Intelligent coal crusher monitoring method and system

Abstract

The application provides an intelligent coal crusher monitoring method and system. The intelligent coal crusher monitoring method comprises the following steps: collecting video data of the operation of a coal crusher in real time through a camera, and performing video processing on the video data; judging whether a blockage condition exists in the current operation of the coal crusher according to the video image of the operation of the coal crusher; and when the operation of the coal crusher has a blockage condition, performing dredging processing on the blocked part and issuing a blockage alarm through a mechanical arm. The system comprises modules corresponding to the method steps.

Description

TECHNICAL FIELD

[0001] The application provides an intelligent coal crusher monitoring method and system, and belongs to the technical field of coal equipment monitoring. BACKGROUND

[0002] After the coal crusher is blocked, workers are arranged to process and dredge by manual operation after the dispatching room discovers the problem, the blocked coal gangue is cleaned and transported. However, this state has the problems of low efficiency and high safety risk, the manual cleaning and transporting speed is limited, and the large coal gangue cannot be effectively processed, which affects the production progress, and the coal crusher is dangerous, and manual operation has great safety hazards. SUMMARY

[0003] The application provides an intelligent coal crusher monitoring method and system, which solves the problems of low efficiency and high safety risk in the prior art in the process of cleaning the blocked coal crusher, and adopts the following technical solutions:

[0004] An intelligent coal crusher monitoring method, the intelligent coal crusher monitoring method comprises:

[0005] Real-time collection of video data of the operation of the coal crusher by a camera, and video processing of the video data;

[0006] Judgment of whether the current operation of the coal crusher has a blocking condition according to a video image of the operation of the coal crusher;

[0007] When the operation of the coal crusher has a blocking condition, dredging processing of the blocked part and blocking alarm are performed by controlling a mechanical arm.

[0008] Further, real-time collection of video data of the operation of the coal crusher by a camera, and video processing of the video data, comprises:

[0009] Real-time collection of video data of the operation of the coal crusher by a camera;

[0010] Frame processing of the video data to obtain frame image data after frame processing, and image processing of the frame image data to obtain frame image data after image processing;

[0011] Extraction of a feed inlet area image and a discharge outlet area image of the coal crusher for each frame image;

[0012] Screening of frame image data in which the feed inlet area has primary occlusion and the discharge outlet area has primary occlusion, and taking the frame image data in which the feed inlet area has primary occlusion and the discharge outlet area has primary occlusion as target image data;

[0013] Storage of the target image data in a database;

[0014] The judgment standard of the primary shielding is that the shielding area of the feeding port area and the discharging port area reaches the first shielding area corresponding to the feeding port and the discharging port.

[0015] The first shielding area of the feeding port is:

[0016]

[0017] Wherein, S 01 represents the first shielding area of the feeding port; S c and S j respectively represent the area of the discharging port and the feeding port;

[0018] The first shielding area of the discharging port is:

[0019]

[0020] Wherein, S 02 represents the first shielding area of the discharging port.

[0021] Further, judging whether the current coal crusher operation exists a blocking condition according to the video image of the coal crusher operation, comprising:

[0022] sequentially calling the feeding port corresponding image in the target image data in the database;

[0023] comparing the shielding area in the feeding port corresponding image with the second shielding area of the feeding port, when the shielding area in the feeding port corresponding image exceeds the second shielding area of the feeding port, it is determined that the current feeding port is in a blocking state;

[0024] sequentially calling the discharging port corresponding image in the target image data in the database;

[0025] comparing the shielding area in the discharging port corresponding image with the second shielding area of the discharging port, when the shielding area in the discharging port corresponding image exceeds the second shielding area of the discharging port, it is determined that the current discharging port is in a blocking state.

[0026] Further, the second shielding area of the feeding port is:

[0027]

[0028] Wherein, S 03 represents the second shielding area of the feeding port; S c and S j respectively represent the area of the discharging port and the feeding port; V1 represents the feeding speed of the coal crusher; V2 represents the discharging speed of the coal crusher;

[0029] The second shielding area of the discharging port is:

[0030]

[0031] wherein S 04 represents the second blocking area of the discharge port; S c and S j respectively represent the area of the discharge port and the area of the feeding port; V1 represents the feeding speed of the coal crusher; and V2 represents the discharging speed of the coal crusher.

