Crawler chassis type coal bunker detection robot system

Abstract

The invention discloses a crawler chassis type coal bunker detection robot system, and belongs to the technical field of coal bunker detection. The problems that existing coal bunker detection equipment is limited by the structure of a coal bunker and is difficult to implement and apply are solved. Comprising a crawler-type base which adopts a crawler-type chassis to support a carriage; the front end of the carriage is sequentially connected with a rotating arm and a telescopic arm through a stand column; a gap of at least 100mm is formed between the telescopic arm and the rotating arm; the tail ends of the telescopic arms are connected with detection assemblies; after the control module controls the telescopic arm to stretch into the coal bunker, the pan-tilt camera and the three-dimensional laser radar are started, the three-dimensional laser radar conducts experimental scanning on the interior of the coal bunker, and the pan-tilt camera conducts image collection synchronously; and a data processing module is adopted to fuse the coal bunker internal distance information and the coal bunker internal image to obtain a three-dimensional model after coal bunker internal fusion, and then target positioning is performed to obtain coal bunker inner wall data, coal position data and target equipment position data. The method is used for coal bunker internal environment detection.

Description

Technical Field

[0001] The invention relates to a crawler chassis type coal bunker detection robot system, belonging to the technical field of coal bunker detection. Background Art

[0002] With the acceleration of industrialization, coal, as an important part of the global energy structure, has become particularly important for safe and efficient production and transportation. In the process of coal production, washing and transportation, coal bunkers play a vital role as key facilities to buffer the difference in production and transportation rates. Due to the storage and transfer of raw coal, the inner wall of the coal bunker is subjected to the impact, wear and corrosion of coal and corrosive elements (such as sulfur, phosphorus, etc.) for a long time, which is prone to problems such as lining aging, fastener oxidation, corrosion and lining edge warping. If these problems are not repaired in time, they may cause damage to the inner wall of the coal bunker, affect the service life of the coal bunker, and even cause safety accidents.

[0003] Traditional coal bunker inspections rely mainly on manual inspections, where workers need to build scaffolding and use headlights to perform inspections in an environment with low light and heavy dust. This method is not only inefficient and inaccurate, but also poses a threat to workers' health and there is a safety risk of falling into the coal pile. In addition, manual inspections are time-consuming, usually taking several days to complete the inspection of the entire coal bunker, which seriously affects the continuity and efficiency of production.

[0004] In order to improve the automation of coal bunker detection, achieve efficient maintenance, and reduce the safety risks of manual detection, some studies have attempted to use machine vision and image processing technology to achieve automatic detection of coal bunker linings. However, these methods are often limited by the complex environmental conditions inside the coal bunker, such as insufficient light and dust interference, and it is difficult to achieve ideal detection results. The existing coal bunker coal level detection based on laser imaging and image processing technology uses laser active imaging technology to obtain coal level images, and obtains coal level depth information through image processing systems and recognition algorithms. However, due to the structural limitations of the coal bunker itself, this detection system has problems such as complex installation, restricted mine environment, and difficulty in transfer. Summary of the invention

[0005] In view of the problem that the existing coal bunker detection equipment is limited by the structure of the coal bunker itself and is difficult to implement and apply, the present invention provides a crawler chassis type coal bunker detection robot system.

[0006] A crawler chassis type coal bunker detection robot system of the present invention comprises:

[0007] The crawler base includes a crawler chassis and a vehicle box; the crawler chassis is used to support the vehicle box and enable the vehicle box to rotate 360 ​​degrees;

[0008] The detection arm comprises a column, a rotating arm and a telescopic arm; the head end of the column is connected to the front end of the vehicle box, the end of the column is connected to the head end of the rotating arm, the end of the rotating arm is connected to the head end of the telescopic arm through a connecting piece, and the end of the telescopic arm is connected to the detection component; there is a gap of at least 100 mm between the telescopic arm and the rotating arm;

