A cold-rolled strip steel deviation detection system and method

Abstract

The application provides a cold-rolled strip steel deviation detection system and method, relates to the cold-rolled technology field, and comprises an industrial area array camera, a calculation and display device, a switch and a PLC controller; the calculation and display device is respectively provided with a communication system and a deviation calculation and display system, and the calculation and display device is in communication connection with the industrial area array camera through GIGE; the calculation and display device is in communication connection with the switch; and the calculation and display device is in communication connection with the PLC controller.The application provides a cold-rolled strip steel deviation detection system, saves manpower, is convenient for real-time detection, has high detection accuracy, issues an alarm sound when the strip steel deviation is detected, reminds an operator, effectively avoids the strip steel deviation from scratching an edge portion, and improves production stability.The application provides a cold-rolled strip steel deviation detection system, which is reasonable in structure and easy to install and arrange.The application provides a cold-rolled strip steel deviation detection system, which uses a machine vision technology to measure, is low in cost, and has strong popularization significance.

Description

Technical Field

[0001] This application relates to the field of cold rolling technology, and in particular to a system and method for detecting deviation of cold-rolled strip steel. Background Technology

[0002] In cold rolling production, strip steel must run along the center line of the production line. Deviation from the center line, or strip misalignment, can lead to edge scraping, operational malfunctions, or strip breakage, significantly impacting production. However, due to factors such as the strip's shape, camber, and the precision of equipment control, strip misalignment frequently occurs. This necessitates timely detection and appropriate measures from production operators to prevent further adverse consequences. However, humans cannot monitor the strip in real time and rely solely on subjective judgment, lacking accuracy. Summary of the Invention

[0003] The purpose of this invention is to provide a cold-rolled strip misalignment detection system and method, which effectively avoids strip misalignment and edge rubbing, which could lead to operational failures or strip breakage, and improves production stability, thereby solving the problems mentioned in the background art.

[0004] To achieve the above objectives, the present invention provides the following technical solution:

[0005] A cold-rolled strip steel deviation detection system includes:

[0006] An industrial area scan camera is installed above the edge of a strip steel to acquire images of the strip steel edge in real time.

[0007] The computing and display equipment is equipped with a communication system and a deviation calculation and display system. The computing and display equipment is connected to the industrial area scan camera via GIGE.

[0008] Switches are used for communication connections between computing and display devices.

[0009] The PLC controller is a communication connection between the computing and display devices and the PLC controller.

[0010] As a further embodiment of the present invention: the industrial area array camera can capture images of the minimum and maximum width strip steel produced on the production line. The camera is installed 50cm above the median of the minimum and maximum width, and illuminates the strip steel vertically.

[0011] As a further aspect of the present invention: the computing and display device acquires image data in real time from an industrial area array camera via GIGE communication, and identifies the position of the strip edge based on an image processing algorithm.

[0012] As a further aspect of the present invention: the deviation calculation and display system of the calculation and display device communicates with the industrial area array camera through the GIGE protocol to acquire real-time image data of the strip edge.

[0013] As a further aspect of the present invention: the computing and display device is communicatively connected to the PLC controller to obtain strip width and weld position data.

[0014] As a further aspect of the present invention: the communication system of the computing and display device acquires the strip width and weld position data of the production line PLC controller in real time based on the OPC protocol.

[0015] As a further aspect of the present invention: the computing and display device is connected to the production line local area network switch and the industrial area scan camera respectively through two RJ45 network interfaces, and the network interface connected to the industrial area scan camera is gigabit.

[0016] Based on the same inventive concept, this application also provides a method for detecting deviation of cold-rolled strip steel, the method comprising:

[0017] The communication system acquires real-time data on strip width and weld position from the production line PLC controller using the OPC protocol. Strip width is used to calculate edge reference points, and weld position is used to match the deviation to the actual strip position and store the data for historical retrieval and analysis. The deviation calculation and display system communicates with an industrial area scan camera via the GIGE protocol to acquire real-time image data of the strip edge. Then, an image processing edge measurement algorithm is used to locate the strip edge position, as detailed below:

[0018] (1) Determine the detection position reference line, which is perpendicular to the strip steel, and select the image center as the detection position reference line;

[0019] (2) Calculate the gray value g on the reference line. i The rate of change, find its derivative. Find the maximum derivative (max(g)) along the width direction of the image. i The position coordinates (px, py) of the strip are the edge of the image, where py is the edge of the image in the width direction, and the position Pact is obtained.

[0020] (3) The deviation calculation and display system also includes a calibration function, which selects data of two coils of steel with different widths at the center position, namely widths W1 and W2, and image pixel positions P1 and P2 in the width direction; and calculates the length-to-pixel ratio. and pixel length ratio

[0021] (4) If the actual width obtained is W, then its reference point position on the image is Pref = (W-W1)*P2LCOEFF+P1, and then Pdiff = Pact-Pref is calculated, while the actual deviation is P = Pdiff*L2PCOEFF.

[0022] (5) Display the actual deviation amount together with the strip edge image in real time on the calculation and display device interface, and display the deviation amount in both numerical and real-time curve formats; when the value exceeds the predetermined value, display different colors and trigger an audible alarm to remind the production operator; then match and store the value with the weld position for use in historical query and analysis.

