WO2021185009A1 - 一种辊压机辊面自动检测装置及检测方法 - Google Patents
一种辊压机辊面自动检测装置及检测方法 Download PDFInfo
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- WO2021185009A1 WO2021185009A1 PCT/CN2021/076080 CN2021076080W WO2021185009A1 WO 2021185009 A1 WO2021185009 A1 WO 2021185009A1 CN 2021076080 W CN2021076080 W CN 2021076080W WO 2021185009 A1 WO2021185009 A1 WO 2021185009A1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/95—Investigating the presence of flaws or contamination characterised by the material or shape of the object to be examined
- G01N21/952—Inspecting the exterior surface of cylindrical bodies or wires
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/01—Arrangements or apparatus for facilitating the optical investigation
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/8851—Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/89—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles
- G01N21/8901—Optical details; Scanning details
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/89—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles
- G01N21/892—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles characterised by the flaw, defect or object feature examined
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T17/00—Three dimensional [3D] modelling, e.g. data description of 3D objects
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T7/00—Image analysis
- G06T7/0002—Inspection of images, e.g. flaw detection
- G06T7/0004—Industrial image inspection
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T7/00—Image analysis
- G06T7/80—Analysis of captured images to determine intrinsic or extrinsic camera parameters, i.e. camera calibration
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/8851—Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges
- G01N2021/8854—Grading and classifying of flaws
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/8851—Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges
- G01N2021/8887—Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges based on image processing techniques
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2201/00—Features of devices classified in G01N21/00
- G01N2201/10—Scanning
Definitions
- the invention relates to the technical field of industrial automation detection, in particular to an automatic detection device and a detection method for the roller surface of a roller press.
- Roller press is a large-scale engineering equipment used to squeeze and crush materials. It is widely used in cement, mining, chemical and other industries. Its working principle is shown in Figure 1: Feeding materials from above the equipment, relying on two horizontally installed and synchronously rotating squeezing rollers to crush the materials under high pressure. The squeezing force experienced by the material layer in the process of being forced to move downward gradually increases to a large enough level, until it is crushed and squeezed into a dense cake to be discharged from under the roller.
- FIG 2 shows the common defects of the roller surface of various roller presses: a) The roller surface is unevenly worn, due to the edge effect of the roller press. That is, the middle of the roller surface wears quickly, and the wear on both sides is slow. After long-term operation, the phenomenon of depression in the middle of the roller surface appears, making it impossible to extend the service life of the roller surface by adjusting the roller gap; b) Roll surface pits, when there are steel ball hammers, etc. When metal foreign matter enters the roller press, it is easy to cause partial damage to the roller surface, such as pits on the roller surface. If they are not found and handled in time, the pits will quickly expand and damage the entire roller surface, resulting in overhaul or scrapping of the roller surface.
- a pair of rollers of the roller press are the key parts of the roller press, and their wear condition directly determines the quality of the product.
- the equipment operation rate of the roller press is high, the time required for a systematic inspection and repair of the rollers is tight, and the workload is large; on the other hand, the roller surface is made of special materials and special processes, and the cost is high. If defects cannot be found and repaired in time, Later defects will quickly expand, and maintenance costs will be very high.
- the inspection and maintenance of the roller surface of the roller press on the market mainly rely on manual visual observation of the roller surface to find problems, and there is no actual roll surface inspection and maintenance equipment of the roller press.
- the defects of the traditional manual method of overhauling the roller surface of the roller press are mainly reflected in the following points: a) The monitoring of the roller surface is not detailed enough. To detect the defects of the roller surface of the roller press only by naked eyes, some small defects are often difficult to detect and easy to miss. Once the small defects are not found, they can easily expand into large defects; b) The cost of repairing the roller surface is mainly The cost of welding consumables cannot be quantified by human eyes, which increases the cost of maintenance and transportation; c) There is a lack of digital records for the entire life cycle of the roll surface.
- Cisoka patent CN110288545A proposes an online three-dimensional imaging device and method for the roller surface of a roller press.
- Patent CN110288545A uses a binocular camera to detect the topography of the roller surface.
- the key steps are: partial point cloud reconstruction: recover the three-dimensional point cloud of the roller surface in a single line laser irradiation area through a pair of laser line images of the roller surface; point cloud splicing: The binocular camera moves left and right on the lead screw at a specified speed, and shoots image pairs of the roller surface at a certain frame rate. Each pair of images restores the three-dimensional coordinates of a single laser line. It is necessary to splice multiple lines into a surface.
- roller surface reconstruction method when the reconstruction algorithm rebuilds, the roller surface rotates at a certain angular velocity, and it is necessary to splice multiple scan data into a complete roller surface data.
- roller surface reconstruction method of patent CN110288545A some places can be further optimized: a). In terms of mechanical structure, the inside of the roller press is in a high dust environment, and the lead screw, binocular camera, and laser are directly exposed to the dust environment. Dust-proof measures, the mechanism will soon be covered with dust and cause shooting failure; b).
- each pair of images can restore the three-dimensional coordinates of a single laser line irradiation area, if the complete roll is to be restored Surface, it is necessary to splice the detection areas of multiple laser lines, and how to splice the detection areas of each laser line is the key.
- the binocular camera shoots the image of the roller surface at a certain frame rate, the binocular camera moves along the axial direction of the roller surface, and the roller surface rotates in the circumferential direction.
- the binocular camera shoots the image of the roller surface at a certain frame rate
- the binocular camera moves along the axial direction of the roller surface, and the roller surface rotates in the circumferential direction.
- the typical value of the roller surface speed of the roller press is 1.5m. /s or so, at this frame rate, there may be smear in the image when shooting the roller surface at close range, which has a greater impact on the binocular recognition effect;
- Patent CN110288545A does not specify the realization process of the splicing algorithm in detail; c).