[0009] Detection components, including a pan-tilt camera and a 3D laser radar, are used to detect the internal environment of the coal bunker;

[0010] The control module controls the telescopic arm to extend into the coal bunker, starts the PTZ camera and the 3D laser radar, enables the 3D laser radar to perform an experimental scan of the interior of the coal bunker, and enables the PTZ camera to synchronously collect images;

[0011] The data processing module obtains the three-dimensional point cloud inside the coal bunker based on the internal distance information of the coal bunker obtained by the three-dimensional laser radar through emitting laser beams; the three-dimensional point cloud inside the coal bunker is fused with the internal image of the coal bunker collected by the pan-tilt camera to obtain a fused three-dimensional model of the coal bunker, and the target is positioned based on the fused three-dimensional model of the coal bunker to obtain the coal bunker inner wall data, coal position data and target equipment position data.

[0012] According to the crawler chassis type coal bunker detection robot system of the present invention, for the detection arm, the posture of each section of the telescopic arm is controlled by telescoping the hydraulic cylinder;

[0013] The head end of the column is connected to the front end of the vehicle box through a rotary reducer; the rotating arm is connected to the column and the telescopic arm respectively by hydraulic cylinders to control the angle of the telescopic arm;

[0014] The maximum extension length of the detection arm is 6.2m from the ground.

[0015] According to the crawler chassis type coal bunker detection robot system of the present invention, the three-dimensional model after fusion inside the coal bunker is subjected to target positioning after denoising, filtering and registration.

[0016] According to the crawler chassis type coal bunker detection robot system of the present invention, the detection component also includes a sound collection module and a gas monitoring sensor. The sound collection module is used to collect sound signals inside the coal bunker; the gas monitoring sensor is used to monitor the gas content inside the coal bunker; the sound signals inside the coal bunker are used to characterize the coal and slag accumulation and collapse of the coal bunker;

[0017] The sound signal inside the coal bunker and the gas content signal inside the coal bunker are compared with the corresponding set thresholds respectively. When the threshold is exceeded, an alarm is issued.

[0018] According to the crawler chassis type coal bunker detection robot system of the present invention, the gases monitored by the gas monitoring sensor include carbon monoxide, methane and oxygen.

[0019] The crawler chassis coal bunker detection robot system according to the present invention also includes an alarm module, which is used to alarm when the coal bunker inner wall data, coal position data and target equipment position data are abnormal; at the same time, it is used to alarm when any of the sound signal inside the coal bunker and the gas content signal inside the coal bunker exceeds the set threshold.

[0020] The crawler chassis coal bunker detection robot system according to the present invention also includes a data storage module for storing internal distance information of the coal bunker collected by the three-dimensional laser radar, internal images of the coal bunker collected by the pan-tilt camera, coal bunker inner wall data, coal position data, target equipment location data and alarm information.

[0021] The crawler chassis type coal bunker detection robot system according to the present invention further includes a data analysis module for analyzing the data stored in the data storage module to obtain the coal position change trend and the target equipment operating status.

[0022] According to the crawler chassis type coal bunker detection robot system of the present invention, a counterweight is arranged at the rear end of the carriage.

[0023] According to the crawler chassis coal bunker detection robot system of the present invention, a camera is arranged on the column for monitoring the posture of the rotating arm and the telescopic arm; the control module controls the position of the rotating arm and the telescopic arm according to the posture feedback of the rotating arm and the telescopic arm.

[0024] Beneficial effects of the present invention: The system of the present invention is used to automatically detect coal sticking and blockage conditions on the internal bunker wall, and through data processing, the actual contour of the inner wall of the coal bunker, coal position data and target equipment position data can be obtained.

[0025] The system of the present invention is suitable for working in coal bunker environment; it does not require external power traction, can be transferred, and the crawler chassis can be driven and positioned for detection work. The detection component is used to realize all-round image acquisition inside the coal bunker and local detail image acquisition of key inspection equipment at different angles, and can collect the on-site working conditions along the track direction in real time, realizing all-round visual monitoring in the bunker.

