PF line material tracking method and system based on machine vision

Abstract

The application relates to a PF line material tracking method and system based on machine vision, which comprises the following steps: pre-setting characters on a winding core frame in a PF line winding station and a C-shaped hook on a PF line, as a winding core frame label and a C-shaped hook label; at a material winding position, associating the obtained winding core frame label image with material information input into the PF line, and tracking position information of the winding core frame carrying the material; at a C-shaped hook feeding position, associating the obtained C-shaped hook label image with the winding core frame label carrying the material, and transferring material information associated with the winding core frame to the C-shaped hook; the C-shaped hook carrying the material sequentially passes through packaging, weighing, label hanging and unloading, and according to the label image of the C-shaped hook during the packaging, weighing, label hanging and unloading, the corresponding information of the material after the packaging, weighing, label hanging and unloading is associated, and position information of the C-shaped hook carrying the material is tracked.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of metallurgy, in particular to a PF line material tracking method and system based on machine vision. BACKGROUND

[0002] The statements in this section merely provide background information related to the present application and do not necessarily constitute the prior art.

[0003] The PF line is a device for realizing the transportation and cooling of coiled wire in the wire production process. It transports the high-temperature coiled wire from the upstream by using the C-shaped hook mounted on the trolley, and after the cooling, inspection, head cutting, trimming, sampling, compression, bundling and weighing, and labeling processes, the coiled wire is finally unloaded from the C-shaped hook by the unloading device, and the empty hook returns to the PF line.

[0004] During the operation of the PF line, the material, i.e. the high-temperature coiled wire, needs to be tracked at each process to facilitate the traceability after the wire is shipped. The prior art adopts the RFID (Radio Frequency Identification) method to fix the RFID code carrier at the position to be tracked, and installs an RFID reader on the C-shaped hook. When the C-shaped hook reaches the position of the RFID code carrier, the hook number information is read and written, thereby realizing the tracking of the coiled wire transported on the C-shaped hook. However, the RFID is not resistant to high temperature and cannot be applied to the coiling station, so it is impossible to realize the material tracking in the coiling station. In addition, the maintenance cost of the RFID is relatively high. SUMMARY

[0005] In order to solve the technical problems existing in the background art, the present application provides a PF line material tracking method and system based on machine vision. The set marks (such as letters and numbers) are sprayed on the coil core frame and the C-shaped hook using high-temperature paint, image acquisition modules are added at the positions to be tracked, and the material tracking is realized by using the method of identifying the hook number by machine vision algorithm. The hardware cost is low, the stability is strong, the network camera is multi-purpose, the maintenance method is convenient, the maintenance cost is low by using the method of repainting the characters, and the maintenance can be carried out during normal production without affecting the normal production.

[0006] In order to achieve the above-mentioned purpose, the present application adopts the following technical solutions:

[0007] The first aspect of the present application provides a PF line material tracking method based on machine vision, comprising:

[0008] The set characters resistant to high temperature are sprayed in advance on the coil core frame in the coiling station of the PF line and the C-shaped hook on the PF line, as the coil core frame label and the C-shaped hook label;

[0009] At the material uncoiling position, the position information of the coil core frame carrying the material is tracked according to the obtained coil core frame label image and the material information input into the PF line;

[0010] At the C-shaped hook loading position, the C-shaped hook label image is acquired and associated with the material carrying core frame label, and the material information associated with the core frame is transferred to the C-shaped hook;

[0011] The C-shaped hook carrying material sequentially passes through packing, weighing, label hanging and unloading, and the C-shaped hook label image is acquired and associated with the corresponding information after the material passes through packing, weighing, label hanging and unloading, and the position information of the C-shaped hook carrying material is tracked.

[0012] When the material starts to unload, the core frame label image is acquired based on the image acquisition module arranged below the winding drum, the core frame label is associated and bound with the unloading material number, and the core frame carrying the unloading material continues to run.

[0013] When the core frame carrying the material is finished, the image acquisition module arranged at the core frame tilting position acquires the image of the core frame, and identifies whether the material bound on the core frame is normally tilted.

[0014] At the C-shaped hook loading position, the C-shaped hook label image is acquired and associated with the material carrying core frame label, and the material information associated with the core frame is transferred to the C-shaped hook.

[0015] When the C-shaped hook reaches the packing position, the image acquisition module is called based on the working signal of the packing device to acquire the C-shaped hook label image, and the packing information of the material is bound according to the material information associated with the C-shaped hook number.