- the realization cost, as in b) third As mentioned above, splicing a complete roller surface requires multiple laser line detection areas to be spliced together. Since the area of each laser line detection area is small, splicing a complete roller surface requires multiple images to be taken. Each image needs to perform operations such as distortion correction, filtering, threshold segmentation, and three-dimensional coordinate calculation. The calculation cost is high and the real-time performance is poor.
- the invention provides an automatic detection device and a detection method for the roller surface of a roller press, which can solve the technical problem of low detection accuracy of the existing detection device.
- An automatic detection device for the roller surface of a roller press comprising:
- the shooting control module includes an industrial line scan camera, a motion controller, and a local computer; the industrial line scan camera is set above the roller surface of the roller press; the local computer and The industrial line scan camera communication connection is used to set the shooting parameters of the industrial line scan camera and receive the photos taken by it;
- the motion execution module includes a screw, a screw motor, a ball, and a camera dust box;
- the lead screw is fitted on the lead screw base through a bearing, the ball is mounted on the lead screw, and the ball can move linearly forward and backward along the lead screw;
- the screw motor is fixedly connected with the screw through the screw coupling.
- the camera support plate is fixedly connected under the ball.
- the bottom of the camera support plate is fixedly connected to the camera dust box.
- the inside of the camera dust box is provided with an electric push rod in the longitudinal direction.
- the electric push rods are respectively rotatably connected to the inner side of the upper and lower end faces of the camera dustproof box, the electric push rods are retractable, and the opening and closing of the lower end face of the camera dustproof box can be controlled by controlling the extension and contraction of the electric push rods;
- the industrial line scan camera is fixed inside the camera dust-proof box, and the industrial line scan camera is in communication with the motion controller. After the industrial line scan camera receives the photographing signal sent by the motion controller, it performs the photographing task; the industrial line array After the camera has finished shooting, send the taken photos to the local computer;
- the local computer sends the taken photos and shooting parameters to the data processing module.
- the data processing module decomposes, crops, splices, and corrects the original photo data sent by the local computer, extracts the depth information according to the gray value of the image, and generates the data in the specified format.
- Detect the cloud data of roller surface points and then generate two-dimensional and three-dimensional models of the roller surface, and detect its defects, compare its historical data to obtain the wear speed and defect changes of the roller surface, store the detection results and report to the user.
- the camera dust-proof box is also provided with a camera dust-proof cover and a bearing seat of the camera dust-proof cover;
- the bearing seat of the camera dust cover is fixedly connected to the lower end surface of the camera dust box, and the industrial line scan camera is fixedly connected to the bearing seat of the camera dust cover through the support shaft of the industrial camera;
- the camera dust cover is a transparent cylindrical cover. Both ends are installed on the support shaft of the industrial camera through bearings.
- the inner side of the bearing is fixedly connected to the support shaft of the industrial camera, and the outer side of the bearing is fixedly connected to the camera dust cover.
- the camera is dust-proof.
- the cover can rotate along the supporting shaft of the industrial camera;
- the inner wall of the camera dust box is fixedly connected with a brush.
- the length of the brush is equal to the length of the camera dust cover, and the brush is in contact with the outer wall of the camera dust cover.
- one end of the camera dust cover is fixedly connected with the large pulley
- the dust cover motor is fixedly connected to the inner side of the lower end of the camera dust box, its output shaft is fixedly connected to the small pulley, and the timing belt is connected to the large pulley and the small pulley;
- the dust cover motor drives the timing belt to rotate, which in turn drives the camera dust cover to rotate.
- the photographing control module further includes a displacement sensor, and the displacement sensor is a cable displacement sensor; the displacement sensor is in communication connection with the motion controller;
- One end of the displacement sensor is fixed on the ball, and the other end is fixed on the screw base to measure the displacement of the ball, realize the negative feedback control of the ball displacement, and improve the realization accuracy of the ball displacement control.
- an organ cover is provided on the outside of the lead screw
- the organ cover is divided into two parts, one end of each part is fixedly connected to the two ends of the screw base, and the other end is fixed to the two ends of the camera support plate, so as to completely wrap the screw and prevent external dust pollution.
- the screw bearing seat is fixedly connected to the support frame
- One end of the cable drag is fixedly connected to the support frame, and the other end is fixed to the camera dust-proof box, through which the cables of the electrical equipment are passed to protect and regulate the cable installation.
- the shooting control module specifically includes a first limit switch, a second limit switch, a roller proximity block, a roller proximity switch, a shooting trigger switch, an industrial line scan camera, a motion controller, a local computer, a power supply, and electrical equipment. box;
- the first limit switch and the second limit switch are fixedly connected to both ends of the screw base to limit the movement range of the camera dust box;
- the roller close to the stop is fixedly connected to the roller of the roller press, and rotates with the roller;
- the roller proximity switch is fixedly connected to the frame of the roller press. When the roller proximity stopper rotates to the detection area of the roller proximity switch, the roller proximity switch sends out a proximity signal;
- the industrial line scan camera is installed on the support shaft of the industrial camera and is wrapped by the camera dust cover.
- the camera dust cover is transparent, which does not affect the shooting of the industrial line scan camera;
- the electrical box is fixed on the frame of the roller press; the shooting trigger switch, motion controller, local computer, and power supply are installed inside the electrical box;
- the trigger shooting switch is manually pressed to trigger the roll surface detection program to start detection; motion controller and lead screw motor, dust cover motor, electric push rod, displacement sensor, first limit switch, second limit switch , Roller proximity switch and industrial line scan camera respectively communicate with each other;
- the local computer is connected with the data line and control line of the industrial line scan camera, and is used to set the shooting parameters of the industrial line scan camera and receive the photos taken by it;
- the power supply provides power to the system.
