Fault detection equipment and system for bucket equipment in coal washing plant

Abstract

The present application provides a fault detection device and system for a bucket device in a coal washing plant, which relates to the field of coal washing technology and can solve the technical problem that a serious overflow of the bucket device in a coal washing plant occurs inside the bucket device in a coal washing plant due to failure to handle the accident in a timely manner. The fault detection device for the bucket device in a coal washing plant includes: an image acquisition device for acquiring an internal image of the bucket device in the coal washing plant; a processor connected to the image acquisition device for extracting image features of an area of ​​interest in the internal image, and determining the internal operating state of the bucket device in the coal washing plant according to the preset state features that the image features meet; and a communication device connected to the processor for sending the internal operating state of the bucket device in the coal washing plant to a user end.

Description

Technical Field

[0001] The present application relates to the technical field of intelligent identification and equipment fault detection, and in particular to a fault detection device and system for bucket equipment in a coal washing plant. Background Art

[0002] At present, many operations such as ore dressing, grinding, and coal washing require the use of equipment such as barrels (pools). At the same time, by detecting the operating status inside the barrel (pool), it can be determined whether there are problems with the overall system. Since the opening of the large-scale coal washing plant barrel (pool) equipment is high, the area inside the coal washing plant barrel (pool) equipment is large, the environment inside the coal washing plant barrel (pool) equipment is complex, and the visibility inside the coal washing plant barrel (pool) equipment is low, it is usually necessary for staff to climb along the ladder next to the coal washing plant barrel (pool) equipment to the opening of the coal washing plant barrel (pool) equipment at a height of several meters, and carefully observe the operating conditions inside the barrel (pool) equipment to determine whether the internal operation of the coal washing plant barrel (pool) equipment is normal.

[0003] However, it is difficult for staff to frequently climb to inspect the internal operation of the barrel (pool) equipment in the coal washing plant. If abnormal conditions occur inside the barrel (pool) equipment in the coal washing plant and measures are not taken in time to deal with them, it will cause serious accidents such as overflow of the rough barrel (pool) in the coal washing plant. Summary of the invention

[0004] The purpose of the present application is to provide a fault detection device and system for a coal washing plant bucket equipment, so as to solve the technical problem of accidents such as serious leakage and overflow of the coal washing plant bucket due to failure to handle in time, and to accurately alarm the system faults such as leakage.

[0005] The present invention provides a coal washing plant bucket equipment fault detection device, comprising:

[0006] An image acquisition device for acquiring internal images of the barrel equipment of the coal washing plant;

[0007] a processor, connected to the image acquisition device, for extracting image features of the region of interest in the internal image, and determining the internal operating state of the bucket equipment of the coal washing plant according to the preset state features that the image features meet;

[0008] A communication device is connected to the processor and is used to send the internal operating status of the coal washing plant bucket equipment to the user end.

[0009] Furthermore, the image feature includes at least one of a coarsening particle size feature and a material accumulation overflow feature.

[0010] Furthermore, it also includes:

[0011] The lighting device is used to provide lighting for the image acquisition process of the image acquisition device.

[0012] Furthermore, it also includes:

[0013] An alarm is connected to the processor and is used to issue an alarm when the internal operating state of the coal washing plant bucket equipment does not conform to a preset state.

[0014] Furthermore, the processor is also used to determine the correspondence between the internal image, the acquisition time of the internal image, and the internal operating state of the bucket equipment of the coal washing plant, and mark the internal image according to the correspondence.

[0015] Furthermore, it also includes:

[0016] The storage device is connected to the processor and is used to store the internal image, the acquisition time of the internal image, and the internal operating state of the coal washing plant bucket equipment corresponding to the internal image according to the corresponding relationship.

[0017] Furthermore, it also includes: an identification and analysis module, which is used to identify and analyze the operation and fault status of the barrel grate through machine vision technology and image analysis.

[0018] Furthermore, it also includes: a development module for developing an image acquisition system including an intelligent AI camera and a light source system.