[0026] In order to reduce space occupation and make the body small enough and the arm long enough in the system of the present invention, a gap of at least 100 mm is set between the telescopic arm and the rotating arm, so that the robot can be deployed from the front of the machine when the arm is extended, avoiding interference caused by normal arm extension. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a structural schematic diagram of the crawler chassis type coal bunker detection robot system of the present invention;

[0028] Figure 2 is a schematic diagram of a crawler base;

[0029] Figure 3is a schematic diagram of the detection arm;

[0030] Figure 4 is a schematic diagram of the extended state of the detection arm;

[0031] Figure 5 It is a schematic diagram of the structure of the detection component;

[0032] Figure 6 It is a schematic diagram of the hoisting form of the crawler chassis type coal bunker detection robot system;

[0033] Figure 7 It is a schematic diagram of the driving form of the crawler chassis type coal bunker detection robot system;

[0034] Figure 8 yes Figure 7 Right view of;

[0035] Fig. 9 It is a coal bunker detection control flow chart of the crawler chassis type coal bunker detection robot system of the present invention. DETAILED DESCRIPTION

[0036] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0037] It should be noted that, in the absence of conflict, the embodiments of the present invention and the features in the embodiments may be combined with each other.

[0038] The present invention will be further described below in conjunction with the accompanying drawings and specific embodiments, but they are not intended to limit the present invention.

[0039] Specific implementation method 1. Combination Figures 1 to 9 As shown, the present invention provides a crawler chassis type coal bunker detection robot system, comprising:

[0040] The crawler base includes a crawler chassis and a vehicle box; the crawler chassis is used to support the vehicle box and enable the vehicle box to rotate 360 ​​degrees;

[0041] The detection arm comprises a column, a rotating arm and a telescopic arm; the head end of the column is connected to the front end of the vehicle box, the end of the column is connected to the head end of the rotating arm, the end of the rotating arm is connected to the head end of the telescopic arm through a connecting piece, and the end of the telescopic arm is connected to the detection component; there is a gap of at least 100 mm between the telescopic arm and the rotating arm;

[0042] Detection components, including a pan-tilt camera and a 3D laser radar, are used to detect the internal environment of the coal bunker;

[0043] The control module controls the telescopic arm to extend into the coal bunker, starts the PTZ camera and the 3D laser radar, enables the 3D laser radar to perform an experimental scan of the interior of the coal bunker, and enables the PTZ camera to synchronously collect images;

[0044] The data processing module obtains the three-dimensional point cloud inside the coal bunker based on the internal distance information of the coal bunker obtained by the three-dimensional laser radar through emitting laser beams; the three-dimensional point cloud inside the coal bunker is fused with the internal image of the coal bunker collected by the pan-tilt camera to obtain a fused three-dimensional model of the coal bunker, and the target is positioned based on the fused three-dimensional model of the coal bunker to obtain the coal bunker inner wall data, coal position data and target equipment position data.

[0045] The overall vehicle body can be set to be 1.42m long, 1.06m wide and 0.72m high; the track chassis has a large contact area with the ground, good passability and high stability.

[0046] Driven by the rotating mechanism, the three-dimensional laser radar and the gimbal camera are driven to rotate horizontally synchronously to increase the scanning range.

[0047] The detection assembly is set on the detection platform, and the detection platform is rigidly connected to the end arm of the telescopic arm through stud nuts. The size of the detection platform is set to 0.54m long, 0.38m wide and 0.59m high, which is suitable for operation in the narrow environment of the coal bunker.