- the data processing module is a server, which transmits data between the Ethernet and the local computer;
- the data processing software is installed in the data processing module, which can be divided into two sub-systems: the original image processing system and the operation management system;
- the original image processing system is used to process the original roller surface image data sent by the local computer, pre-processing, cutting, splicing, and resolving roller surface point cloud data;
- the operation management system performs modeling based on the point cloud data of the roll surface, and detects defects and wear on the roll surface;
- the operation management system classifies and manages different roll surfaces according to manufacturers, roll surface types, and ID numbers of industrial line scan cameras used for testing, and saves the roll surface detection results in a local database and reports the detection results to users.
- the present invention also discloses an automatic detection method for the roller surface of a roller press. Based on the above-mentioned automatic detection device for the roller surface of a roller press, the method includes the following steps:
- the calibration of the industrial line scan camera only needs to be done once, and there is no need to calibrate it again after shooting;
- the origin of the established world coordinate system is the starting position before shooting by the industrial line scan camera, the X direction is along the axis of the roller, the Z direction is the direction taken by the laser line of the industrial line scan camera, and the Y direction is determined by the right-hand screw rule, namely
- the user sets the parameters in the shooting control module
- the user sets the shooting parameters of the industrial line scan camera in the local computer
- the user establishes a unique database for each roller surface in the operation management system according to information such as group, manufacturer, equipment type, etc., a specific roller surface is only set once to set the shooting parameters to enter and build the database once, and there is no need to repeat the setting when shooting again in the future; After completion, the user presses the shooting trigger switch, and the system starts to run the automatic roll surface detection program;
- the motion controller first initializes the program to check whether the camera dust box cover has been closed and whether the ball has returned to the original point. If it is not completed, the camera dust box cover is closed and the ball returns to the starting point;
- the motion controller sequentially executes the opening of the camera dust box cover, and the camera dust cover sweeps the dust
- the motion controller sends a photo command
- the motion controller sends a command to drive the ball back to the starting point and drive the camera dust box to close the lid;
- the local computer sends the taken photos and shooting parameters to the original image processing system
- the original image processing system decomposes, cuts, splices, and corrects the original photo data sent from the local computer, extracts depth information according to the image gray value, and generates cloud data of the detected roller surface points in a prescribed format;
- the original image processing system sends the generated point cloud data of the roller surface to the specific path of the database established by the user in the operation management system in S200;
- the operation management system analyzes the received point cloud data, generates two-dimensional and three-dimensional models of the roller surface, and detects its defects, compares its historical data to obtain the wear speed and defect changes of the roller surface, stores the inspection results and reports user;
- the execution of the camera command by the motion controller in the S300 specifically includes:
- the motion controller After the motion controller confirms that the roller operating cycle of the roller press is stable, it drives the ball to the designated camera position. When the ball reaches the designated position, when the roller approaches the stop and approaches the roller proximity switch again, the motion controller listens to the roll proximity switch. At this time, the motion controller sends a photo command to the industrial line array camera.
- the automatic roller surface detection device and detection method of the roller press of the present invention aim at the defects such as low degree of automation, low detection accuracy, and no quantitative data support for manual roller surface detection by the roller press.
- the detection device scans the roller surface with an industrial line scan camera to obtain a partial picture of the roller surface, and moves the shooting position of the industrial line scan camera to obtain multiple partial pictures of the roller surface.
- the partial roller surface photos are cut and spliced to obtain a complete roll surface Point cloud data.
- the mechanism of the present invention is equipped with a dustproof device, which has good stability and reliability; users can set different industrial line laser scanning shooting parameters to realize the detection of different roller surface types and have good scalability.
- the automatic detection device and method for the roller surface of a roller press of the present invention uses an industrial line laser camera to detect the roller surface, and the highest detection accuracy can reach 0.6mm, so that small defects on the roller surface can also be detected, thereby Advance maintenance to avoid greater losses.
- There is no need to open the end cover of the roller press in the process of detecting the roller surface no disassembly, one-button start detection, high degree of automation, automatic generation of detection reports and storage of results, reducing the burden of manual detection.
- the inspection results are intuitive, and the roll surface inspection data is digitized and traceable, providing quantitative data support for process analysis;
- the detection has good real-time performance and high efficiency.
- the shooting scheme adopted by the present invention is fixed-point shooting by an industrial camera.
- the roller of the roller press rotates to form a relative motion with the shooting line of the industrial line scan camera. Therefore, the laser line emitted by the industrial camera moves on the roller surface in a trajectory parallel to the roller.
- a cylindrical surface of the axis, that is, a photo contains partial cylindrical surface information on the roller surface.
- a photo may not contain the information of a complete roll surface, but the actual measurement can cover the largest roll surface in the market with only 4 photos at most.
- the typical shooting frame rate of the industrial line scan camera 206 is 1700 frames per second, and the typical time to take a photo of a roller surface is only about 3 seconds, and the detection process has good real-time performance.
- the cropping and stitching of all 2 or more photos is very simple: First, the axial stitching process is simple, the displacement data of the ball 104 movement is converted into pixel displacement according to the calibration relationship of the camera, and the photos are taken in sequence according to the shooting order. Cutting and splicing; second, each photo is taken according to the signal of the roller proximity switch 204 to trigger, so the starting point of each photo is the same position in the circumferential direction of the roller, that is, in the circumferential direction of the roller , The natural alignment of several photos does not need to be cropped; third, the photos taken by the industrial line scan camera 206 contain depth information, and its gray value represents the depth information, so it is very simple to calculate the three-dimensional point cloud data of the roller surface fast. In summary, the above-designed shooting scheme makes the process of cropping and stitching photos very convenient and efficient;
- the operation management system 302 included in the roller surface monitoring system of the present invention stores the detection results digitally, and the detection results can be easily transmitted to the outside and connected to other intelligent management platforms of the factory to realize convenient management expansion. It is very convenient for users to use and set up the system, just change the shooting parameters to adapt to various types of rollers on the market, with good compatibility;
- Industrial line scan cameras use the principle of triangulation to measure distances.
