CN102275723A - Machine-vision-based online monitoring system and method for conveyer belt - Google Patents
Machine-vision-based online monitoring system and method for conveyer belt Download PDFInfo
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Abstract
The invention discloses a machine-vision-based online monitoring system for a conveyer belt , which is used for real-time detection of deflection, surface damage and longitudinal tear faults of the conveyer belt. The machine-vision-based online monitoring system comprises an image acquisition module, an image transmission module, an image processing module, a fault diagnosis and alarm module and a support, wherein the image acquisition module is used for online acquisition of running image information of the conveyer belt by using a linear-array camera; the image transmission module is used for transmitting conveyer belt images acquired by the image acquisition module to a computer through Ethernet; the image processing module is used for processing the conveyer belt images transmitted to the computer in real time; the fault diagnosis and alarm module is used for identifying the running state of the conveyer belt and giving an alarm in time if the deflection, the surface damage and the longitudinal tear faults are detected; and the support is used for fixing the image acquisition module to a proper position of the conveyer belt. The monitoring system provided by the invention is beneficial to promotion of the monitoring level of the state of the conveyer belt so as to achieve the purpose of increasing efficiency by downsizing payrolls for enterprises. The invention further discloses an online monitoring method for a conveyer belt with application of the monitoring system.
Description
Technical field
The present invention relates to a kind of load-transfer device on-line monitoring system and method, relate to a kind of load-transfer device on-line monitoring system and method particularly, belong to the equipment condition monitoring field based on machine vision.
Background technology
Load-transfer device is the vitals of numerous industry belt conveyers such as mine, port and pier, chemical industry, metallurgy, electric power, cement, and it has become the second largest rubber industry product after tire.China is global first load-transfer device production and country of consumption, it is reported, 2003-2008 6 in the period of the output compound growth rate of Chinese load-transfer device more than 20%, reached 2.3 hundred million sq ms by 2008, account for about 1/3rd of the whole world year load-transfer device 6-7 hundred million sq m overall market scales.
In the working process, faults such as sideslip, surface damage and longitudinal tear appear in load-transfer device through regular meeting, not only cause breakdown of equipment easily, cause economic loss, also can cause safety misadventure, serious threat safety and production when serious.With the colliery is example, statistics according to the issue of national security production control general bureau, 1065 of Coal Transport lifting accidents take place in 2004-2005 whole nation colliery altogether, dead 1142 people, and according to " China's coal mines accident and expert comment on collection " statistics, by the end of nineteen ninety-five, the transportation of colliery, the whole nation promotes death by accident 19871 people, accounting for 15.06% of coal mining accident total toll, be only second to top board and gas accident, is the third-largest disaster accident of coal system.In the trouble free service field, the unusual importance of discovering device early that famous extra large grace rule " per 1 serious accident all has minor accident behind 29 times; 300 not accomplished tendencys are arranged; 1000 accident hidden danger are arranged " and black luxuriant and rich with fragrance law " have needed only and existed the reason that has an accident, accident just to be bound to take place " just distinct announcement.
Through existing multiple load-transfer device monitoring technology of the development of decades and method, such as leaking methods such as material detection, electromagnetic sensor detection, ultrasonic testing, X ray detection.But at present common detecting device or simple in structurely can't accurately catch the load-transfer device breakdown signal is easy to generate and fails to report, reports by mistake, otherwise complex structure, cost an arm and a leg, maintenance difficulties is big, is difficult for promoting the use of, X-ray check also easily works the mischief to human body.And the most methods function singleness only at sideslip or tear a kind of fault and design, lacks the comprehensive detection ability of various faults.In addition, present monitoring system lacks the failure prediction ability, and all there is certain limitation in actual applications in the detection principle that these methods of while are subject to itself.Therefore we can say, still do not have at present a kind of accurately, failure-free monitoring system and method, can carry out real time comprehensive to the faults such as sideslip, surface damage and longitudinal tear of load-transfer device and detect.
Summary of the invention
The objective of the invention is provides a kind of load-transfer device on-line monitoring system and method based on machine vision for solving the problem that existing load-transfer device fault detection lacks comprehensive detection, and the real-time online that is used for belt deflection, surface damage and longitudinal tear fault detects.
A kind of load-transfer device on-line monitoring system based on machine vision of the present invention, this monitoring system comprises: image capture module, image transmission module, image processing module, trouble diagnosing and alarm module and support.