[0019] Furthermore, it also includes: a design module for designing and developing an auxiliary device for filtering materials to collect coarse materials into a designated fault detection area for image fault detection.

[0020] The present invention provides a coal washing plant bucket equipment fault detection system, comprising: a user end and the coal washing plant bucket equipment fault detection device;

[0021] The user terminal is connected to the fault detection device of the coal washing plant bucket equipment via wireless communication;

[0022] The user terminal is used to receive and display the internal operating status of the coal washing plant bucket equipment.

[0023] In the present solution, since the image acquisition device can acquire the internal image of the coal washing plant barrel equipment, and the processor connected to the image acquisition device can extract the image features of the area of ​​interest in the internal image, and determine the internal operating state of the coal washing plant barrel equipment according to the preset state features that the image features conform to, so that the communication device connected to the processor can send the internal operating state of the coal washing plant barrel equipment to the user end, so that the staff can obtain the internal operating state of the coal washing plant barrel equipment through the user end more conveniently anytime and anywhere, and the staff no longer need to climb the coal washing plant barrel equipment to inspect the internal operating conditions of the coal washing plant barrel equipment, and can take timely measures according to the internal operating state of the coal washing plant barrel equipment, thereby solving the technical problem of serious rough barrel overflow and other accidents occurring inside the coal washing plant barrel equipment due to failure to handle in time. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] In order to more clearly illustrate the specific implementation methods of the present application or the technical solutions in the prior art, the drawings required for use in the specific implementation methods or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some implementation methods of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0025] Figure 1 A schematic diagram of the structure of a fault detection device for a bucket device in a coal washing plant provided in an embodiment of the present application;

[0026] Figure 2 Another structural schematic diagram of a fault detection device for a coal washing plant bucket device provided in an embodiment of the present application;

[0027] Figure 3 A flow chart of the operation process of a fault detection device for a bucket device in a coal washing plant provided in an embodiment of the present application;

[0028] Figure 4 Another program flow chart of the operation process of the fault detection device for the bucket equipment of the coal washing plant provided in the embodiment of the present application;

[0029] Figure 5 A schematic diagram of the structure of a coal washing plant bucket equipment fault detection system provided in an embodiment of the present application. DETAILED DESCRIPTION

[0030] The technical solution of the present invention will be clearly and completely described below in conjunction with the embodiments. Obviously, the described embodiments are part of the embodiments of the present invention, rather than 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.

[0031] The features and exemplary embodiments of various aspects of the present invention will be described in detail below. In the detailed description below, many specific details are proposed to provide a comprehensive understanding of the present invention. However, it is obvious to those skilled in the art that the present invention can be implemented without the need for some of these specific details. The following description of the embodiments is only to provide a better understanding of the present invention by illustrating examples of the present invention. The present invention is by no means limited to any specific configuration and algorithm proposed below, but covers any modification, replacement and improvement of elements, parts and algorithms without departing from the spirit of the present invention. In the accompanying drawings and the following description, known structures and technologies are not shown to avoid unnecessary ambiguity to the present invention.

[0032] It should be noted that, in the absence of conflict, the embodiments and features in the embodiments of the present application can be combined with each other. The present application will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0033] In the description of the present application, unless otherwise specified, the meaning of "at least one" refers to one or more than one. For example, at least one synchronization frame refers to one synchronization frame or more than one synchronization frame.

[0034] In addition, the terms "including" and "having" and any variations thereof mentioned in the description of the present invention are intended to cover non-exclusive inclusions. For example, a process, method, system, product or device comprising a series of steps or units is not limited to the listed steps or units, but may optionally include other steps or units that are not listed, or may optionally include other steps or units that are inherent to these processes, methods, products or devices.

[0035] At present, the existing coal slime barrels, mixed medium barrels, and thin medium barrels in coal washing plants have high barrel mouths, large barrel areas, complex barrel environments, no lighting, and poor visibility. Therefore, personnel need to climb ladders to the barrel mouths several meters high to observe from a single angle. It is difficult for staff to frequently climb and inspect to determine whether they need to be cleaned. Moreover, if a fault occurs and the machine is not stopped in time for cleaning, the grate may be crushed by accumulated materials or the sieve holes may be blocked by coarse particles, resulting in serious overflow and other faults, delaying production and causing economic losses.