- the camera integrates a transmitter and a receiver. It is small in size and low in power consumption. It is widely used in industrial sites. Its stability and reliability have been tested in industrial site practices.
- the solution used in the present invention uses a dust box and a dust cover to double seal the industrial camera, and uses an organ cover to seal the ball screw, avoiding the damage to the equipment by the high dust environment inside the roller press. Further improve the stability and reliability of the equipment.
- Figure 1 is a diagram of the working principle of the roller press
- Figure 2 is a state diagram of the wear form of the roller surface of the roller press
- FIG. 3 is a system block diagram of the present invention.
- Figure 4 is a schematic diagram of the structure of the present invention.
- Figure 5 is a schematic diagram of the structure of the motion execution module of the present invention.
- FIG. 6 is a schematic diagram of the structure of the camera dust box of the present invention.
- Figure 7 is a flow chart of the roll surface detection of the present invention.
- FIG. 8 is an image processing flowchart of the present invention.
- Figure 9 is a diagram of the roller surface depth Z according to an embodiment of the present invention.
- Figure 10 is the final roller surface Z diagram of the embodiment of the present invention.
- FIG. 11 is a 3D schematic diagram of a roller surface generated by the operation management system according to an embodiment of the present invention according to the roller surface point cloud data.
- the automatic roller surface detection device of a roller press in this embodiment mainly includes three major components: a motion execution module 100, a shooting control module 200, and a data processing module 300.
- the motion execution module 100 includes the following components: a support frame 101, a screw base 102, a screw 103, a ball 104, a wire drag 105, an organ cover 106, a camera support plate 107, a screw coupling 108, a screw motor 109, Camera dust box 110, brush 111, camera dust cover 112, camera dust cover bearing seat 113, dust cover motor 114, timing belt 115, large pulley 116, small pulley 117, industrial camera support shaft 118, Electric push rod 119, displacement sensor 120, roller press 121.
- the lead screw bearing seat 102 is fixedly connected to the support frame 101, and the lead screw 103 is fitted on the lead screw base 102 through a bearing.
- the ball 104 is installed on the screw 103 by threaded fit, and can move linearly back and forth along the screw 103.
- the screw motor 109 is fixedly connected to the screw 103 through a screw coupling 108.
- a camera support plate 107 is fixedly connected to the upper part of the ball 104, and the outer side of the lower end surface of the camera dust-proof box 110 is fixedly connected to the camera support plate 107.
- the inner side of the lower end of the camera dust box 110 is rotatably connected to one end of the electric push rod 119, and the upper end is rotatably connected to the other end of the electric push rod 119.
- the upper end of the camera dust box 110 can be controlled to open. And closed.
- the side inner wall of the camera dust box 110 is fixedly connected with a brush 111, the length of the brush 111 is equivalent to the camera dust cover 112, and the brush 111 is in contact with the outer wall of the camera dust cover 112.
- the camera dust-proof housing bearing seat 113 is fixedly connected to the lower end surface of the camera dust-proof box 110, and the industrial camera support shaft 118 is fixedly connected to the camera dust-proof housing bearing seat 113.
- the camera dust cover 112 is a transparent cylindrical housing, and both ends are fitted on the support shaft 118 of the industrial camera through bearings.
- the inner side of the bearing is fixedly connected to the support shaft 118 of the industrial camera and remains stationary.
- the outer side of the bearing is fixedly connected with the camera dust cover 112 so that the camera dust cover 112 can rotate along the industrial camera support shaft 118.
- One end of the camera dust cover 112 is fixedly connected to the large pulley 116.
- the dust cover motor 114 is fixedly connected to the inner side of the lower end surface of the camera dust box 110, and its output shaft is fixedly connected to the small pulley 117, and the timing belt 115 is connected to the large pulley 116 and the small pulley 117.
- the dust cover motor 114 drives the timing belt 115 to rotate, thereby driving the camera dust cover 112 to rotate, and the brush 111 sweeps away the floating dust attached to the outer side wall of the camera dust cover 112.
- the displacement sensor 120 is a preferably added component.
- a high-precision pull-wire displacement sensor is selected, one end is fixed on the ball 104, and the other end is fixed on the screw base 102 to measure the displacement of the ball 104 and realize the negative displacement of the ball 104.
- Feedback control improves the accuracy of the displacement control of the ball 104.
- the organ cover 106 is divided into two parts. One end of each part is fixedly connected to the two ends of the screw base 102, and the other end is fixed to the two ends of the camera pallet 107, so as to completely wrap the screw 103 to prevent external dust pollution.
- One end of the cable drag 105 is fixedly connected to the support frame 101, and the other end is fixed to the camera dust-proof box 110, and the cables of the electrical equipment are passed through the cable to protect and regulate the cable installation.
- the shooting control module 200 includes the following components: a first limit switch 201, a second limit switch 202, a roller proximity stop 203, a roller proximity switch 204, a shooting trigger switch 205, an industrial line scan camera 206, and a motion controller 207 ( Preferably a PLC), a local computer 208 (preferably an industrial computer), a power supply 209, and an electrical box 210.
- the first limit switch 201 and the second limit switch 202 are fixedly connected to the two ends of the screw base 102 to limit the movement range of the camera dust box 110.
- the roller approaching stop 203 is fixedly connected to the roller of the roller press, and rotates with the roller.
- the roller proximity switch 204 is fixedly connected to the roller press frame.
- the roller proximity switch 204 sends out a proximity signal.
- the industrial line scan camera 206 is installed on the support shaft 118 of the industrial camera and is wrapped by the camera dust cover 112.
