoring device that receives the gap measuring information transmitted by the network at a remote location. The camera
A plurality of positions are installed in the machine room at an angle such that the horizontal axis direction of the image passing through the optical axis is on the radiation from the rotor of the rotating machine,
The image analysis device includes:
The input image is binarized to create a binary image, and the binary image is scanned in the vertical direction to measure the width of the black portion as the gap width on the image. A function for converting the gap width on the image into the actual size gap width from a parameter, comparing the actual size gap width of the input images from all the cameras with a preset reference value, and determining the presence or absence of an abnormality. The rotating machine gap measuring device according to claim 1, wherein the rotating machine gap measuring device is provided. The image analysis device includes:
Each processing parameter includes a binarization threshold that is a threshold of brightness when binarizing the input image, the camera parameter, a distance from the camera to the gap portion of the rotating machine, and the reference value. A process setting unit to set as
An image input unit for inputting an image captured by the camera as the input image;
An image binarization unit that binarizes the input image based on the binarization threshold and creates the binary image;
Measuring the gap width on the image, and further, based on the camera parameters, a gap width measurement unit for creating gap width data in which the gap width on the image is converted into the actual gap width;
An abnormality determination unit that compares the actual size gap width of the input images by all the cameras and the reference value, and determines whether there is an abnormality,
A gap measurement information creating unit for creating the gap measurement information;
A storage unit for storing the input image, the processing parameters, the binary image, the gap width data, a record of the presence or absence of abnormality, and the gap measurement information;
The rotating machine gap measuring device according to claim 3, further comprising a data output unit that outputs the gap measuring information to the outside. The image analysis device includes:
When scanning the binary image in the vertical direction, an edge portion that changes from black to white is detected in the left-right direction of the scanning line from the gap center line set in advance in the gap, and the detected interval between the left and right edges is determined. The rotating machine gap measuring device according to claim 3, wherein the rotating machine gap measuring device measures the gap width on the image. The image analysis device includes:
A binarization threshold that is a threshold for brightness when binarizing the input image, the camera parameter, a distance from the camera to the gap portion of the rotating machine, the reference value, and the gap center line Are set as each processing parameter,
An image input unit for inputting an image captured by the camera as the input image;
An image binarization unit that binarizes the input image based on the binarization threshold and creates the binary image;
Measuring the gap width on the image, and further, based on the camera parameters, a gap width measurement unit for creating gap width data in which the gap width on the image is converted into the actual gap width;
An abnormality determination unit that compares the actual size gap width of the input images by all the cameras and the reference value, and determines whether there is an abnormality,
A gap measurement information creating unit for creating the gap measurement information;
A storage unit for storing the input image, the processing parameters, the binary image, the gap width data, a record of the presence or absence of abnormality, and the gap measurement information;
The rotating machine gap measuring device according to claim 5, further comprising a data output unit that outputs the gap measuring information to the outside.

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