[0048] Further, combined with Figure 3 and Figure 4 As shown, the detection arm is hydraulically controlled as a whole; the posture of each section of the telescopic arm is controlled by telescoping the hydraulic cylinder;

[0049] The head of the column is connected to the front end of the vehicle through a rotary reducer; the servo motor drives the column to rotate horizontally; the rotating arm is connected to the column and the telescopic arm by hydraulic cylinders to control the angle of the telescopic arm; the telescopic arm can be selected to include a six-section arm, which is controlled by a hydraulic cylinder; the end of the telescopic arm can be connected to the detection component through bolts; when the rotating arm adjusts the working angle, the six-section telescopic arm is fully unfolded. When detecting the vertical warehouse, the maximum extension length of the detection arm is 6.2m from the ground.

[0050] Combination Figures 6 to 8 As shown, the robot has two forms: hoisting and traveling, which are respectively suitable for two working conditions: hoisting down the well and traveling in the well. In the hoisting form, the length is 1.45m, the width is 1m, and the height is 2.6m; in the traveling form, the length is 1.95m, the width is 1m, and the height is 1.58m.

[0051] In this embodiment, the fused three-dimensional model inside the coal bunker is subjected to denoising, filtering and registration for target positioning.

[0052] Furthermore, the detection component also includes a sound collection module and a gas monitoring sensor. The sound collection module is used to collect sound signals inside the coal bunker; the gas monitoring sensor is used to monitor the gas content inside the coal bunker; the sound signals inside the coal bunker are used to characterize the coal and slag accumulation in the coal bunker;

[0053] The sound signal inside the coal bunker and the gas content signal inside the coal bunker are compared with the corresponding set thresholds respectively. When the threshold is exceeded, an alarm is issued.

[0054] As an example, the gases monitored by the gas monitoring sensor include carbon monoxide, methane and oxygen.

[0055] This embodiment also includes an alarm module, which is used to sound an alarm when the coal bunker inner wall data, coal position data and target equipment location data are abnormal; it is also used to sound an alarm when any of the coal bunker internal sound signals and coal bunker internal gas content signals exceeds a set threshold.

[0056] This embodiment also includes a data storage module for storing internal distance information of the coal bunker collected by the three-dimensional laser radar, internal images of the coal bunker collected by the pan-tilt camera, inner wall data of the coal bunker, coal position data, target equipment location data and alarm information.

[0057] Furthermore, it also includes a data analysis module for analyzing the data stored in the data storage module to obtain the coal position change trend and the operating status of the target equipment.

[0058] In this embodiment, a counterweight is arranged at the rear end of the vehicle box, and a detection arm is installed at the front end of the vehicle box, and the counterweight can ensure the stability of the vehicle body of the robot when performing detection work.

[0059] Furthermore, a camera is arranged on the column to monitor the posture of the rotating arm and the telescopic arm; the control module controls the position of the rotating arm and the telescopic arm according to the posture feedback of the rotating arm and the telescopic arm.

[0060] In this implementation, the coal bunker detection control process is specifically as follows:

[0061] After the coal bunker detection robot extends its detection arm into the coal bunker, it uses the laser radar and pan-tilt camera to perform an experimental scan of the coal bunker and collect information about the internal conditions of the coal bunker, such as Fig. 9 shown.

[0062] In the data collection phase, the 3D laser radar emits a laser beam and measures the time it takes for the laser beam to reflect back to obtain the distance information of objects in the environment, converts the acquired distance information into 3D point cloud data, and transmits it to the control module in real time. The PTZ camera takes real-time photos of the environment in the coal bunker according to the preset shooting parameters, and transmits the captured image data to the control module for subsequent image processing and recognition.

[0063] In the data processing stage, the three-dimensional point cloud data obtained by the lidar is fused with the image data taken by the gimbal camera to obtain richer environmental information. The fused data is processed, including denoising, filtering, and registration, to improve the accuracy and reliability of the data.

[0064] In the target detection and positioning phase, image processing algorithms are used to detect targets in images taken by the PTZ camera, and target objects such as coal piles and equipment are identified. Based on the 3D point cloud data obtained by the LiDAR, 3D modeling of the target object is performed to obtain information such as its shape and size. Combining the data of the LiDAR and the PTZ camera, the target object is accurately positioned to obtain its position information in the coal bunker, and the position of the robot detection arm is appropriately adjusted as information feedback.

