A video recognition method for monitoring a tape machine system using temperature change material

Abstract

The application provides a video identification method for monitoring a belt conveyor system by using temperature change materials, which identifies the moving mark on the carrier roller by using the video identification method on the collected image; the temperature change mark on the carrier roller is identified by using the video identification method on the collected image, the temperature change mark adopts temperature change paint and is arranged at the connection position of the carrier roller and the bracket; when the carrier roller and the belt conveyor bracket are greatly worn or broken, the connection position of the carrier roller and the bracket starts to heat due to friction, the heat is conducted to the temperature change paint mark by using the heat conduction of the metal part, when the temperature reaches a certain temperature, the temperature change mark starts to change color, the color change is identified by the video identification, and whether the carrier roller is in the over-worn fault state is confirmed; the carrier roller with excessive wear and the missing carrier roller are replaced in time. Through data collection and analysis, the replacement date of the carrier roller is predicted, predictive maintenance is realized, and the production efficiency is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of iron ore processing, and in particular to a video recognition method and device for monitoring a belt conveyor system using a temperature-variable material. Background Art

[0002] Belt conveyors are used in iron ore handling and processing, transporting powdered and lumpy materials between various production stages. They consist of a motor, head and tail pulleys, a bracket, a belt, and a tensioning device. The belt and bracket are the primary transport structure and occupy the largest space. A roller structure is used between the belt conveyor and the bracket, with multiple independent and removable rollers installed. During conveyor transportation, the rollers rotate at high speeds. If a roller malfunctions, rotates abnormally, or becomes stuck, significant static friction is generated between the belt and the rollers. This creates uneven force on both sides of the belt's travel, shifting its path and causing the belt to seriously deviate or even fall off. If a roller is missing, direct contact between the belt and bracket, and between the metal parts of the bracket and the belt, can easily cause the belt to tear or deviate.

[0003] During daily production inspections of belt conveyors, the main task is to inspect the operation of the conveyor rollers and belts to ensure the normal operation of the conveyor. The inspection of the conveyor rollers includes: ensuring good contact between the belt and the rollers, normal rotation of the rollers (good connection between the rollers and the bracket), and no jamming or missing parts.

[0004] Because the mining, beneficiation, sintering, pelletizing, and storage processes involved in iron production are all long processes with frequent material handling and heavy belt conveyor usage, routine inspections require frequent checks of the rollers and belts of each belt conveyor. Because belt conveyor corridors are long and often feature significant height differences, manual inspections consume the majority of the inspectors' time and energy, placing a significant burden on their work.

[0005] Temperature-sensitive coatings are a relatively mature technology, widely used in industries such as daily necessities manufacturing. Based on their formula, temperature-sensitive coatings change color at different temperatures. Therefore, the approximate temperature state of an object can be identified through color changes. Temperature-sensitive coatings can be categorized as reversible or irreversible. Reversible coatings can repeatedly change color with temperature fluctuations. The commonly used color-changing temperature range on the market is between 10°C and 70°C.

[0006] The basic components of visual inspection hardware include a processor, camera, lens, and light source. The two most important parameters related to the light source are its color and shape. Complementary color technology uses the color wheel to match the light source color and the filter color, resulting in a mixed color of colorless (white) light. Objects captured using complementary color technology typically appear lighter white, making them easier to distinguish using video recognition technology.

[0007] Video recognition technology can analyze captured images, identify the shape and position of objects using color difference, and then compare images captured at different times to identify the object's motion state. It is widely used in the current intelligent pelletizing auxiliary system of pelletizing process. Summary of the Invention

[0008] To address the technical problems mentioned in the background art, the present invention provides a video recognition method and device for monitoring a belt conveyor system using temperature-variable materials. This video recognition method monitors the operating status of each roller in the belt conveyor and guides the timely replacement of rollers that are worn or missing. Furthermore, through data collection and analysis, the replacement date for rollers can be predicted, allowing for early preparation for equipment inspection and replacement, achieving predictive maintenance and improving production efficiency.