Image capture module is used for the graphicinformation of online acquisition load-transfer device operation.
Image transmission module is used for the load-transfer device graphicinformation of image capture module collection is transferred to computing machine by Ethernet.
Image processing module is used for handling in real time the load-transfer device image that is transferred to computing machine.
Trouble diagnosing and alarm module are used to discern the running state of load-transfer device, sideslip, surface damage and the longitudinal tear fault of diagnosing out the load-transfer device operational process to occur, and in time report to the police.
Support is used for image capture module is fixed to the correct position of load-transfer device, so that the stable collection of load-transfer device image.
The monitoring method of above-mentioned load-transfer device on-line monitoring system based on machine vision, the principle of this method is: the graphicinformation of obtaining the load-transfer device operation with line array video camera, by Ethernet the load-transfer device operation image that absorbs is transferred to computing machine, utilize computing machine that the load-transfer device operation image is handled, extract necessary fault characteristic information, diagnose sideslip, surface damage, the longitudinal tear fault that occurs in the load-transfer device operational process according to the fault characteristic information that extracts again, if find fault, in time report to the police.
Beneficial effect
The present invention utilizes the running state of machine vision technique monitoring load-transfer device, realizes the comprehensive online non-destructive test of belt deflection, surface damage and longitudinal tear fault.Monitoring system of the present invention can promote the level of load-transfer device condition monitoring, improves the automatization level that enterprise produces, and realizes the safe and reliable operation of load-transfer device, reaches the purpose that enterprise increases efficiency by downsizing payrolls.Method of the present invention not only can reduce the labour intensity of manual detection, improves detection efficiency and precision, can also find the fault that load-transfer device occurs early, helps to realize the precognition maintenance of load-transfer device, in time prevents spreading of fault.
Description of drawings
Fig. 1 is the load-transfer device on-line monitoring system scheme drawing based on machine vision of the present invention;
Fig. 2 is the Ethernet implementation one of image transmission module of the present invention;
Fig. 3 is the Ethernet implementation two of image transmission module of the present invention;
Fig. 4 is the Ethernet implementation three of image transmission module of the present invention;
Fig. 5 is an image processing module diagram of circuit of the present invention;
Fig. 6 is trouble diagnosing of the present invention and alarm module diagram of circuit;
Fig. 7 is the load-transfer device on-line monitoring method structured flowchart based on machine vision of the present invention;
Fig. 8 is sideslip of the present invention, surface damage and longitudinal tear Fault Diagnosis procedure structure block diagram;
Fig. 9 is based on the load-transfer device on-line monitoring system scheme drawing of machine vision in the specific embodiment of the present invention.
The specific embodiment
Load-transfer device on-line monitoring system scheme drawing based on machine vision of the present invention as shown in Figure 1.
Load-transfer device on-line monitoring system based on machine vision of the present invention, this monitoring system comprises: image capture module is used for the graphicinformation that the online acquisition load-transfer device moves; Image transmission module is used for the load-transfer device image of image capture module collection is transferred to computing machine by Ethernet; Image processing module is used for handling in real time the load-transfer device image that is transferred to computing machine; Trouble diagnosing and alarm module are used to discern the running state of load-transfer device, sideslip, surface damage and the longitudinal tear fault of diagnosing out the load-transfer device operational process to occur, and in time report to the police; Support is used for image capture module is fixed to the correct position of load-transfer device.
Image capture module comprises linear light source, line array video camera and camera protective cover.Linear light source provides high bright light source for line array video camera.Line array video camera is used to gather the operation image of load-transfer device.Camera protective cover is used for the protective wire array camera, has cooling, heats, rainproof, snow defence, antisoiling function, and for anti-riot environment, also have anti-riot function.
Image transmission module realizes by Ethernet, and the specific implementation of Ethernet can adopt but be not limited to a kind of in following three kinds of modes:
Implementation one, line array video camera and Ethernet card are by the netting twine direct connection, as shown in Figure 2;
Implementation two, line array video camera links to each other with concentrator by netting twine respectively with Ethernet card, as shown in Figure 3;
Implementation three, line array video camera links to each other with exchange by netting twine respectively with Ethernet card, as shown in Figure 4.
The diagram of circuit of image processing module as shown in Figure 5, this module comprises that image pretreatment, morphological image are handled and image binaryzation is handled.
The diagram of circuit of trouble diagnosing and alarm module as shown in Figure 6, this module comprises fault signature extraction, trouble diagnosing and fault alarm.