[0065] The alarm and feedback link is used to set the alarm. According to the actual needs of the coal bunker, the alarm threshold is set, such as coal level height, equipment operation status, etc. When abnormal conditions are detected, such as too high coal level, equipment failure, excessive harmful gases in the environment, etc., the system can issue an alarm signal in time. At the same time, feedback processing is carried out. When the system issues an alarm signal, the alarm information is transmitted to the control center or the equipment of relevant personnel in time. According to the alarm information, take corresponding treatment measures, such as stopping the detection operation and starting the emergency plan.

[0066] In the data storage and analysis phase, the collected laser radar and PTZ camera data, target detection and positioning results, alarm information and other data are stored for subsequent analysis and query. The stored data is analyzed to extract useful information, such as the change trend of materials in the coal bunker and the operating status of the equipment. Based on the analysis results, the detection and positioning algorithms are optimized to improve the accuracy and reliability of the system.

[0067] Working process: When used for coal bunker detection, as the robot gradually lowers into the depth of the coal bunker, the laser radar scans and records the internal situation of the coal bunker from the top of the coal bunker, and is linked with the pan-tilt camera. When the laser radar is found to be close to the bottom of the coal bunker or in contact with the coal accumulation, it should stop lowering immediately. The three-dimensional laser radar records the inner wall of the coal bunker, which is reflected in the form of an envelope with coordinates. The algorithm can be used to obtain the thickness of the coal accumulation at different depths inside the coal bunker, the defects of the inner wall of the coal bunker (such as the location, depth, and number of damages), and the integrity of the facilities on the inner wall of the coal bunker (such as the degree of wear of the lining, pipeline blockage and damage, etc.). By comparing the three-dimensional view obtained by data processing with the coal bunker design outline, the coal accumulation and defects inside the coal bunker can be observed intuitively, providing accurate data for determining the coal bunker disposal plan.

[0068] The coal bunker detection robot is equipped with an audio acquisition module. It can realize the audio analysis function by comparing the audio collection in the bunker. It can detect the coal accumulation and slag collapse in the coal bunker, and prompt the termination of the detection or change of location. It is also equipped with a gas detector, which can collect environmental information such as gas concentration and alarm when it exceeds the standard. The types of monitored gases include carbon monoxide, methane and oxygen, and an alarm will be issued if an abnormality occurs. The whole machine has a compact structure and a suitable size, and can realize autonomous operation in the coal bunker environment.

[0069] The robot is hoisted down the mine in a hoisting form, and then switched to a driving form to move and transfer in the mine. Within the system LAN, a smart phone can be used to monitor the robot information online in real time. The robot drives to a suitable position near the coal bunker, controls the solenoid valve signal to extend the detection arm to a suitable angle, and gradually extends the six-section arm of the detection arm to drive the detection component into the coal bunker for detection operations. The high-definition pan-tilt camera and three-dimensional laser radar work together to obtain the internal data of the coal bunker of the coal mine through "image, sound, scanning, and big data intelligent algorithm", and use data algorithm processing to identify the current state of the inner wall of the coal bunker. Based on these data, the detection robot can establish a dynamic state monitoring model to detect abnormal changes more accurately and sensitively during the coal bunker exploration process. The fault warning linkage function can ensure the smooth progress of the exploration work.

[0070] Although the present invention is described herein with reference to specific embodiments, it should be understood that these embodiments are merely examples of the principles and applications of the present invention. It should therefore be understood that many modifications may be made to the exemplary embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims. It should be understood that the various dependent claims and features described herein may be combined in a manner different from that described in the original claims. It should also be understood that the features described in conjunction with a single embodiment may be used in other described embodiments.