[0016] When the C-shaped hook reaches the weighing position, the image acquisition module is called based on the working signal of the weighing device to acquire the C-shaped hook label image, and the corresponding weighing result of the material is bound according to the material information associated with the C-shaped hook number.

[0017] When the C-shaped hook reaches the label hanging position, the image acquisition module is called based on the occupying signal to acquire the label image of the C-shaped hook, and the label printing and label hanging are performed according to the material information bound with the C-shaped hook number and sent to the label hanging device.

[0018] When the C-shaped hook reaches the unloading position, the image acquisition module is called based on the working signal of the material carrying trolley connected with the C-shaped hook, the C-shaped hook label image is acquired, and the material information associated with the C-shaped hook number is sent to the inventory system, and then the C-shaped hook returns to the initial position after the associated material information on the C-shaped hook is emptied.

[0019] The second aspect of the application provides a system for implementing the above method, comprising:

[0020] The label module is configured to spray a set of characters resistant to high temperature on the core frame in the PF line winding station and the C-shaped hook on the PF line, as the core frame label and the C-shaped hook label;

[0021] An image acquisition module comprising a camera or a camera located below the winding drum, at the tipping position of the core holder, at the loading position of the C-shaped hook, at the packing position, at the weighing position, at the label hanging position and at the unloading position of the roll;

[0022] The material tracking module is configured to associate the material information of the material put into the PF line with the position information of the core holder carrying the material according to the obtained core holder label image at the roll-off position of the material;

[0023] The material tracking module is further configured to associate the material information of the core holder with the label of the C-shaped hook according to the obtained C-shaped hook label image at the loading position of the C-shaped hook, and transfer the material information associated with the core holder to the C-shaped hook. The C-shaped hook carrying the material sequentially passes through the packing, weighing, label hanging and unloading, and associates the corresponding information of the material after passing through the packing, weighing, label hanging and unloading with the label image of the C-shaped hook at the time of packing, weighing, label hanging and unloading, and tracks the position information of the C-shaped hook carrying the material.

[0024] The air cooling line material tracking module is configured to obtain the speed data of the motor in the air cooling roller, calculate the position information of the material advancing on the air cooling line, and correct the material information through the input device to prevent information disorder when the air cooling line appears abnormal.

[0025] Compared with the prior art, the above one or more technical solutions have the following beneficial effects:

[0026] 1. High-temperature paint or coating is used on the core holder and the C-shaped hook to spray a set of marks (such as letters and numbers), and an image acquisition module is added at the position that needs to be tracked. The method of identifying the hook number by machine vision algorithm realizes material tracking, and can solve the problem of radio frequency equipment not being resistant to high temperature in the traditional radio frequency identification process.

[0027] 2. The material information does not need to be directly identified, but is bound (associated) with the identified core holder number by the upstream system. The image part only needs to identify the core holder number and the C-shaped hook number, and does not need complex algorithms. At the same time, since only simple letters or numbers need to be identified, the algorithm implementation cost is low and the speed is fast.

[0028] 3. Convenient maintenance, only the character paint or coating is used, the maintenance cost is low, and the maintenance can be carried out during normal production, without affecting normal production during maintenance. BRIEF DESCRIPTION OF DRAWINGS

[0029] The drawings accompanying the specification of this application form a part of the application and serve to provide further understanding of the application, the exemplary embodiments of the application and their descriptions serve to explain the application, and do not constitute an improper limitation on the application.

[0030] Figure 1Fig. 1 is a schematic diagram of the arrangement of machine vision in a PF line material tracking system according to one or more embodiments of the present application;

[0031] Figure 2 Fig. 2 is a schematic diagram of the architecture of a PF line material tracking system according to one or more embodiments of the present application. DETAILED DESCRIPTION

[0032] The application will be further described below in conjunction with the accompanying drawings and embodiments.

[0033] It should be noted that the following detailed description is exemplary in nature and is intended to provide further description of the application. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs.

[0034] It is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments in accordance with the present application. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and / or "comprising," when used in this specification, specify the presence of stated features, steps, operations, elements, components, and / or groups thereof, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof.

[0035] As described in the background, the prior art takes the form of RFID (Radio Frequency Identification), and an RFID carrier body is fixedly installed at a position that needs to be tracked, and an RFID reader is installed on a C-shaped hook, and when the C-shaped hook reaches the position of the RFID carrier body, the reading and writing of the hook number information is performed, thereby realizing the tracking of the transport disc coil on the C-shaped hook. However, RFID is not resistant to high temperature and cannot be applied to a coil collecting station, and material tracking in the coil collecting station cannot be realized, and the maintenance cost of RFID is relatively high.