[0032] Further, when the coal crusher is running in a jamming condition, the mechanical arm is controlled to dredge the jammed part and give a jamming alarm, including:

[0033] When only the feeding port is jammed, the mechanical arm is controlled to dredge the jammed part of the feeding port;

[0034] When only the discharge port is jammed, the mechanical arm is controlled to dredge the jammed part of the discharge port;

[0035] When the feeding port and the discharge port are both jammed, the mechanical arm is controlled to dredge the feeding port and the discharge port while giving a jamming alarm.

[0036] An intelligent coal crusher monitoring system, the intelligent coal crusher monitoring system comprising:

[0037] a video data acquisition module configured to acquire video data of the running of the coal crusher in real time through a camera and perform video processing on the video data;

[0038] a jamming condition judgment module configured to judge whether the running of the coal crusher is in a jamming condition according to the video image of the running of the coal crusher;

[0039] a jamming alarm module configured to, when the running of the coal crusher is in a jamming condition, control the mechanical arm to dredge the jammed part and give a jamming alarm.

[0040] Further, the video data acquisition module comprises:

[0041] a data acquisition module configured to acquire video data of the running of the coal crusher in real time through a camera;

[0042] an image frame processing module configured to perform frame processing on the video data to obtain frame image data after frame processing and perform image processing on the frame image data to obtain frame image data after image processing;

[0043] a region image extraction module configured to extract a feeding port region image and a discharge port region image of the feeding port of the coal crusher for each frame image;

[0044] The primary screening module is configured to screen frame image data in which the primary blockage exists in the feeding port area and the primary blockage exists in the discharging port area, and take the frame image data in which the primary blockage exists in the feeding port area and the primary blockage exists in the discharging port area as target image data;

[0045] The target image data storage module is configured to store the target image data into a database;

[0046] The judgment standard of the primary blockage is that the blockage area of the feeding port area and the discharging port area reaches a first blockage area corresponding to the feeding port and the discharging port.

[0047] The first blockage area of the feeding port is:

[0048]

[0049] S 01 represents the first blockage area of the feeding port; S c and S j respectively represent the area of the discharging port and the feeding port.

[0050] The first blockage area of the discharging port is:

[0051]

[0052] S 02 represents the first blockage area of the discharging port.

[0053] Further, the blockage condition judgment module comprises:

[0054] The first image data calling module is configured to call the feeding port corresponding image in the target image data in the database in sequence.

[0055] The feeding port blockage judgment module is configured to compare the blockage area in the feeding port corresponding image with a second blockage area of the feeding port, and when the blockage area in the feeding port corresponding image exceeds the second blockage area of the feeding port, it is determined that the current feeding port is in a blockage state.

[0056] The second image data calling module is configured to call the discharging port corresponding image in the target image data in the database in sequence.

[0057] The discharging port blockage judgment module is configured to compare the blockage area in the discharging port corresponding image with a second blockage area of the discharging port, and when the blockage area in the discharging port corresponding image exceeds the second blockage area of the discharging port, it is determined that the current discharging port is in a blockage state.

[0058] Further, the second blockage area of the feeding port is:

[0059]

[0060] wherein S 03 represents the second blocking area of the feed inlet; S c and S j respectively represent the area of the discharge outlet and the feed inlet; V1 represents the feed speed of the coal crusher; and V2 represents the discharge speed of the coal crusher.

[0061] The second blocking area of the discharge outlet is:

[0062]

[0063] wherein S 04 represents the second blocking area of the discharge outlet; S c and S j respectively represent the area of the discharge outlet and the feed inlet; V1 represents the feed speed of the coal crusher; and V2 represents the discharge speed of the coal crusher.

[0064] Further, the blocking alarm module comprises:

[0065] a first dredging control module, configured to control the mechanical arm to dredge the blocked part of the feed inlet when only the feed inlet is blocked;

[0066] a second dredging control module, configured to control the mechanical arm to dredge the blocked part of the discharge outlet when only the discharge outlet is blocked;

[0067] a third dredging control module, configured to control the mechanical arm to dredge the feed inlet and the discharge outlet at the same time and simultaneously perform a blocking alarm prompt when the feed inlet and the discharge outlet are simultaneously blocked.