[0009] In order to achieve the above object, the present invention adopts the following technical solutions:

[0010] A video recognition method for monitoring a tape dispenser system using a temperature-variable material includes the following steps:

[0011] 1) The operation picture of the belt conveyor is collected by a camera installed on the top of the belt conveyor corridor or on one side of the belt conveyor. The status of the belt conveyor rollers is monitored by identifying the logo in the video recognition area set at the end of the roller (outside the belt shielding area);

[0012] 2) The motion mark on the roller is identified by using a video recognition method on the collected images. The motion mark is painted on the roller and is painted in two colors (colors with large color difference when video analysis is selected). When the roller moves, the motion mark appears as an intermittent color. By adjusting the video acquisition cycle, the operating status of the roller can be identified, thereby determining whether the roller is missing, damaged, or stuck.

[0013] 3) Using video recognition methods on the collected images, the temperature-variable marking on the roller is identified. The temperature-variable marking is made of temperature-variable paint and is set at the connection between the roller and the bracket. When the roller and the belt conveyor bracket are severely worn or broken, the connection between the roller and the bracket begins to heat up due to friction. The heat conductivity of the metal parts is used to transfer the heat to the temperature-variable paint marking. When the temperature reaches a certain temperature, the temperature-variable marking begins to change color. The color change is identified by video recognition to confirm whether the roller is in a fault state of excessive wear.

[0014] 4) By utilizing video detection and the regular characteristic that the color of temperature-variable coating changes gradually within the temperature range, the degree of wear can be detected through the change in the color of the temperature-variable mark, and special attention can be paid to the rollers that are beginning to wear, so that material preparation and replacement can be carried out in advance before excessive wear occurs.

[0015] Furthermore, by selecting temperature-variable materials, the alarm temperature can be adjusted within a wide range to suit different production requirements and situations.

[0016] Furthermore, video recognition uses complementary color technology to enhance the ability to recognize color changes.

[0017] Furthermore, the solution to the problem that dust may be generated during material transportation and cover the roller markings, affecting the video recognition effect, is as follows:

[0018] 1) Taking advantage of the rotation of the roller, a cleaning brush is set near the mark to clean the mark during the rotation of the roller;

[0019] 2) To protect the paint layer, a transparent protective coating of paint or resin is added on top of the coating.

[0020] The present invention also provides a device for implementing the video recognition method of monitoring the tape machine system using temperature-changing materials, including an image acquisition device for acquiring equipment operation images, data storage and power supply equipment arranged next to the machine, data storage and image analysis equipment arranged in the machine room, and a terminal display device.

[0021] Furthermore, the image acquisition device for acquiring images of equipment operation is arranged at the upper part of the belt conveyor corridor for video image acquisition.

[0022] Furthermore, the data storage and image analysis equipment is arranged in a remote computer room for storing and analyzing video images.

[0023] Furthermore, the data transmission and power supply equipment is arranged next to the tape machine, and is used to supply power to the equipment and transmit network signals.

[0024] Furthermore, the terminal display device is arranged in a room where someone is on duty or on patrol, and is used to display the data of the video analysis.

[0025] Furthermore, the device is incorporated into the equipment preventive maintenance system as a subsystem.

[0026] Compared with the prior art, the present invention has the following beneficial effects:

[0027] This invention, used in belt conveyors, can promptly detect roller loss, jamming, or excessive wear, guiding and prompting maintenance personnel to replace rollers promptly. It can also detect roller temperature rise by displaying color differences and predicting roller replacement time. This is of great significance for ensuring smooth production, assisting in equipment maintenance and spare parts management for belt conveyors, and achieving intelligent and information-based equipment maintenance and spare parts management. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 Schematic diagram of the overall structure of the apparatus of the video recognition method for monitoring the tape dispenser system using the temperature-variable material of the present invention;

[0029] Figure 2 It is a schematic diagram of the auxiliary identification video acquisition of the roller of the present invention.

[0030] In the figure: 1-image acquisition device 2-data transmission and power supply equipment 3-data storage and image analysis equipment 4-terminal display device 5-image acquisition direction 6-image recognition area 7-temperature change mark 8-motion mark. DETAILED DESCRIPTION

[0031] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings:

[0032] like Figure 1-Figure 2 As shown, a video recognition method for monitoring a tape dispenser system using a temperature-variable material includes the following steps:

[0033] 1) A camera (image acquisition device 1) installed at the top of the conveyor corridor or on one side of the conveyor collects the running image of the conveyor, and monitors the status of the conveyor rollers by identifying the markers (including the temperature change marker 7 and the motion marker 8) in the video image recognition area 6 set at the roller end (outside the belt shielding area);

[0034] 2) Using a video recognition method on the captured images, the motion marker 8 on the roller is identified; the motion marker 8 is painted on the roller in two colors (colors with a large color difference when video analysis is used); when the roller moves, the motion marker 8 appears as an intermittent color. By adjusting the video acquisition cycle, the operating state of the roller can be identified, thereby determining whether the roller is missing, damaged, or stuck.