[0036] Therefore, the following embodiments give a PF line material tracking method and system based on machine vision, in which a set of marks (such as letters and numbers) are sprayed on the coil core frame and the C-shaped hook using high-temperature paint, a network camera is added at a position that needs to be tracked, and a method of identifying the hook number by using machine vision algorithm is used to realize material tracking. This method has low hardware cost and strong stability, the network camera has multiple purposes, the maintenance method is convenient, and only the method of repainting characters is needed, the maintenance cost is low, and maintenance can be performed during normal production without affecting normal production.

[0037] Embodiment one:

[0038] As shown in Figure 1 A PF line material tracking method based on machine vision, comprising:

[0039] Pre-spray high-temperature resistant characters on the coil core frame in the PF line set winding station and the C-shaped hook on the PF line, as the coil core frame label and the C-shaped hook label;

[0040] At the material winding place, according to the obtained coil core frame label image, the material information input into the PF line is associated, and the position information of the coil core frame carrying the material is tracked;

[0041] At the C-shaped hook feeding place, according to the obtained C-shaped hook label image, the material information associated with the coil core frame label carrying the material is transferred to the C-shaped hook;

[0042] The C-shaped hook carrying the material sequentially passes through packing, weighing, label hanging and unloading, and according to the label image of the C-shaped hook during packing, weighing, label hanging and unloading, the corresponding information of the material after passing through packing, weighing, label hanging and unloading is associated, and the position information of the C-shaped hook carrying the material is tracked.

[0043] Specifically:

[0044] Obtain material information. Communicate with the upstream heating furnace and rolling line system, and obtain the material information of the upstream process through message exchange. For example, obtain the information of the wire rod coil after hot rolling, such as steel grade, wire diameter, coil outer diameter, coil inner diameter, wire length and time of entering the PF line.

[0045] Obtain the position information of the material on the cooling line. Real-time collection of speed data of all motors of the first level PLC of the air cooling roller is realized through opc communication, and the real-time position information of the material wire on the air cooling line is calculated.

[0046] In this embodiment, an abnormality handling touch screen is installed at the end of the air cooling line. When an abnormality occurs in the air cooling line and needs to be rejected or divided, manual rejection or division is performed on the touch screen to correct the material information in the material tracking system in time to prevent information disorder.

[0047] Winding station material tracking. Different letters A-P are sprayed on all coil core frames using a high-temperature paint character template, network cameras or network cameras are installed on the fixed supports below the winding drum and at the coil core frame tilting position, real-time data of the first level PLC is collected through opc communication, when the material starts to wind signal (the signal comes from the control system of the PF line) is obtained, the winding position image analysis interface is called, the camera is triggered to capture and identify the coil core frame number, then the coil core frame number and the material number of the winding are bound, and the coil core frame carrying the winding material continues to run; when the coil core frame tilting end signal is obtained, the tilting position image analysis interface is called, the camera is triggered to capture and identify, and whether the material bound on the coil core frame is normally tilted is identified.

[0048] Because the core frame number and the material number of the falling roll have been bound (associated), under normal circumstances, after the tipping process, the part of the falling roll material will be completely tipped, and there will be no material left on the core frame.

[0049] The core frame and the C-shaped hook are bound to track the material. Different numbers 01-70 are sprayed on all C-shaped hooks using high-temperature paint and a digital template. A network camera is fixed on the material loading position of the C-shaped hook. The data of the first-level PLC is collected in real time through opc communication. When the signal of starting material transportation of the material transportation trolley is acquired, the hook position image analysis interface is called, the camera is triggered to capture and identify the C-shaped hook number, then the core frame number and the C-shaped hook number are bound, and the material information bound by the core frame is transmitted to the C-shaped hook for binding, laying the foundation for the subsequent PF line to directly query the material number by identifying the hook number; the C-shaped hook carrying the material reaches the packing, weighing, label hanging, and unloading positions in turn.

[0050] PF line material tracking.

[0051] A network camera or network camera is installed at the packing position, the weighing position 1, the weighing position 2, the label hanging position, the flat warehouse unloading position, the vertical warehouse unloading position 1, and the vertical warehouse unloading position 2, respectively.

[0052] When the C-shaped hook first reaches the packing machine position and the clamp is clamped, the data of the first-level PLC of the packing position is collected in real time through opc communication. When the signal of starting packing of the packing machine is acquired, the packing position image analysis interface is called, the camera is triggered to capture and identify the C-shaped hook number, and the material information associated with the C-shaped hook number is bound according to the C-shaped hook number.