[0023] Compared with the prior art, the beneficial effects of the present invention are:

[0024] 1. This application provides a cold-rolled strip steel deviation detection system, which replaces manual inspection, saves manpower, facilitates real-time inspection, has high detection accuracy, and emits an alarm sound when strip steel deviation is detected to remind operators, effectively preventing strip steel deviation from scratching the edge, causing operational failure or strip breakage, and improving production stability;

[0025] 2. This application provides a cold-rolled strip steel deviation detection system, which has a reasonable structure and is easy to install and arrange;

[0026] 3. This application provides a cold-rolled strip steel deviation detection system that uses machine vision technology for measurement. It is low in cost and has strong promotional value. Attached Figure Description

[0027] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0028] To gain a more complete understanding of this application and its beneficial effects, the following description will be provided in conjunction with the accompanying drawings. In the following description, the same reference numerals denote the same parts.

[0029] Figure 1 This is a schematic diagram of a cold-rolled strip steel deviation detection system provided in an embodiment of this application.

[0030] Figure 2 This is a functional schematic diagram of a cold-rolled strip steel deviation detection system provided in an embodiment of this application.

[0031] Figure 3 This is a schematic diagram illustrating the workflow of a cold-rolled strip steel deviation detection system provided in an embodiment of this application.

[0032] Markings in the image:

[0033] 1. Industrial area scan cameras; 2. Computing and display equipment; 3. Switches; 4. PLC controllers. Detailed Implementation

[0034] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0035] Please refer to the attached document. Figures 1-3 This application provides a cold-rolled strip steel deviation detection system, including:

[0036] Industrial area scan camera 1 is installed above the edge of the strip to acquire images of the strip edge in real time; furthermore, the industrial area scan camera 1 can capture images of the minimum and maximum width strip produced on the production line, with the camera installed 50cm above the median of the minimum and maximum widths, illuminating the strip vertically.

[0037] The computing and display device 2 is equipped with a communication system and a deviation calculation and display system. The computing and display device 2 is connected to the industrial area scan camera 1 via GIGE.

[0038] Switch 3, and computing and display device 2 are connected to switch 3 for communication;

[0039] PLC controller 4, computing and display device 2 are connected to PLC controller 4 for communication.

[0040] This application provides a cold-rolled strip steel deviation detection system that replaces manual inspection, saving manpower, facilitating real-time detection, and offering high accuracy. When strip deviation is detected, an alarm sounds to alert operators, effectively preventing strip deviation from scraping the edges and causing operational malfunctions or breakage, thus improving production stability. This application also provides a cold-rolled strip steel deviation detection system with a reasonable structure that is easy to install and arrange. Furthermore, this application provides a cold-rolled strip steel deviation detection system that uses machine vision technology for measurement, resulting in low cost and significant potential for widespread application.

[0041] In a preferred embodiment of the present invention, the computing and display device 2 acquires image data from the industrial area scan camera 1 in real time via GIGE communication and identifies the position of the strip edge based on the image processing algorithm; further, the deviation calculation and display system of the computing and display device 2 communicates with the industrial area scan camera 1 via the GIGE protocol to acquire the strip edge image data in real time.

[0042] In a preferred embodiment of the present invention, the computing and display device 2 is communicatively connected to the PLC controller 4 to obtain strip width and weld position data; furthermore, the communication system of the computing and display device 2 obtains strip width and weld position data of the production line PLC controller 4 in real time based on the OPC protocol.

[0043] In a preferred embodiment of the present invention, the computing and display device 2 is connected to the production line local area network switch 3 and the industrial area scan camera 1 respectively through two RJ45 network interfaces, and the network interface connected to the industrial area scan camera 1 is gigabit.

[0044] Based on the same inventive concept, this application also provides a method for detecting deviation of cold-rolled strip steel, the method comprising:

[0045] The communication system acquires strip width and weld position data from the production line PLC controller 4 in real time via the OPC protocol. Specifically, the production line control system transmits strip width and weld position signals to the communication system through the PLC controller 4. The strip width is used to calculate edge reference points, and the weld position is used to match the deviation amount to the actual position of the strip and store it for easy historical query and analysis. The deviation calculation and display system communicates with the industrial area array camera 1 via the GIGE protocol to acquire real-time image data of the strip edge. After acquiring the image data, image enhancement is performed, which is implemented programmatically by uniformly increasing the grayscale values ​​by a certain factor. Noise filtering is also implemented programmatically, using Gaussian filtering, a common algorithm. Then, the strip edge position is located using an image processing edge measurement algorithm, as detailed below:

[0046] (1) Determine the detection position reference line, which is perpendicular to the strip steel, and select the image center as the detection position reference line;

[0047] (2) Calculate the gray value g on the reference line. i The rate of change, find its derivative. Find the maximum derivative (max(g)) along the width direction of the image. i The position coordinates (px, py) of the strip are the edge of the image, where py is the edge of the image in the width direction, and the position Pact is obtained.