[0068] The present application has the following advantages:

[0069] The intelligent coal crusher monitoring method and system provided by the present application installs a camera near the coal crusher to capture video when the coal crusher is running. The algorithm can determine whether the coal crusher is blocked according to the image analysis result. A mechanical arm is integrated into the system. If the blockage is identified, the mechanical arm can be used to handle the blockage. The intelligent coal crusher monitoring method and system provided by the present application can automatically monitor the state of the coal crusher, detect blockage in time and handle it, thereby reducing the production interruption time, improving the continuous operation time of the coal crusher and increasing the coal mine production efficiency. Since the mechanical arm handles the blockage, miners do not need to personally enter the dangerous working area. This reduces the potential danger and safety risk faced by the miners and helps to improve the working environment. BRIEF DESCRIPTION OF DRAWINGS

[0070] Figure 1 a flowchart of the method of the present application;

[0071] Figure 2 System block diagram of the system of the present application. DETAILED DESCRIPTION

[0072] The preferred embodiments of the present application are described below in conjunction with the accompanying drawings, it should be understood that the preferred embodiments described here are only used to explain and describe the present application, and are not used to limit the present application.

[0073] The embodiment of the present application proposes an intelligent coal crusher monitoring method, as shown in the figure, the intelligent coal crusher monitoring method comprises: Figure 1

[0074] S1, real-time video data of the coal crusher operation is collected by the camera, and the video data is processed;

[0075] S2, according to the video image of the coal crusher operation, whether the current coal crusher operation exists the blockage condition is judged;

[0076] S3, when the coal crusher operation exists the blockage condition, then the blockage part is dredged and the blockage alarm is processed by controlling the mechanical arm.

[0077] The working principle of the above technical solution is: real-time video acquisition (S1): real-time video data of the coal crusher operation is collected by the camera.

[0078] Video processing (S1): the collected video data is processed, which may include image processing, feature extraction and other analysis methods.

[0079] Blockage condition judgment (S2): according to the processed video image, the algorithm judges whether the current coal crusher exists the blockage condition. This can be realized by detecting the abnormal or blocked part of the material flow.

[0080] Blockage processing and alarm (S3): if the coal crusher exists the blockage condition, the system will trigger the operation of the mechanical arm to dredge the blockage part. This can clear or dredge the blockage part through the action of the mechanical arm to ensure the normal operation of the equipment.

[0081] At the same time, the system will also trigger the blockage alarm to notify the relevant operators or record the event.

[0082] The effect of the above technical solution is: real-time monitoring: through real-time video acquisition and image processing, the system can monitor the running state of the coal crusher in real time, and find the problem in time.

[0083] Blockage detection: the system can automatically judge whether the coal crusher exists the blockage condition without manual intervention.

[0084] ​Automatic dredging: Once a blockage is detected, the system can resolve the issue by controlling the robotic arm, improving the availability and efficiency of the equipment.

[0085] Alarm notification: The system can generate an alarm notification, allowing relevant personnel to take prompt action to ensure the normal operation of the equipment.

[0086] This method can improve the supervision efficiency of the coal crusher, reduce downtime, and enhance the reliability and automation level of the equipment.

[0087] In one embodiment of the present application, video data of the coal crusher in operation is collected in real time by a camera, and the video data is processed, including:

[0088] S101, real-time collection of video data of the coal crusher in operation by a camera;

[0089] S102, frame processing of the video data to obtain frame image data after frame processing, and image processing of the frame image data to obtain frame image data after image processing; wherein the image processing includes:

[0090] Extracting the area of the feed inlet and the area of the discharge outlet in the frame image data after frame processing from the image area in the frame image data;

[0091] Obtaining the target contrast of the frame image data according to the image area in the frame image data; wherein the target contrast is obtained by the following formula:

[0092]

[0093] Wherein D represents the target contrast; D0 represents the original target contrast corresponding to the frame image data after frame processing; S represents the image area of the frame image data; S tc and S tj respectively represent the area of the feed inlet region and the area of the discharge outlet region corresponding to the frame image data; λ 01 and λ 02 respectively represent the first adjustment coefficient and the second adjustment coefficient, and the first adjustment coefficient and the second adjustment coefficient are obtained by the following formula:

[0094]

[0095] Wherein Q rc and Q rj represent the natural environmental brightness of the discharge outlet and the feed inlet; b represents the brightness value that the camera can still capture in a completely dark environment; k represents the proportion coefficient, and the proportion coefficient is obtained by the following formula:

[0096]

[0097] wherein, K represents a theoretical proportional relationship value between the image brightness of the camera in an ideal case and the ambient brightness; ξ represents an exposure compensation coefficient of the camera; L min and L max respectively represent the brightness values of the brightest area and the darkest area that can be captured by the camera.