- the camera dust cover 112 is transparent, which does not affect the shooting of the industrial line scan camera 206.
- the electrical box 210 is fixed on the frame of the roller press 121.
- the shooting trigger switch 205, the motion controller 207, the local computer 208, and the power supply 209 are installed inside the electrical box 210. Among them, the trigger shooting switch 205 is manually pressed to trigger the roll surface detection program to start detection.
- the motion controller 207 is preferably a PLC controller, which is combined with the lead screw motor 109, the dust cover motor 114, the electric push rod 119, the displacement sensor 120, the first limit switch 201, the second limit switch 202, and the roller proximity switch 204,
- the control line or data line of the industrial line scan camera 206 is connected.
- the local computer 208 is connected to the data line and the control line of the industrial line scan camera 206, and is used to set the shooting parameters of the industrial line scan camera 206 and receive the photos taken by it.
- the power supply 209 provides power to the system.
- the data processing module 300 is a server that transmits data between the local computer 208 via Ethernet.
- Data processing software is installed in the data processing module 300, which can be specifically divided into two subsystems: the original image processing system 301 and the operation management system 302.
- the original image processing system 301 is used to process the original roller surface image data sent by the local computer 208, and perform preprocessing, cropping, splicing, and calculation of the roller surface point cloud data.
- the operation management system 302 performs modeling based on the roller surface point cloud data, and detects roller surface defects and wear conditions.
- the operation management system 302 can classify and manage different roll surfaces according to manufacturers, roll surface types, ID numbers of industrial line scan cameras 206 used for testing, etc., save the roll surface detection results in a local database, and report the detection results to users.
- the detection method corresponding to the roller surface defect recognition device of the roller press according to the embodiment of the present invention is performed as follows:
- S100 Camera calibration.
- the industrial line scan camera 206 is calibrated, and the conversion relationship between the pixel gray value and the real-world displacement is established, that is, the homography matrix of the industrial line scan camera 206.
- the calibration of the industrial line scan camera 206 is performed using a calibration block whose size is accurately known, and has nothing to do with the size of the roller press and its related components.
- the calibration of the industrial line scan camera 206 only needs to be performed once before the first shooting, and there is no need to calibrate again after shooting.
- the world coordinate system of the roller surface detection system is established, and the result captured by the industrial camera 206 is converted into the roller surface point cloud data and expressed in this coordinate system.
- the origin of the established world coordinate system is the starting position before shooting by the industrial line scan camera 206, the X direction is the direction along the roller axis, the Z direction is the direction taken by the laser line of the industrial line scan camera 206, and the Y direction is determined by the right-hand screw rule.
- the system is powered on, and the rollers of the roller press 121 start to rotate.
- the user sets parameters in the shooting control module 200.
- the user sets the parameters taken by the industrial line scan camera 206 in the local computer 208, including the frame rate taken by the industrial line scan camera 206, the number of taken photos, the number of frames taken by a single photo, and the exposure time.
- the user establishes a unique database for each roller surface in the operation management system 302 according to information such as group, manufacturer, and equipment type. A specific roller surface only needs to set the shooting parameters once to enter and build the database once, and there is no need to repeat it when shooting again in the future.
- the user presses the shooting trigger switch 205, and the system starts to run the automatic roller surface detection program;
- the motion controller 207 first initializes the program to check whether the lid of the camera dust box 110 has been closed and whether the ball 104 has returned to the original point. If not, the camera dust box 110 will close the lid and the ball 104 will return to the starting point. . Then the motion controller 207 sequentially executes the opening of the camera dust box 110 and the camera dust cover 112 to sweep dust. After the motion controller 207 confirms that the roller operating cycle of the roller press 121 is stable, it drives the ball 104 to move to the designated photographing position.
- the motion controller 207 monitors the proximity signal sent by the roller proximity switch 204, and at this time the motion controller 207 sends a photo command to the industrial line array camera 206;
- the industrial line scan camera 206 executes a photographing task.
- the number of frames of the captured picture is equal to the number of single-shot frames set in S200. Theoretically, the number of single-shot frames is the roller running period multiplied by the camera's shooting frame rate. The information contained in a single picture is exactly a part of the roller surface. Cylindrical surface.
- S500 Repeatedly execute actions such as running the ball 104 in S300 to the designated photographing position and the motion controller 207 sending a photographing command and S400 until the number of photographs is equal to the number of photographs set by the user in S200;
- the motion controller 207 sends a command to drive the ball 104 back to the starting point, and drives the camera dust box 110 to close the lid.
- S700 The local computer 208 sends the taken photos and shooting parameters to the original image processing system 301;
- the original image processing system 301 decomposes, crops, splices, and corrects the original photo data sent by the local computer 208, extracts depth information according to the image gray value, and generates cloud data of the detected roller surface points in a prescribed format.
- the original image processing system 301 sends the generated point cloud data of the roller surface to the specific path of the database established by the user in the operation management system 302 in S200;
- the operation management system 302 analyzes the received point cloud data, generates two-dimensional and three-dimensional models of the roller surface, and detects its defects, compares its historical data to obtain the wear speed and defect changes of the roller surface, stores the inspection results and Report user
- the implementation process of the present invention is explained by taking a detection roller surface with a diameter of 1200 mm and an axial length of the roller surface of 500 mm as an example. An experimental environment for testing has been built.
- Step1 Calibrate the industrial line scan camera 206, and establish the conversion relationship between the pixel gray value and the actual displacement, that is, the homography matrix of the industrial line scan camera 206.
- the calibration of the industrial line scan camera 206 is performed using a calibration block whose size is accurately known, and has nothing to do with the size of the roller press and its related components.
- the calibration of the industrial line scan camera 206 only needs to be performed once, and there is no need to calibrate again for subsequent shooting.