[0036] Based on this, the embodiment of the present application provides a fault detection device and system for a coal washing plant barrel equipment. This fault detection device determines whether an upstream device has a fault by detecting the coarsening phenomenon on the barrel grate. If the fault detects that large particles are coarsening or blockage overflows in the coal washing plant barrel (pool) equipment, an alarm will be issued that the upstream device has a fault. Furthermore, the preventive alarm of the fault detection system is used to protect the safety of downstream equipment. Therefore, the technical problem existing in the prior art that accidents such as serious overflow of the coal washing plant barrel (pool) equipment due to failure to handle in time can be solved, and accurate alarms can be issued for system faults such as coarsening.

[0037] To facilitate understanding of this embodiment, a fault detection device and system for a coal washing plant bucket equipment disclosed in an embodiment of the present application are first introduced in detail.

[0038] Embodiment 1:

[0039] The present application embodiment provides a coal washing plant bucket equipment fault detection device, such as Figure 1 As shown, the fault detection device 1 of the bucket equipment of the coal washing plant includes:

[0040] The image acquisition device 11 is used to acquire the internal image of the bucket equipment 12 of the coal washing plant. The image acquisition device 11 may be a camera;

[0041] The processor 13 is connected to the image acquisition device and is used to identify the internal image and obtain the internal operating state of the bucket equipment in the coal washing plant;

[0042] The communication device 14 is connected to the processor and is used to send the internal operating status of the coal washing plant bucket equipment to the user end 15.

[0043] In the embodiment of the present application, the barrel equipment of the coal washing plant may be a pool equipment of the coal washing plant, and the following description will be given taking the barrel (pool) equipment of the coal washing plant as an example.

[0044] like Figure 2 As shown, the fault detection device for the bucket (pool) equipment of the coal washing plant further includes: an illumination device 16, which is used to provide illumination for the image acquisition process of the image acquisition device. The illumination device includes: at least one of a light emitting diode LED and a searchlight.

[0045] In practical applications, the internal operating state of the coal washing plant bucket (pool) equipment detected by the fault detection device of the coal washing plant bucket (pool) equipment may include various fault operating states in the coal washing plant bucket (pool) equipment, such as the coarse particle size state and the material accumulation overflow state. This embodiment is described by taking the state of the grate in the coal washing plant bucket (pool) equipment as an example.

[0046] It should be noted that the image acquisition device 11 is combined with the lighting device 16 as an auxiliary light source. The image acquisition device 11 is used to collect image information of various states such as the barrel grate inside the barrel (pool) equipment of the coal washing plant in real time. The auxiliary light source is used to illuminate the barrel environment with extremely poor visibility and improve the image quality so as to perform more effective image recognition and fault detection.

[0047] For the operation process of the fault detection equipment of the coal washing plant bucket (pool) equipment, for example, Figure 3 and Figure 4 As shown, the data acquisition module (i.e., the image acquisition device) first obtains the real-time video stream of the grate status in the bucket (pool) equipment of the coal washing plant, that is, the grate status in the bucket is visualized through the light source and the data acquisition module, and the real-time video stream is collected. After that, the data processing module (i.e., the processor) decodes the obtained video stream.

[0048] Then, the coarsening fault detection submodule (used for fault detection of coarsening fault state) in the data acquisition module calculates the coarsening characteristics of the grate pixels in the coarsening area of ​​interest, and superimposes the determined grate state information on the current frame. The video with the time information and grate state information superimposed is re-encoded and stored in the storage device. After judging that the alarm push conditions are met, the information push platform (i.e., the communication device) pushes the alarm signal and the video generating the alarm signal to the staff's handheld tablet computer PAD device through the network. For the calculation part, specifically, the image information obtained by the data acquisition module is processed and calculated, the barrel grate features in the area of ​​interest are calculated, and the coarsening feature values ​​of the mineral particles that need to be alarmed are extracted through layer-by-layer filtering, and converted into alarm signals, and the alarm information and the video generating the alarm information are pushed through the network. For the barrel grate image in the non-coarsening state, the ore slurry water flow state and the empty grate state are also calculated and distinguished, and the current barrel grate state is marked on the image for historical video and data query.