[0035] 3) Using video recognition methods on the collected images, the temperature-variable marker 7 on the roller is identified. The temperature-variable marker 7 is made of temperature-variable paint and is set at the connection between the roller and the bracket. When the roller and the belt conveyor bracket are severely worn or broken, the connection between the roller and the bracket begins to heat up due to friction. The heat conductivity of the metal parts is used to transfer the heat to the temperature-variable paint marker. When the temperature reaches a certain temperature, the temperature-variable marker 7 begins to change color. The color change is identified by video recognition to confirm whether the roller is in a fault state of excessive wear.

[0036] 4) By utilizing video detection and the regular characteristic that the color of temperature-variable coating changes gradually within the temperature range, the degree of wear can be detected through the change in the color of the temperature-variable mark, and special attention can be paid to the rollers that are beginning to wear, so that material preparation and replacement can be carried out in advance before excessive wear occurs.

[0037] Based on daily collected data, the wear and heat of the rollers can be predicted, and replacement warnings can be issued in advance, facilitating the early implementation of spare parts and reducing the possibility of failures that affect production.

[0038] In this embodiment, by selecting the temperature-variable material, the alarm temperature can be adjusted within a relatively large range to suit different production requirements and situations.

[0039] In this embodiment, video recognition uses complementary color technology to enhance the ability to recognize color changes.

[0040] In this embodiment, the solution to the problem that dust may be generated during material transportation and cover the roller markings, thereby affecting the video recognition effect, is as follows:

[0041] 1) Taking advantage of the rotation of the roller, a cleaning brush is set near the mark to clean the mark during the rotation of the roller;

[0042] 2) To protect the paint layer, a transparent protective coating of paint or resin is added on top of the coating.

[0043] like Figure 1As shown, the present invention also provides a device for implementing the video recognition method of monitoring the belt conveyor system using temperature-changing materials, including an image acquisition device 1 for acquiring equipment operation images, a data storage and power supply device 2 arranged next to the machine, a data storage and image analysis device 3 arranged in the machine room, and a terminal display device 4.

[0044] In this embodiment, the image acquisition device 1 for acquiring images of equipment operation is arranged at the upper part of the belt conveyor corridor for video image acquisition.

[0045] In this embodiment, the data storage and image analysis device 3 is set in a remote computer room for storing and analyzing video images.

[0046] In this embodiment, the data transmission and power supply device 2 is arranged next to the tape machine and is used to supply power to the device and transmit network signals.

[0047] In this embodiment, the terminal display 4 device is set in a room where someone is on duty or patrolling, and is used to display video analysis data.

[0048] In this embodiment, the device is incorporated into the equipment preventive maintenance system as a subsystem.

[0049] In this embodiment, the device can share components with other video recognition systems in the factory.

[0050] The present invention uses a video image acquisition device 1 installed on the top of the belt conveyor corridor or on one side of the belt conveyor to capture video images of the rollers during the belt conveyor production process. The acquisition and identification content includes: using the identification to identify the operating status of the rollers and determine whether they are stuck; using the identification to identify the position of the rollers and determine whether the rollers are missing; and identifying the color changes of the identification to determine whether the rollers are overheated (excessively worn).

[0051] Considering the long length of the tape conveyor, multiple cameras are required to work simultaneously for monitoring. Therefore, a control box is set up next to the tape conveyor to power the equipment and transmit network signals.

[0052] The video recognition server is used to store and analyze collected image information. It can identify various fault conditions by collecting pixel information from the images. It has a universal (Ethernet) protocol communication interface that can connect to and communicate with the on-site camera and the display terminal 4. It can output statistical data and fault information via the network for display on the display terminal.

[0053] The display terminal 4 is used to display device information and fault information, and can push and display alarm information.

[0054] This invention, used in belt conveyors, can promptly detect roller loss, jamming, or excessive wear, guiding and prompting maintenance personnel to replace rollers promptly. It can also detect roller temperature rise by displaying color differences and predicting roller replacement time. This is of great significance for ensuring smooth production, assisting in equipment maintenance and spare parts management for belt conveyors, and achieving intelligent and information-based equipment maintenance and spare parts management.