In the working process, when being radiated at conveyor belt surface, the light of the linear light emitted of high brightness produces diffuser reflection, line array video camera diffuses by the line sweep induction and absorbs the load-transfer device image, by ethernet the load-transfer device graphicinformation is transferred to computing machine, utilize computing machine to carry out image processing, extract the fault signature signal and discerned the running state of load-transfer device afterwards,, in time report to the police if detect sideslip, surface damage and the longitudinal tear fault of load-transfer device.
The monitoring method constructional drawing of above-mentioned load-transfer device on-line monitoring system based on machine vision as shown in Figure 7.
This method specifically comprises the steps:
Step 1 for load-transfer device to be detected, utilizes line array video camera to gather the graphicinformation of this load-transfer device operation.
For the monitoring of the some positions of load-transfer device, line array video camera can be one, also can be many.If adopt many line array video cameras placed side by side, need a controller to control these line array video camera synchronous workings along the load-transfer device Width.
Step 2 transfers to computing machine by Ethernet with the load-transfer device graphicinformation of step 1.
For the graphicinformation of effective transmission of large capacity, need the Ethernet card of configuration respective performances.Ethernet card need be selected according to institute's image transmitted data volume each second.
Step 3 on the basis of step 2, utilizes computing machine that the load-transfer device image is handled, and through after the image processing, the load-transfer device image has become bianry image.
Image processing process comprises that image pretreatment, morphological image are handled, image binaryzation is handled.Image pre-processing method can be that one or more methods that geometric manipulations, image smoothing, image sharpening, image filtering and histogram strengthen are used in combination.
Step 4 on the basis of step 3, is extracted the load-transfer device fault characteristic information and is carried out trouble diagnosing, if find fault, in time reports to the police.
The sideslip of load-transfer device, surface damage and longitudinal tear Fault Diagnosis procedure structure block diagram are as shown in Figure 8.For the sideslip fault, need at first discern the edge of load-transfer device, extract the sideslip characteristic information according to belt edges then, judge whether sideslip of load-transfer device according to the sideslip characteristic information that extracts, if the sideslip fault occurs, just carry out sideslip and report to the police.For the surface damage fault, at first surface damage is positioned and indicates, extract the surface damage feature then, judge whether to occur surface damage according to the surface damage characteristic information again, if surface damage occurs, just carry out surface damage and report to the police.For the longitudinal tear fault; at first longitudinal tear is positioned and indicates, extract the longitudinal tear feature then, judge whether to occur longitudinal tear according to the longitudinal tear characteristic information again; if longitudinal tear occurs, just carry out the longitudinal tear warning and provide the load-transfer device shutdown signal.
The sideslip fault characteristic information comprises the distance, the distance between the load-transfer device two edges, load-transfer device image rectangle degree at degree of dip, the belt edges range image edge of belt edges etc.
The characteristic information of surface damage and longitudinal tear can be the part or all of of following feature, and these features are: area, girth, length, projected length, Euler number, slenderness, rectangle degree, eccentricity, direction, density, central moment, invariant moments etc.
Step 5 on the basis of step 4, after demonstration and the preservation monitoring result, is handled piece image down.
Embodiment
Present embodiment is that example describes with industrial grade linear array CCD camera and gigabit Ethernet network, and the scheme drawing of load-transfer device on-line monitoring system as shown in Figure 9.The number of pixels of industrial grade linear array CCD camera can be selected according to actual needs.
Utilize the industrial grade linear array CCD camera to gather the graphicinformation of load-transfer device in real time, by the gigabit Ethernet network graphicinformation of load-transfer device is transferred to computing machine, utilize computing machine that the load-transfer device operation image is handled, and then realize monitoring and trouble diagnosing the load-transfer device running state.Such as: for pixel is 2048, the work line frequency is the industrial grade linear array CCD camera of 19kHz, and when the monitoring running velocity was the load-transfer device of 6m/s, can produce the graphicinformation of 37.1MB each second, and, can satisfy the real-time Transmission of 37.1MB data volume for PCI-Express.The computing machine of configuration proper property, the timely processing through to the 37.1MB graphicinformation just can realize real-time monitoring and trouble diagnosing to the load-transfer device state.
Above-described specific descriptions; purpose, technical scheme and beneficial effect to invention further describe; institute is understood that; the above only is specific embodiments of the invention; and be not intended to limit the scope of the invention; within the spirit and principles in the present invention all, any modification of being made, be equal to replacement, improvement etc., all should be included within protection scope of the present invention.