[0098] contrast adjustment is performed on the frame image data according to the target contrast, to obtain frame image data after contrast adjustment, wherein the frame image data after contrast adjustment is the frame image data after image processing;

[0099] S103, extracting a feed inlet area and a discharge outlet area image of the coal crusher feed inlet for each frame image;

[0100] S104, screening frame image data in which the feed inlet area has primary occlusion and the discharge outlet area has primary occlusion, and taking the frame image data in which the feed inlet area has primary occlusion and the discharge outlet area has primary occlusion as target image data;

[0101] S105, storing the target image data into a database;

[0102] wherein, the judgment standard of the primary occlusion is that the occlusion area of the feed inlet area and the discharge outlet area reaches the first occlusion area corresponding to the feed inlet and the discharge outlet;

[0103] The first occlusion area of the feed inlet is:

[0104]

[0105] wherein, S 01 represents the first occlusion area of the feed inlet; S c and S j respectively represent the area of the discharge outlet and the area of the feed inlet;

[0106] The first occlusion area of the discharge outlet is:

[0107]

[0108] wherein, S 02 represents the first occlusion area of the discharge outlet.

[0109] The working principle of the above technical solution is as follows: video data acquisition (S101): real-time acquisition of video data of the operation of the coal crusher through the camera.

[0110] Frame processing (S102): frame processing is performed on the acquired video data, and the video data is divided into one frame by one frame of image.

[0111] Region extraction (S103): For each frame of image, the image of the coal crusher's feeding port and discharging port region is extracted. These regions usually contain information about the feeding port and discharging port.

[0112] Obstruction detection (S104): The extracted feeding port region and discharging port region images are analyzed to detect whether there is a primary obstruction. Obstruction can be caused by material or other obstacles. If a primary obstruction is detected, the frame image is marked as target image data.

[0113] Data storage (S105): The target image data is stored in the database for further processing and recording.

[0114] At the same time, the primary obstruction judgment of the feeding port:

[0115] By obtaining the areas of the feeding port region and the discharging port region, denoted as Sc (discharging port area) and Sj (feeding port area).

[0116] The first obstruction area of the feeding port is calculated using the above formula, which is used to judge the primary obstruction. The first obstruction area of the feeding port is related to the area of the feeding port. If the actual obstruction area of the feeding port exceeds this calculated first obstruction area, it will be judged as a primary obstruction.

[0117] Primary obstruction judgment of the discharging port:

[0118] The first obstruction area of the discharging port is calculated using the above formula, which is used to judge the primary obstruction. The first obstruction area of the discharging port is related to the area of the feeding port Sj and the area of the discharging port Sc. If the actual obstruction area of the discharging port exceeds this calculated first obstruction area, it will be judged as a primary obstruction.

[0119] The effect of the above technical solution is: through real-time collection of video data by the camera, the system can monitor the running state of the coal crusher in real time. The system analyzes the images of the feeding port and discharging port regions to detect whether there is a primary obstruction, which helps to discover running problems early. The frame image detected with a primary obstruction is marked as target image data for subsequent analysis and processing. The target image data is stored in the database and can be used for historical data analysis and problem tracking. Through this method, the system can quantitatively judge the primary obstruction of the feeding port and discharging port, not just rely on visual recognition, improving the accuracy of detection. Once the primary obstruction is detected, the system can take measures immediately, such as automatically notifying the operator or triggering the dredging mechanical arm, to reduce the risk of production interruption. By timely detection and handling of primary obstructions, the system can ensure smooth feeding and discharging, thereby improving the production efficiency of the coal crusher.

[0120] Meanwhile, by performing frame processing and subsequent image processing on the video data, more accurate area information (such as the feed inlet and discharge outlet areas) can be extracted, and the image quality can be further optimized. This processing can improve the accuracy and usability of the image data. The technical solution achieves dynamic adjustment of the contrast of the image according to the area occupied by the feed inlet and discharge outlet areas in the frame image data by calculating the target contrast. This dynamic adjustment can make the image clearer and help subsequent data analysis and processing. The scheme adjusts the image processing parameters by introducing the natural environment brightness, so that the processed image can better reflect the brightness changes in the actual environment, improving the authenticity and reliability of the image. By introducing the exposure compensation coefficient of the camera, the technical solution can fine-tune the image brightness according to the actual situation, further optimizing the display effect of the image. The technical solution takes into account the brightness values of the brightest and darkest areas that the camera can capture, which allows the processed image to maintain good visual effects and analysis value in different brightness environments.