- the world coordinate system of the roller surface detection system is established, and the result captured by the industrial camera 206 is converted into the roller surface point cloud data and expressed in this coordinate system.
- the origin of the established world coordinate system is the starting position before shooting by the industrial line scan camera 206, the X direction is the direction along the roller axis, the Z direction is the direction taken by the laser line of the industrial line scan camera 206, and the Y direction is determined by the right-hand screw rule.
- Step2 Power on the system.
- the user sets the shooting parameters of the industrial line scan camera 206 in the local computer 208, including the frame rate when the industrial line scan camera 206 shoots, the number of pictures taken by the industrial line scan camera 206, and the number of frames contained in a single photo.
- the number of shots taken by the industrial line scan camera 206 is equal to the length of the roller surface in the axial direction divided by the length of the laser line shooting area in the axial direction.
- the number of line laser frames of a single photo taken by the industrial line camera 206 (corresponding to the number of rows of a single photo) is theoretically equal to the period when the roller rotates steadily multiplied by the camera's shooting frame rate.
- the position of the industrial line scan camera 206 is set in the motion controller 207 when each picture is taken.
- the user establishes a unique database for each roller surface in the operation management system 302 according to information such as group, manufacturer, equipment type, etc., and sets a threshold value for determining a roller surface defect.
- a specific roller surface only needs to set the shooting parameters once to enter and build the database once, and there is no need to repeat the setting when shooting again in the future.
- Step3 The operation steps of the automatic roller surface photographing program can be subdivided as follows:
- the motion controller 207 initializes the parameters, sends a command to the electric push rod 119, and the electric push rod 119 shrinks to ensure that the top plate of the camera dust box 110 is closed;
- the motion controller 207 confirms whether the ball 104 is at the starting position by querying the signal of the first limit switch 201, that is, the position on the lead screw 103 where the first limit switch 201 is located. If the ball 104 is at the initial position, no action is performed; if the ball 104 is not at the initial position, the motion controller 207 sends a command to the screw motor 109, and the screw motor 109 drives the screw 103 to rotate so that the ball 104 returns to the initial position. Thus, the industrial line scan camera 206 fixedly connected to the ball 104 is brought back to the starting position;
- the motion controller 207 sends a command to the electric push rod 119 to extend, open the top plate of the camera dust box 110, so that the industrial line scan camera 206 has the field of view of the shooting roller surface;
- the motion controller 207 sends a command to the dust cover motor 114, the dust cover motor 114 drives the camera dust cover 112 to rotate through the timing belt 115, and the brush 111 sweeps away the floating dust on the outer side of the camera dust cover 112 to Ensure that the industrial line scan camera 206 is not blocked by floating dust when shooting, and the pictures taken are clear;
- the motion controller 207 judges the signal returned by the roller proximity switch 204, confirms that the roller operating cycle of the roller press 121 reaches a stable state, and then executes the next step;
- the motion controller 207 sends a command to the lead screw motor 109, and the lead screw motor 109 drives the lead screw 103 to rotate to move the ball 104 to the shooting position set by the user in Step 2, so that the industrial line array camera is fixedly connected to the ball 104 206 is transported to the set shooting position.
- the motion controller 207 performs negative feedback control through the measurement signal of the displacement sensor 120, so that the displacement control of the ball 104 is more accurate.
- the motion controller 207 simultaneously monitors the signals of the first limit switch 201 and the second limit switch 202 to ensure that the current position of the ball 104 is limited to the first limit switch 201 and the second limit switch Between 202;
- the motion controller 207 waits for the triggering shooting signal of the roller proximity switch 204.
- the roller proximity stop 203 fixedly connected to the roller moves to the detection area of the roller proximity switch 204
- the roller proximity switch 204 sends a proximity signal to the motion controller 207.
- the motion controller 207 detects the signal, it sends a shooting command to the industry
- the industrial line scan camera 206 immediately shoots the image of the roller surface.
- the industrial line scan camera 206 sends the photo data to the local computer 208 via the data cable;
- the motion controller 207 sends a signal to the electric push rod 119 to contract the electric push rod, thereby closing the upper cover of the camera dust box 110.
- the motion controller 207 sends a control signal to the screw motor 109, and drives the screw 103 to rotate to make the ball 104 return starting point.
- the local computer 208 sends the photos and shooting parameters taken by the industrial line scan camera 206 to the original image processing system 301 via Ethernet.
- Step4 The original image processing system 301 stores and reads the original photos sent by the local computer 208.
- Each original image can be decomposed into a depth map X along the axial direction of the roller, a depth map Y along the circumferential direction of the roller, and a depth map Z along the radial direction of the roller.
- the depth map Z is shown in Figure 9.
- the effective roller surface area in all Z images is extracted and spliced according to the shooting order to obtain a complete roller surface Z image. Perform linear calibration on the complete roll surface Z map, filter out noise points, and get the final roll surface Z map.
- the final Z map of the roll surface is shown in Figure 10. Extract depth information from the final roll surface Z map, and generate roll surface point cloud data T according to the specified format;
- Step5 The original image processing system 301 sends the generated roller surface point cloud data T to the specific path of the roller surface database established by the user in the operation management system 402 in Step2.
- the operation management system 302 regularly detects or is triggered by the user, and scans for the newly sent roll surface point cloud data T under a specific path. If a new roll surface point cloud data T is detected, the roll surface point cloud data T will be analyzed immediately to generate a two-dimensional and three-dimensional model of the roll surface, and its defects will be detected according to the image processing algorithm. At the same time, the operation management system 302 compares the results of this inspection with the historical inspection data, and obtains the dynamic change information of the roller surface wear.