[0049] Similarly, the material overflow fault detection submodule (used to detect the material overflow fault state) in the data processing module (i.e., the processor) calculates the material overflow characteristics in the area of ​​interest, and converts them into alarm signals when the material overflow characteristics appear continuously and stably, and pushes the material overflow alarm information and the video generating the alarm information through the network. Specifically: the material overflow fault detection submodule superimposes the determined grate status information on the current frame. The video with the time information and grate status information superimposed is re-encoded and stored in the storage device. After determining that the alarm push conditions are met, the information push platform (i.e., the communication device) pushes the alarm signal and the video generating the alarm signal to the staff's handheld tablet computer PAD device through the network. For the calculation part, specifically, the image information obtained by the data acquisition module is subjected to image processing calculation, the barrel grate characteristics in the area of ​​interest are calculated, and the material overflow characteristic values ​​that need to be alarmed are extracted through layer-by-layer filtering, and converted into alarm signals, and the alarm information and the video generating the alarm information are pushed through the network.

[0050] Therefore, the image collected by the data acquisition module is feature-calculated, and the calculated state information is superimposed on the image and stored in the video. When the coarse ore particle state or the material overflow state is identified, the calculated value is converted into an alarm signal. Specifically, when the generated alarm information is continuously stable and meets the alarm information push conditions, the alarm push platform pushes the alarm information, that is, the information push platform pushes the alarm signal and the video that forms the alarm signal to the handheld terminal device of the on-duty staff through the network.

[0051] In this embodiment, the fault detection device of the barrel (pool) equipment of the coal washing plant can be used as a machine vision-based fault detection device for the coarse particle size of the barrel grate material, which can detect the coarse particle size fault and the accumulation material overflow fault of the barrel grate material of the coal slime, thin medium and combined medium barrels of the re-washing system, especially when there are coarse ore particles on the barrel grate to form an accumulation material fault, a real-time video fault detection system that automatically identifies the fault state through machine vision and issues an alarm. When there is coarse ore particles on the barrel grate, a visual fault detection system that automatically and timely identifies the coarse accumulation material state and issues an alarm.

[0052] like Figure 2 As shown, the fault detection device for the bucket (pool) equipment of the coal washing plant also includes: an alarm 17, which is connected to the processor and is used to issue an alarm prompt when the internal operating state of the bucket (pool) equipment of the coal washing plant does not meet the preset state. The alarm is also used to send an alarm signal to the user end when the internal operating state of the bucket (pool) equipment of the coal washing plant does not meet the preset state. Exemplarily, the alarm signal and the video forming the alarm signal are pushed to the handheld PAD device of the staff on duty through the network. The communication device is also used to send the internal image to the user end.

[0053] Furthermore, the fault detection device for the bucket equipment of the coal washing plant provided in the embodiment of the present application may also include: an identification and analysis module for identifying and analyzing the operation and fault status of the bucket grate through machine vision technology and image analysis. It should be noted that the identification and analysis module can be applied at the location of the image acquisition device in the embodiment of the present application.

[0054] As a preferred implementation of the embodiment of the present application, the fault detection device for the bucket equipment of the coal washing plant provided in the embodiment of the present application may also include: a development module for developing an image acquisition system including an intelligent AI camera and a light source system. In practical applications, the development module can be applied at the location of the image acquisition device in the embodiment of the present application.

[0055] It should be noted that the fault detection device for the coal washing plant bucket equipment provided in the embodiment of the present application may also include: a design module for designing and developing an auxiliary device for filtering materials to collect the coarse materials into a designated fault detection area for image fault detection. In the embodiment of the present application, the design module can be applied at the location of the image acquisition device provided in the embodiment.