[0053] When the C-shaped hook reaches the weighing position and the clamp is clamped, the data of the first-level PLC of the weighing position is collected in real time through opc communication. When the signal of the weighing platform rising is acquired, the corresponding weighing position image analysis interface is called, the camera is triggered to capture and identify the C-shaped hook number, and the weighing result corresponding to the material information associated with the C-shaped hook number is obtained according to the C-shaped hook number.

[0054] When the C-shaped hook reaches the label hanging position, the data of the first-level PLC of the label hanging position is collected in real time through opc communication. When the occupancy signal is acquired, the label hanging position image analysis interface is called, the camera is triggered to capture and identify the C-shaped hook number, and the material information associated with the C-shaped hook number is obtained according to the C-shaped hook number, and the material information is sent to the label hanging robot system for printing and hanging labels.

[0055] When the C-shaped hook reaches the flat warehouse unloading position and the clamp is clamped, the data of the first-level PLC of the flat warehouse unloading position is collected in real time through opc communication. When the signal of the flat warehouse material transportation trolley starting work is acquired, the flat warehouse unloading position image analysis interface is called, the camera is triggered to capture and identify the C-shaped hook number, and the material information associated with the C-shaped hook number is obtained according to the C-shaped hook number, and the material information is sent to the flat warehouse system, and the material information bound on the C-shaped hook is emptied for the next cycle.

[0056] When the C-shaped hook reaches the storage unloading position and the clamp is clamped, the data of the first-level PLC of the storage unloading position is collected in real time through opc communication, the corresponding storage unloading position image analysis interface is called after the working signal of the storage material car is acquired, the camera is triggered to capture and the C-shaped hook number is identified, the material information is sent to the storage system according to the C-shaped hook number associated binding, and the material information bound on the C-shaped hook is emptied to enter the next cycle.

[0057] The data of the first-level PLC is collected in real time through opc communication, all station images on the spot are captured after reaching the self-defined trigger condition, which can ensure that the characters are fixed in the position of the captured image of each station; the image classification data set is made according to the collected data; the optimal convolutional neural network architecture is used; the image data is enhanced according to the possible occlusion, contamination and other conditions on the spot; the model is trained and tested; the model is deployed and verified online to verify the accuracy.

[0058] In this embodiment, the visual recognition algorithm for the core reel in the winding station and the visual recognition algorithm for the C-shaped hook are consistent, both of which are the recognition algorithm in the prior art, and a network camera or a network camera is used as an image acquisition module for acquiring the core reel and the C-shaped hook to cooperate with the visual recognition algorithm, which can solve the high temperature problem on the spot of the PF line.

[0059] In addition, the material information does not need to be directly identified, but is bound (associated) with the identified core reel number by the upstream system, and the image acquisition module only needs to identify the core reel number and the C-shaped hook number, without the need for complex algorithms, and since only simple letters or numbers need to be identified, the implementation cost of the algorithm is low and the speed is fast.

[0060] Embodiment two:

[0061] As shown in Figure 2 The system for implementing the above method comprises:

[0062] The label module is configured to spray the set characters resistant to high temperature on the core reel in the PF winding station and the C-shaped hook on the PF line as the core reel label and the C-shaped hook label;

[0063] The image acquisition module comprises a camera or a camera located below the winding drum, at the core reel tilting position, at the loading position of the C-shaped hook, at the packaging position, at the weighing position, at the label hanging position and at the unloading position;

[0064] The material tracking module is configured to associate the material information input into the PF line with the position information of the core reel carrying the material according to the acquired core reel label image at the material winding position.

[0065] The material tracking module is further configured to: at the C-shaped hook feeding position, associate the winding core frame carrying the material with the winding core frame label according to the obtained C-shaped hook label image, and transfer the material information associated with the winding core frame to the C-shaped hook; the C-shaped hook carrying the material sequentially passes through packing, weighing, label hanging, and roll unloading; according to the label image of the C-shaped hook during the packing, weighing, label hanging, and roll unloading, the corresponding information of the material after the packing, weighing, label hanging, and roll unloading is associated; and the position information of the C-shaped hook carrying the material is tracked.

[0066] By using high-temperature paint to spray a set of marks (such as letters and numbers) on the winding core frame and the C-shaped hook, an image acquisition module is added at a position that needs to be tracked, and a method of identifying the hook number by using a machine vision algorithm is used to realize material tracking. The hardware cost is low, the stability is strong, the network camera is multipurpose, the maintenance method is convenient, the maintenance cost is low, and the maintenance can be performed during normal production without affecting normal production.