- FIG. 7 is a flowchart of image processing performed by the data processing module 300
- FIG. 11 is a 3D diagram of the roller surface generated by the operation management system 302 according to the roller surface point cloud data T;
- Step6 When the user does not need to detect the roller surface, you can choose to turn off the system power to end the process. Conversely, if you need to continue to detect the roller surface, repeat Step2–Step5 until you no longer need to detect the roller surface.
- the automatic detection device and detection method for the roll surface of the roll press aim at the low degree of automation, low detection accuracy, and no quantitative data support in the roll press for manual roll surface detection.
- the automatic surface detection device scans the roller surface with an industrial line scan camera to obtain a partial photo of the roll surface, and moves the shooting position of the industrial line scan camera to obtain multiple partial photos of the roll surface.
- the partial roll surface photos are cut and spliced to obtain a complete roll.
- Point cloud data of the surface Establish two-dimensional and three-dimensional roll surface models based on point cloud data, detect roll surface defects, and establish a database system to manage different roll surfaces.
- the mechanism of the present invention is equipped with a dustproof device, which has good stability and reliability; users can set different industrial line laser scanning shooting parameters to realize the detection of different roller surface types and have good scalability.
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Abstract
Description
Claims (10)
- 一种辊压机辊面自动检测装置,包括拍摄控制模块(200)、运动执行模块(100)和数据处理模块(300),其特征在于:拍摄控制模块(200)包括工业线阵相机(206)、运动控制器(207)和本地计算机(208);所述工业线阵相机(206)设置在辊压机辊面的上方;所述本地计算机(208)与工业线阵相机(206)通讯连接,用于设置工业线阵相机(206)的拍摄参数和接收其拍摄照片;其中,所述运动执行模块(100)包括丝杠(103)、丝杠电机(109)、滚珠(104)和相机防尘箱(110);所述丝杠(103)通过轴承配合安装在丝杠底座(102)上,滚珠(104)安装在丝杠(103)上,滚珠(104)可沿着丝杠(103)前后直线运动;丝杠电机(109)通过丝杠联轴器(108)与丝杠(103)固定连接,滚珠(104)下方固定连接有相机托板(107),相机托板(107)的底部固定连接相机防尘箱(110),相机防尘箱(110)的内部沿纵向方向设置电推杆(119),电推杆(119)分别与相机防尘箱(110)上下端面内侧转动连接,所述电推杆(119)可伸缩,通过控制电推杆(119)的伸长和缩短可以控制相机防尘箱(110)下端面的开启和关闭;所述工业线阵相机(206)固定在相机防尘箱(110)的内部,所述工业线阵相机(206)与运动控制器(207)通讯连接,工业线阵相机(206)收到运动控制器(207)发出的拍照信号后,执行拍照任务;工业线阵相机(206)拍摄完成后,将拍摄的照片发送至本地计算机(208);本地计算机(208)将已拍摄照片及拍摄参数发送至数据处理模块(300),数据处理模块(300)对本地计算机(208)发送过来的原始照片数据进行分解、裁剪、拼接、校正,根据图像灰度值提取深度信息,按规定格式生成所检测辊面点的云数据,进而生成辊面的二维和三维模型,并检测其缺陷,对比其历史数据得出辊面的磨损速度及缺陷变化,存储检测结果并报告用户。
- 根据权利要求1所述的辊压机辊面自动检测装置,其特征在于:所述相机防尘箱(110)内部还设置相机防尘罩(112)和相机防尘罩轴承座(113);相机防尘罩轴承座(113)固定连接在相机防尘箱(110)的下端面,工业线阵相机(206)通过工业相机支撑轴(118)固定连接在相机防尘罩轴承座(113)上;相机防尘罩(112)是一个透明的圆柱体罩壳,两端通过轴承配合安装在工业相机支撑轴(118)上,轴承的内侧与工业相机支撑轴(118)固定连接,轴承外侧与相机防尘罩(112)固定连接,相机防尘罩(112)可沿着工业相机支撑轴(118)转动;所述相机防尘箱(110)侧面内壁固定连接毛刷(111),毛刷(111)的长度等于相机防尘罩(112)的长度,且毛刷(111)与相机防尘罩(112)外侧壁接触,当相机防尘罩(112)绕工业相机支撑轴(118)转动时,所述毛刷(111)扫除附着在相机防尘罩(112)外侧壁的浮灰。