[0048] (3) The deviation calculation and display system also includes a calibration function, which selects data of two coils of steel with different widths at the center position, namely widths W1 and W2, and image pixel positions P1 and P2 in the width direction; and calculates the length-to-pixel ratio. and pixel length ratio

[0049] (4) If the actual width obtained is W, then its reference point position on the image is Pref = (W-W1)*P2LCOEFF+P1, and then Pdiff = Pact-Pref is calculated, while the actual deviation is P = Pdiff*L2PCOEFF.

[0050] (5) Display the actual deviation amount together with the strip edge image on the interface of the calculation and display device 2 in real time, and display the deviation amount in two ways: numerical value and real-time curve; when the value exceeds the predetermined value, display different colors and trigger an audible alarm to remind the production operator; then match and store the value with the weld position for use in historical query and analysis.

[0051] This application provides a cold-rolled strip steel deviation detection system that replaces manual inspection, saving manpower, facilitating real-time detection, and offering high accuracy. When strip deviation is detected, an alarm sounds to alert operators, effectively preventing strip deviation from scraping the edges and causing operational malfunctions or breakage, thus improving production stability. This application also provides a cold-rolled strip steel deviation detection system with a reasonable structure that is easy to install and arrange. Furthermore, this application provides a cold-rolled strip steel deviation detection system that uses machine vision technology for measurement, resulting in low cost and significant potential for widespread application.

[0052] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0053] In the description of this application, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more features.

[0054] This document uses specific examples to illustrate the principles and implementation methods of this application. The descriptions of the above embodiments are only for the purpose of helping to understand the methods and core ideas of this application. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of this application. Therefore, the content of this specification should not be construed as a limitation of this application.

Claims

1. A method for detecting deviation of cold-rolled strip steel, characterized in that, The method for detecting deviation of cold-rolled strip steel includes: The communication system acquires real-time data on strip width and weld position from the production line PLC controller using the OPC protocol. Strip width is used to calculate edge reference points, and weld position is used to match the deviation to the actual strip position and store the data for historical retrieval and analysis. The deviation calculation and display system communicates with an industrial area scan camera via the GIGE protocol to acquire real-time image data of the strip edge. Then, an image processing edge measurement algorithm is used to locate the strip edge position, as detailed below: (1) Determine the detection position reference line, which is perpendicular to the strip steel, and select the image center as the detection position reference line; (2) Calculate the gray value g on the reference line. i Find the derivative of the rate of change. Find the maximum derivative max(g) along the width direction of the image. i The position coordinates (px, py) of the strip are the edge of the image, where py is the edge of the image in the width direction, and the position Pact is obtained. (3) The deviation calculation and display system also includes a calibration function, which selects the data of two rolls of steel with different widths at the center position, namely the widths W1 and W2, and the positions of the image pixels in the width direction P1 and P2; and calculates the length-to-pixel ratio. and pixel length ratio ; (4) If the actual width obtained is W, then its reference point position on the image is Pref = (W-W1)*P2LCOEFF+P1, and then Pdiff = Pact-Pref is calculated, while the actual deviation is P = Pdiff*L2PCOEFF. (5) Display the actual deviation amount together with the strip edge image in real time on the calculation and display device interface, and display the deviation amount in two ways: numerical value and real-time curve; when the value exceeds the predetermined value, display different colors and trigger an audible alarm to remind the production operator; then match and store the value with the weld position for use in historical query and analysis.

2. A cold-rolled strip steel deviation detection system, used to implement the detection method as described in claim 1, characterized in that, include: An industrial area scan camera is installed above the edge of a strip steel to acquire images of the strip steel edge in real time. The computing and display equipment is equipped with a communication system and a deviation calculation and display system. The computing and display equipment is connected to the industrial area scan camera via GIGE. Switches are used for communication connections between computing and display devices. The PLC controller is a communication connection between the computing and display devices and the PLC controller.

3. The cold-rolled strip steel deviation detection system according to claim 2, characterized in that, The industrial area array camera can capture images of the minimum and maximum width strip steel produced on the production line. The camera is installed 50cm above the median of the minimum and maximum width, and illuminates the strip steel vertically.

4. The cold-rolled strip steel deviation detection system according to claim 2, characterized in that, The computing and display device acquires image data in real time from an industrial area array camera via GIGE communication and identifies the position of the strip edge based on image processing algorithms.

5. The cold-rolled strip steel deviation detection system according to claim 4, characterized in that, The deviation calculation and display system of the computing and display device communicates with an industrial area array camera via the GIGE protocol to acquire real-time image data of the strip edge.

6. The cold-rolled strip steel deviation detection system according to claim 2, characterized in that, The computing and display device is connected to the PLC controller to obtain data on strip width and weld position.

7. The cold-rolled strip steel deviation detection system according to claim 2, characterized in that, The communication system of the computing and display device acquires data on the strip width and weld position of the production line PLC controller in real time based on the OPC protocol.

8. The cold-rolled strip steel deviation detection system according to claim 2, characterized in that, The computing and display devices are connected to the production line local area network switch and the industrial area scan camera respectively through two RJ45 network interfaces, and the network interface connected to the industrial area scan camera is ensured to be gigabit.

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