[0056] In actual applications, the fault detection device for the coal washing plant bucket (pool) equipment also includes: a storage device connected to the processor, which is used to store internal images, the acquisition time of the internal images, and the internal operating status of the coal washing plant bucket (pool) equipment corresponding to the internal images according to the corresponding relationship.

[0057] As a preferred solution, the processor is also used to determine the correspondence between the internal image and the acquisition time of the internal image, and the internal operating state of the barrel (pool) equipment of the coal washing plant, and mark the internal image according to the correspondence. The processor performs image processing calculation on the image information collected by the data acquisition module, and superimposes the time and date information and the calculated barrel grate status information on the original image and stores the video. When the coarse state of the ore particles is identified, the calculated value is converted into an alarm signal. The storage stores historical videos with time and date information and barrel grate status information for later playback and query at any time.

[0058] Among them, the processor may be an integrated circuit chip with signal processing capabilities. In the implementation process, each step of the above method can be completed by the hardware integrated logic circuit in the processor or the instruction in the form of software. The above processor can be a general-purpose processor, including a central processing unit (CPU), a network processor (NP), etc.; it can also be a digital signal processor (DSP), an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA) or other programmable logic devices, discrete gates or transistor logic devices, discrete hardware components. The methods, steps and logic block diagrams disclosed in the embodiments of the present application can be implemented or executed. The general-purpose processor can be a microprocessor or the processor can also be any conventional processor. The steps of the method disclosed in the embodiments of the present application can be directly embodied as a hardware decoding processor to execute, or the hardware and software modules in the decoding processor can be executed. The software module can be located in a mature storage medium in the field such as a random access memory, a flash memory, a read-only memory, a programmable read-only memory or an electrically erasable programmable memory, a register, etc. The storage medium is located in the memory, and the processor reads the information in the memory and completes the steps of the above method in combination with its hardware.

[0059] In this embodiment, the difficult-to-observe environment in the barrel is visualized by the cooperation of the auxiliary light source and the data acquisition module, and the image information of each frame is calculated by the data calculation unit, and the image containing the coarse information of the ore particles is timely identified and converted into an alarm signal. It has the functions of 24-hour online, real-time fault detection, and remote information transmission. When the alarm signal is generated, the alarm information and the video generating the alarm are pushed to the staff at the same time, which is more reliable and more timely and accurate than the personnel inspection. The data storage unit can save the historical video with time information and alarm information, which is convenient for playback and query at any time later, and is more readable than the existing shift record table. Moreover, the fault detection equipment of the barrel (pool) equipment of the coal washing plant is easy to install and easy to implement, which can effectively improve the timeliness and accuracy of fault identification, and has the value of wide promotion and application. The fault detection equipment of the barrel (pool) equipment of the coal washing plant can also realize parallel fault detection of multiple barrels, and the alarm information is uniformly sent to the staff on duty, which truly reduces the physical labor of climbing to the barrel mouth for observation one by one, shortening the working time and reducing the labor intensity.

[0060] Embodiment 2:

[0061] An embodiment of the present application provides a coal washing plant bucket equipment fault detection system, and the coal washing plant bucket equipment fault detection system includes: a user end and the coal washing plant bucket equipment fault detection device as described in the above-mentioned embodiment 1.

[0062] As a preferred implementation of this embodiment, the user terminal is connected to the fault detection device of the bucket (pool) equipment of the coal washing plant through wireless communication. The user terminal is used to receive and display the internal operating status of the bucket (pool) equipment of the coal washing plant. Specifically, Figure 5 As shown, the image acquisition device is an intelligent AI camera; the user end is a customer management system, and the customer management system obtains the internal operating status of the coal washing plant barrel (pool) equipment through the TIE software platform.

[0063] As another implementation of this embodiment, the communication device in the fault detection device of the bucket (tank) equipment of the coal washing plant is also used to send the internal image to the user terminal. The user terminal is also used to receive and display the internal image.