- 根据权利要求2所述的辊压机辊面自动检测装置,其特征在于:所述相机防尘罩(112)的一端与大带轮(116)固定连接;防尘罩电机(114)固定连接在相机防尘箱(110)下端面内侧,其输出轴固定连接小带轮(117),同步带(115)连接大带轮(116)和小带轮(117);通过防尘罩电机(114)驱动同步带(115)转动,进而带动相机防尘罩(112)转动。
- 根据权利要求1所述的辊压机辊面自动检测装置,其特征在于:所述拍摄控制模块(200)还包括位移传感器(120),所述位移传感器(120)选用拉线位移传感器;位移传感器(120)与运动控制器(207)通讯连接;所述位移传感器(120)一端固定在滚珠(104)上,另一端固定在丝杠底座(102)上,用以测量滚珠(104)的位移,实现对滚珠(104)位移的负反馈控制,提高滚珠(104)位移控制的实现精度。
- 根据权利要求1所述的辊压机辊面自动检测装置,其特征在于:所述丝杠(103)的外部设置风琴罩(106);风琴罩(106)分为两部分,每部分的一端分别固定连接在丝杠底座(102)的两头,另一端分别固定相机托板(107)的两头,从而将丝杠(103)完整地包裹,防止外界灰尘污染。
- 根据权利要求1所述的辊压机辊面自动检测装置,其特征在于:还包括线拖(105);所述丝杠轴承座(102)固定连接在支撑架(101)上;线拖(105)一端固定连接在支撑架(101)上,另一端固定相机防尘箱(110)上,在其中穿过电气设备的线缆,用于保护和规范线缆安装。
- 根据权利要求1所述的辊压机辊面自动检测装置,其特征在于:所述拍摄控制模块(200)具体包括第一限位开关(201)、第二限位开关(202)、 辊子接近挡块(203)、辊子接近开关(204)、拍摄触发开关(205)、工业线阵相机(206)、运动控制器(207)、本地计算机(208)、电源(209)、电气箱(210);所述第一限位开关(201)和第二限位开关(202)固定连接在丝杠底座(102)的两端,用以限定相机防尘箱(110)的活动范围;辊子接近挡块(203)固定连接在辊压机的辊子上,随辊子一起转动;辊子接近开关(204)固定连接在辊压机机架上,当辊子接近挡块(203)转动到辊子接近开关(204)的检测区域时,辊子接近开关(204)向外发出接近信号;工业线阵相机(206)安装在工业相机支撑轴(118)上,且被相机防尘罩(112)包裹,相机防尘罩(112)是透明的,则不影响工业线阵相机(206)的拍摄;电气箱(210)固定在辊压机(121)机架上;拍摄触发开关(205)、运动控制器(207)、本地计算机(208)、电源(209)被安装在电气箱(210)内部;其中,触发拍摄开关(205)用于人工按下,触发辊面检测程序开始检测;运动控制器(207)与丝杠电机(109)、防尘罩电机(114)、电推杆(119)、位移传感器(120)、第一限位开关(201)、第二限位开关(202)、辊子接近开关(204)、工业线阵相机(206)分别通讯连接;本地计算机(208)与工业线阵相机(206)的数据线和控制线相连,用于设置工业线阵相机(206)的拍摄参数和接收其拍摄照片;电源(209)为***提供电源。
- 根据权利要求1所述的辊压机辊面自动检测装置,其特征在于:所述数据处理模块(300)是一台服务器,通过以太网与本地计算机(208)之间传输数据;数据处理模块(300)中安装有数据处理软件,具体可分为两个子***:原始图像处理***(301)和运营管理***(302);其中原始图像处理***(301)用来处理本地计算机(208)发送过来的原始辊面图像数据,对其进行预处理、裁剪、拼接、解算辊面点云数据;运营管理***(302)根据辊面点云数据进行建模,检测辊面缺陷及磨损;运营管理***(302)对不同辊面按厂家、辊面类型、检测所用工业线阵相机(206)的ID号等进行分类管理,并将辊面检测结果保存在本地数据库,以及将检测结果报告用户。
- 一种辊压机辊面自动检测方法,基于权利要求8任意一项所述的辊压机辊面自动检测装置,其特征在于:包括以下步骤:S100、相机标定;对工业线阵相机(206)进行标定,建立像素灰度值与现实世界位移之间的转换关系;对工业线阵相机(206)的标定工作只需要进行一次,以后拍摄不需要再次标定;建立辊面检测***的世界坐标系,工业相机(206)拍摄的结果转换为辊面点云数据是在此坐标系下表示的;S200、***上电,辊压机(121)121辊子开始转动;用户在拍摄控制模块(200)中设置参数;用户在本地计算机(208)中设置工业线阵相机(206)拍摄的参数;用户在运营管理***(302)中按集团、厂家、设备类型等信息为每个辊面建立唯一的数据库,一个特定的辊面只设置一次拍摄参数进和建立一次数据库,以后再次拍摄时不需要重复;设置完成后,用户按下拍摄触发开关(205),***开始运行自动辊面检测程序;S300、运动控制器(207)首先初始化程序,检查相机防尘箱(110)箱盖是否已关闭,滚珠(104)是否已回到原点,若未完成则执行相机防尘箱(110)关箱盖、滚珠(104)回起始点动作;接着运动控制器(207)顺序执行相机防尘箱(110)开箱盖,相机防尘罩(112)扫尘;运动控制器(207)发送拍照命令;S400、工业线阵相机(206)收到运动控制器(207)发出的拍照信号后,执行拍照任务;工业线阵相机(206)拍摄完成后,将拍摄的照片发送至本地计算机(208);S500、反复执行Step3中的滚珠(104)运行至指定拍照位置、运动控制器(207)发送拍摄命令等动作和Step4,直至拍照的张数等于Step2中用户设置的拍摄张数;S600、运动控制器(207)发送命令驱动滚珠(104)回到起始点、驱动相机防尘箱(110)关箱盖;S700、本地计算机(208)将已拍摄照片及拍摄参数发送至原始图像处理***(301);S800、原始图像处理***(301)对本地计算机(208)发送过来的原始照片数据进行分解、裁剪、拼接、校正,根据图像灰度值提取深度信息,按规定格式生成所检测辊面点的云数据;原始图像处理***(301)将生成的辊面的的点云数据发送至Step2中用户在运营管理***(302)中所建立数据库的特定路径下;S900、运营管理***(302)对收到的点云数据进行分析,生成辊面的二维和三维模型,并检测其缺陷,对比其历史数据得出辊面的磨损速度及缺陷变化,存储检测结果并报告用户;S1000:当用户不需要再检测辊面时,关闭***电源;反之,如果需要继续检测辊面,反复执行S200–S900直至不需要再检测辊面。
- 根据权利要求9所述的一种辊压机辊面自动检测方法,其特征在于:所述S300中运动控制器(207)执行拍照命令,具体包括:运动控制器(207)确认辊压机(121)的辊子运行周期稳定之后,驱动滚珠(104)运行至指定拍照位置,当滚珠(104)运行到指定位置后,辊子接近挡块(203)再次靠近辊子接近开关(204)时,运动控制器(207)监听到辊子接近开关(204)发出的接近信号,此时运动控制器(207)向工业线阵相机(206)发送拍照命令。
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