[0055] The present invention utilizes the camera's recognition range to monitor the belt's operating status and the material on it. Video recognition can be used to detect belt deviations, belt tears, and other faults. The video surveillance system can also be used as a camera for daily production monitoring, reducing monitoring system investment.

[0056] The above embodiments are implemented under the premise of the technical solution of the present invention, and detailed implementation methods and specific operation processes are given, but the protection scope of the present invention is not limited to the above embodiments. The methods used in the above embodiments are conventional methods unless otherwise specified.

Claims

1. A video recognition method for monitoring a tape conveyor system using a temperature-variable material, characterized in that: Through video recognition, the operating status of each roller of the belt conveyor can be mastered, and the rollers with excessive wear and missing can be replaced in time, including the following: 1) The operation picture of the belt conveyor is collected by a camera installed on the top of the belt conveyor corridor or on one side of the belt conveyor. The status of the belt conveyor rollers is monitored by identifying the logo in the video recognition area set at the end of the rollers; 2) The motion markers on the rollers are identified by using a video recognition method on the captured images. The motion markers are painted on the rollers in two colors. When the rollers are moving, the motion markers appear as intermittent colors. By adjusting the video acquisition cycle, the operating status of the rollers can be identified, thereby determining whether the rollers are missing, damaged, or stuck. 3) Using video recognition methods on the collected images, the temperature-variable marking on the roller is identified. The temperature-variable marking is made of temperature-variable paint and is set at the connection between the roller and the bracket. When the roller and the belt conveyor bracket are severely worn or broken, the connection between the roller and the bracket begins to heat up due to friction. The heat conductivity of the metal parts is used to transfer the heat to the temperature-variable paint marking. When the temperature reaches a certain temperature, the temperature-variable marking begins to change color. The color change is identified by video recognition to confirm whether the roller is in a fault state of excessive wear. 4) By utilizing video detection and the regular characteristic that the color of temperature-variable coating changes gradually within the temperature range, the degree of wear can be detected through the change in the color of the temperature-variable mark, and special attention can be paid to the rollers that are beginning to wear, so that material preparation and replacement can be carried out in advance before excessive wear occurs.

2. The video recognition method for monitoring a tape conveyor system using a temperature-variable material according to claim 1, characterized in that: By selecting temperature-variable materials, the alarm temperature can be adjusted within a wide range to suit different production requirements and situations.

3. The video recognition method for monitoring a tape conveyor system using a temperature-variable material according to claim 1, characterized in that: Video recognition uses complementary color technology to enhance the ability to recognize color changes.

4. The video recognition method for monitoring a tape conveyor system using a temperature-variable material according to claim 1, characterized in that: The solution to the problem that dust may be generated during material transportation and cover the roller markings, affecting the video recognition effect, is as follows: 1) Taking advantage of the rotation of the roller, a cleaning brush is set near the mark to clean the mark during the rotation of the roller; 2) To protect the paint layer, a transparent protective coating of paint or resin is added on top of the coating.

5. A device for implementing the video recognition method for monitoring a tape conveyor system using a temperature-variable material as claimed in claim 1, characterized in that: The device includes an image acquisition device for acquiring the image of the equipment running, a data transmission and power supply device arranged beside the machine, a data storage and image analysis device arranged in the machine room, and a terminal display device.

6. The device for a video recognition method for monitoring a tape conveyor system using a temperature-variable material according to claim 5, characterized in that: The image acquisition device for acquiring the image of the equipment operation is arranged on the upper part of the belt conveyor corridor and is used for video image acquisition.

7. The device for a video recognition method for monitoring a tape conveyor system using a temperature-variable material according to claim 5, characterized in that: The data storage and image analysis equipment is arranged in a remote machine room and is used for storing and analyzing video images.

8. The device for a video recognition method for monitoring a tape conveyor system using a temperature-variable material according to claim 5, characterized in that: The data transmission and power supply equipment is arranged beside the tape machine and is used to supply power to the equipment and transmit network signals.

9. The device for a video recognition method for monitoring a tape conveyor system using a temperature-variable material according to claim 5, characterized in that: The terminal display device is arranged in a room where someone is on duty or on patrol, and is used to display the data of video analysis.

10. The device for a video recognition method for monitoring a tape conveyor system using a temperature-variable material according to claim 5, characterized in that: The device is incorporated into the equipment preventive maintenance system as a subsystem.

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