Claims (10)
1. load-transfer device on-line monitoring system based on machine vision, it is characterized in that: this monitoring system comprises:
Image capture module is used for the graphicinformation that the online acquisition load-transfer device moves;
Image transmission module is used for the load-transfer device graphicinformation of image capture module collection is transferred to computing machine by Ethernet;
Image processing module is used for handling in real time the load-transfer device image that is transferred to computing machine;
Trouble diagnosing and alarm module are used to discern the running state of load-transfer device, sideslip, surface damage and the longitudinal tear fault of diagnosing out the load-transfer device operational process to occur, and in time report to the police;
Support is used for image capture module is fixed to the correct position of load-transfer device, so that the stable collection of load-transfer device image.
2. a kind of load-transfer device on-line monitoring system according to claim 1 based on machine vision, it is characterized in that: image capture module comprises:
Linear light source is for line array video camera provides high bright light source;
Line array video camera is used to gather the operation image of load-transfer device, and line array video camera can be one, also can be more than two or two, for two or two above line array video cameras, needs a controller control these line array video camera synchronous workings;
Camera protective cover is used for the protective wire array camera, has cooling, heats, rainproof, snow defence, antisoiling function, and for anti-riot environment, also have anti-riot function.
3. a kind of load-transfer device on-line monitoring system based on machine vision according to claim 1 is characterized in that: image transmission module realizes by Ethernet, and the specific implementation of Ethernet can adopt but be not limited to a kind of in following three kinds of modes:
Implementation one, line array video camera and Ethernet card are by the netting twine direct connection;
Implementation two, line array video camera links to each other with concentrator by netting twine respectively with Ethernet card;
Implementation three, line array video camera links to each other with exchange by netting twine respectively with Ethernet card.
4. a kind of load-transfer device on-line monitoring system based on machine vision according to claim 1 is characterized in that: image processing module comprises that image pretreatment, morphological image are handled and image binaryzation is handled.
5. a kind of load-transfer device on-line monitoring system based on machine vision according to claim 1, it is characterized in that: trouble diagnosing and alarm module comprise fault signature extraction, trouble diagnosing and fault alarm.
6. according to the monitoring method of the described a kind of load-transfer device on-line monitoring system based on machine vision of claim 1 to 5, it is characterized in that: this method specifically comprises the steps:
Step 1 for load-transfer device to be detected, utilizes line array video camera to gather the graphicinformation of this load-transfer device operation;
Step 2 transfers to computing machine by Ethernet with the load-transfer device graphicinformation of step 1;
Step 3 on the basis of step 2, utilizes computing machine that the load-transfer device image is handled, and through after the image processing, the load-transfer device image has become bianry image;
Step 4 on the basis of step 3, is extracted the load-transfer device fault characteristic information and is carried out trouble diagnosing, if find fault, in time reports to the police;
Step 5 on the basis of step 4, after demonstration and the preservation monitoring result, is handled piece image down.
7. a kind of load-transfer device on-line monitoring method based on machine vision according to claim 6, it is characterized in that: in the described step 1, line array video camera can be one, also can be more than two or two.
8. a kind of load-transfer device on-line monitoring method based on machine vision according to claim 6 is characterized in that: in the described step 2, Ethernet need dispose performance and Ethernet card that each second, institute's transmit image data amount was complementary.
9. a kind of load-transfer device on-line monitoring method based on machine vision according to claim 6 is characterized in that: in the described step 3, image processing process comprises that image pretreatment, morphological image are handled, image binaryzation is handled,
Image pre-processing method can be that one or more methods that geometric manipulations, image smoothing, image sharpening, image filtering and histogram strengthen are used in combination.
10. a kind of load-transfer device on-line monitoring method according to claim 6 based on machine vision, it is characterized in that: in the described step 4, trouble diagnosing and alarm module comprise fault signature extraction, trouble diagnosing and fault alarm,
The sideslip fault characteristic information extracts by the edge of identification load-transfer device, and the sideslip fault characteristic information comprises degree of dip, the distance at belt edges range image edge, the distance between the load-transfer device two edges, the load-transfer device image rectangle degree of belt edges,
The characteristic information of surface damage and longitudinal tear can be the part or all of of following feature, and these features are: area, girth, length, projected length, Euler number, slenderness, rectangle degree, eccentricity, direction, density, central moment, invariant moments.
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