[0064] The fault detection system for the bucket equipment in a coal washing plant provided in the embodiment of the present application has the same technical features as the fault detection device for the bucket equipment in a coal washing plant provided in the above-mentioned embodiment, so it can also solve the same technical problems and achieve the same technical effects.

[0065] The flow chart and block diagram in the accompanying drawings show the possible architecture, function and operation of the system, method and computer program product according to multiple embodiments of the present application. In this regard, each box in the flow chart or block diagram can represent a module, a program segment or a part of a code, and the module, a program segment or a part of a code contains one or more executable instructions for realizing the specified logical function. It should also be noted that in some alternative implementations, the functions marked in the box can also occur in a different order from the order marked in the accompanying drawings. For example, two consecutive boxes can actually be executed substantially in parallel, and they can sometimes be executed in the opposite order, depending on the functions involved. It should also be noted that each box in the block diagram and / or flow chart, and the combination of the boxes in the block diagram and / or flow chart can be implemented with a dedicated hardware-based system that performs a specified function or action, or can be implemented with a combination of dedicated hardware and computer instructions.

[0066] If the functions are implemented in the form of software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present application, or the part that contributes to the prior art or the part of the technical solution, can be embodied in the form of a software product, which is stored in a storage medium and includes several instructions for a computer device (which can be a personal computer, a server, or a network device, etc.) to perform all or part of the steps of the methods described in each embodiment of the present application. The aforementioned storage medium includes: various media that can store program codes, such as a USB flash drive, a mobile hard disk, a read-only memory (ROM), a random access memory (RAM), a magnetic disk or an optical disk.

[0067] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A fault detection device for a bucket device in a coal washing plant, characterized in that: include: An image acquisition device for acquiring internal images of the barrel equipment of the coal washing plant; a processor, connected to the image acquisition device, for extracting image features of the region of interest in the internal image, and determining the internal operating state of the bucket equipment of the coal washing plant according to the preset state features that the image features meet; A communication device, connected to the processor, for sending the internal operating status of the coal washing plant bucket equipment to the user end; The processor is also used to determine the correspondence between the internal image, the acquisition time of the internal image, and the internal operating state of the bucket equipment of the coal washing plant, and mark the internal image according to the correspondence; It also includes: a storage device connected to the processor, and configured to store the internal image, the acquisition time of the internal image, and the internal operating state of the bucket equipment of the coal washing plant corresponding to the internal image according to the corresponding relationship; The processor is also used to perform image processing calculations on the internal image, and superimpose the time and date information and the calculated barrel grate status information on the original image and store the video. When the coarse mineral particles are identified, the calculated value is converted into an alarm signal; the storage stores historical videos with time and date information and barrel grate status information for later playback and query at any time.

2. The device according to claim 1, characterized in that The image feature includes at least one of a coarsening particle size feature and a material accumulation overflow feature.

3. The device according to claim 1, characterized in that Also includes: The lighting device is used to provide lighting for the image acquisition process of the image acquisition device.

4. The device according to claim 1, characterized in that Also includes: An alarm is connected to the processor and is used to issue an alarm when the internal operating state of the coal washing plant bucket equipment does not conform to a preset state.

5. The device according to claim 1, characterized in that Also includes: The recognition and analysis module is used to recognize and analyze the operating and fault conditions on the barrel grate through machine vision technology and image analysis.

6. The device according to claim 1, characterized in that Also includes: Development module for developing image acquisition systems including intelligent AI cameras and light source systems.

7. The device according to claim 1, characterized in that Also includes: The design module is used to design and develop auxiliary devices for filtering materials so as to collect coarse materials into the designated fault detection area for image fault detection.

8. A fault detection system for bucket equipment in a coal washing plant, characterized in that: include: A user terminal and a fault detection device for a coal washing plant bucket device as claimed in any one of claims 1 to 7; The user terminal is connected to the fault detection device of the coal washing plant bucket equipment via wireless communication; The user terminal is used to receive and display the internal operating status of the coal washing plant bucket equipment.

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