[0067] The above only describes the preferred embodiments of the present application and is not used to limit the present application. For those skilled in the art, the present application can have various modifications and changes. Any modification, equivalent replacement, improvement, etc. within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A machine vision based PF line material tracking method, characterized by: Includes the following steps: High-temperature resistant design characters are pre-sprayed onto the core racks in the PF line collection station and the C-hooks on the PF line as core rack and C-hook labels; The system acquires the speed data of the motor in the air-cooled roller conveyor, calculates the position information of the material moving forward on the air-cooled line, and corrects the material information through the input device to prevent information confusion when the air-cooled line malfunctions. At the material drop point, the location of the core frame carrying the material is tracked by associating the acquired core frame label image with the material information of the PF line. At the C-hook loading point, the material information associated with the core frame carrying the material is transferred to the C-hook based on the obtained image of the C-hook label and the label of the core frame carrying the material. The C-hook carries the material through packaging, weighing, labeling and unwinding in sequence. Based on the label images of the C-hook during packaging, weighing, labeling and unwinding, the corresponding information of the material after packaging, weighing, labeling and unwinding is associated with the location information of the C-hook carrying the material. When the C-hook reaches the unloading position, the image acquisition module is called based on the working signal of the material transport trolley connected to the C-hook to obtain the image of the C-hook label, and the material information associated with the C-hook number is sent to the inventory system. At the same time, after clearing the material information associated with the C-hook, the C-hook returns to the initial position.

2. The machine vision-based PF line material tracking method of claim 1, wherein: When the material begins to fall, the image acquisition module located below the winding drum acquires the image of the winding core frame label, associates and binds the winding core frame label with the material number being fallen, and the winding core frame continues to run carrying the fallen material.

3. The machine vision-based PF line material tracking method of claim 1, wherein: When the tilting of the core roll frame carrying the material is completed, the image acquisition module based on the tilting position of the core roll frame acquires an image of the core roll frame and identifies whether the material bound to the core roll frame has tilted normally.

4. The machine vision-based PF line material tracking method of claim 1, wherein: At the C-hook loading point, the image acquisition module is invoked based on the signal that the material transport trolley has started transporting materials. The image of the C-hook label is acquired and associated with the core frame number, and the material information associated with the core frame is transmitted to the C-hook.

5. The machine vision-based PF line material tracking method of claim 1, wherein: When the C-hook reaches the packing position, the image acquisition module is called based on the working signal of the packing equipment to obtain the image of the C-hook label. Based on the material information associated with the C-hook label, the packing information of the material is bound.

6. The machine vision-based PF line material tracking method of claim 1, wherein: When the C-hook reaches the weighing position, the image acquisition module is called to obtain the image of the C-hook label based on the working signal of the weighing equipment. According to the material information associated with the C-hook number, the weighing result corresponding to the material is bound.

7. The machine vision-based PF line material tracking method of claim 1, wherein: When the C-hook reaches the labeling position, the image acquisition module is called based on the position signal to obtain the label image of the C-hook. According to the material information associated with the C-hook number, it is sent to the labeling device to perform label printing and labeling.

8. A system for implementing the method according to any one of claims 1-7, characterized in that: include: The labeling module is configured to spray high-temperature resistant setting characters onto the core racks in the PF line reeling station and the C-hooks on the PF line as core rack labels and C-hook labels; The image acquisition module includes cameras or cameras located below the winding drum, at the core frame tilting position, at the C-hook loading position, at the packing position, at the weighing position, at the labeling position, and at the unloading position; The material tracking module is configured to: at the material drop point, based on the acquired core frame label image, associate it with the material information of the input PF line, and track the location information of the core frame carrying the material. The material tracking module is also configured to: at the C-hook loading point, based on the acquired C-hook label image, associate it with the core frame label carrying the material, and transfer the material information associated with the core frame to the C-hook. The C-hook carries the material through packaging, weighing, labeling, and unloading in sequence. Based on the C-hook label image during packaging, weighing, labeling, and unloading, associate it with the corresponding information of the material after packaging, weighing, labeling, and unloading, and track the location information of the C-hook carrying the material.

9. The PF line material tracking system based on machine vision as described in claim 8, characterized in that: It also has a material tracking module for the air-cooled line, which is configured to: acquire the speed data of the motor in the air-cooled roller conveyor, calculate the position information of the material moving forward on the air-cooled line, and correct the material information through the input device to prevent information confusion when the air-cooled line malfunctions.

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