Claims

1. A crawler chassis type coal bunker detection robot system, characterized in that: include: The crawler base includes a crawler chassis and a vehicle box; the crawler chassis is used to support the vehicle box and enable the vehicle box to rotate 360 ​​degrees; The detection arm comprises a column, a rotating arm and a telescopic arm; the head end of the column is connected to the front end of the vehicle box, the end of the column is connected to the head end of the rotating arm, the end of the rotating arm is connected to the head end of the telescopic arm through a connecting piece, and the end of the telescopic arm is connected to the detection component; there is a gap of at least 100 mm between the telescopic arm and the rotating arm; Detection components, including a pan-tilt camera and a 3D laser radar, are used to detect the internal environment of the coal bunker; The control module controls the telescopic arm to extend into the coal bunker, starts the PTZ camera and the 3D laser radar, enables the 3D laser radar to perform an experimental scan of the interior of the coal bunker, and enables the PTZ camera to synchronously collect images; The data processing module obtains the three-dimensional point cloud inside the coal bunker based on the internal distance information of the coal bunker obtained by the three-dimensional laser radar through emitting laser beams; the three-dimensional point cloud inside the coal bunker is fused with the internal image of the coal bunker collected by the pan-tilt camera to obtain a fused three-dimensional model of the coal bunker, and the target is positioned based on the fused three-dimensional model of the coal bunker to obtain the coal bunker inner wall data, coal position data and target equipment position data.

2. The crawler chassis type coal bunker detection robot system according to claim 1, characterized in that: For the detection arm, the posture of each section of the telescopic arm is controlled by telescoping the hydraulic cylinder; The head end of the column is connected to the front end of the vehicle box through a rotary reducer; the rotating arm is connected to the column and the telescopic arm respectively by hydraulic cylinders to control the angle of the telescopic arm; The maximum extension length of the detection arm is 6.2m from the ground.

3. The crawler chassis type coal bunker detection robot system according to claim 1, characterized in that: The fused 3D model inside the coal bunker is used for target positioning after denoising, filtering and registration.

4. The crawler chassis type coal bunker detection robot system according to claim 1, characterized in that: The detection component also includes a sound collection module and a gas monitoring sensor. The sound collection module is used to collect sound signals inside the coal bunker; the gas monitoring sensor is used to monitor the gas content inside the coal bunker; the sound signals inside the coal bunker are used to characterize the coal and slag accumulation in the coal bunker; The sound signal inside the coal bunker and the gas content signal inside the coal bunker are compared with the corresponding set thresholds respectively. When the threshold is exceeded, an alarm is issued.

5. The crawler chassis type coal bunker detection robot system according to claim 4, characterized in that: The gases monitored by the gas monitoring sensor include carbon monoxide, methane and oxygen.

6. The crawler chassis type coal bunker detection robot system according to claim 4, characterized in that: It also includes an alarm module, which is used to sound an alarm when the coal bunker inner wall data, coal position data and target equipment location data are abnormal; it is also used to sound an alarm when any of the coal bunker internal sound signals and coal bunker internal gas content signals exceeds a set threshold.

7. The crawler chassis type coal bunker detection robot system according to claim 6, characterized in that: It also includes a data storage module for storing the internal distance information of the coal bunker collected by the three-dimensional laser radar, the internal image of the coal bunker collected by the pan-tilt camera, the inner wall data of the coal bunker, the coal position data, the target equipment location data and the alarm information.

8. The crawler chassis type coal bunker detection robot system according to claim 7, characterized in that: It also includes a data analysis module for analyzing the data stored in the data storage module to obtain the coal position change trend and the operating status of the target equipment.

9. The crawler chassis type coal bunker detection robot system according to claim 1, characterized in that: A counterweight is provided at the rear end of the carriage.

10. The crawler chassis type coal bunker detection robot system according to claim 1, characterized in that: A camera is arranged on the column to monitor the posture of the rotating arm and the telescopic arm; the control module controls the position of the rotating arm and the telescopic arm according to the posture feedback of the rotating arm and the telescopic arm.

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