[0121] In summary, this method can help improve the supervision and maintenance efficiency of the coal crusher, ensuring the normal operation of the equipment. At the same time, the technical solution comprehensively considers factors such as frame processing, image processing, natural environment brightness, exposure compensation coefficient, and the brightness capture range of the camera to achieve comprehensive optimization of video data processing, improving image quality and data analysis accuracy.

[0122] In one embodiment of the present application, the current coal crusher operation is determined according to the video image of the coal crusher operation, including:

[0123] S201, sequentially retrieve the feed inlet corresponding image in the target image data in the database;

[0124] S202, compare the occlusion area in the feed inlet corresponding image with the second occlusion area of the feed inlet, and when the occlusion area in the feed inlet corresponding image exceeds the second occlusion area of the feed inlet, determine that the current feed inlet is in a blocked state;

[0125] S203, sequentially retrieve the discharge outlet corresponding image in the target image data in the database;

[0126] S204, compare the occlusion area in the discharge outlet corresponding image with the second occlusion area of the discharge outlet, and when the occlusion area in the discharge outlet corresponding image exceeds the second occlusion area of the discharge outlet, determine that the current discharge outlet is in a blocked state.

[0127] Wherein, the second occlusion area of the feed inlet is:

[0128]

[0129] Sj 03 Sj c Sc and Sj j Sc and Sj

[0130] The second shielding area of the discharge port is:

[0131]

[0132] Sj 04 Sj c Sc and Sj j Sc and Sj

[0133] The working principle of the above technical solution is as follows: feeding port shielding detection (S201-S202): the corresponding images of the feeding port in the target image data in the database are sequentially called. For each image corresponding to the feeding port, the system compares the shielding area in the image with the second shielding area of the feeding port. If the shielding area in the image exceeds the second shielding area threshold of the feeding port, it is determined that the current feeding port has a clogging state.

[0134] Discharge port shielding detection (S203-S204): the corresponding images of the discharge port in the target image data in the database are sequentially called. For each image corresponding to the discharge port, the system compares the shielding area in the image with the second shielding area of the discharge port. If the shielding area in the image exceeds the second shielding area threshold of the discharge port, it is determined that the current discharge port has a clogging state.

[0135] At the same time, the second shielding judgment of the feeding port is:

[0136] By obtaining the areas of the feeding port region and the discharge port region, which are respectively represented as Sc (discharge port area) and Sj (feeding port area).

[0137] The feeding speed V1 and the discharge speed V2 of the coal crusher are obtained.

[0138] The second shielding area of the feeding port is calculated by using the above formula, and the area is used to judge the second level shielding. The second shielding area of the feeding port is related to the area Sj of the feeding port, the area Sc of the discharge port, and the feeding speed V1 and the discharge speed V2. If the actual shielding area of the feeding port exceeds the calculated second shielding area, it will be determined as the second level shielding.

[0139] The second shielding judgment of the discharge port is:

[0140] The second shielding area of the discharge port is calculated using the above formula, which is used to determine the second level shielding. The second shielding area of the discharge port is related to the area Sj of the inlet port, the area Sc of the discharge port, and the feeding speed V1 and the discharging speed V2. If the actual shielding area of the discharge port exceeds the calculated second shielding area, it will be judged as the second level shielding.

[0141] The effect of the above technical solution is: real-time monitoring of the blocking state: by comparing the shielding areas of the inlet port and the discharge port corresponding images, the system can monitor whether the coal crusher exists the blocking condition in real time. The method of the embodiment considers the feeding speed (V1) and the discharging speed (V2) of the coal crusher, which helps to more accurately determine the blocking state. Early detection of the blocking state of the coal crusher can take measures to handle to prevent equipment failure and production interruption. When the system detects the blocking state, it can automatically generate an alarm to notify the operator to take necessary measures, improving the efficiency and safety of equipment supervision.

[0142] At the same time, by considering the feeding speed, discharging speed, and the area of the inlet port and the discharge port and other factors, the system can more accurately determine whether there is a second level shielding, not just relying on a single factor. This method can help the system improve the accuracy of detecting the shielding condition of the coal crusher, reducing the possibility of false positives or false negatives. Once the second level shielding is detected, the system can take appropriate measures, such as triggering the mechanical arm, to reduce the risk of production interruption.

[0143] An embodiment of the present application, when the coal crusher runs in a blocking condition, then through the control of the mechanical arm to dredge the blocked part and the blocking alarm, comprising:

[0144] S301, when only the inlet port appears to be blocked, control the mechanical arm to dredge the blocked part of the inlet port;

[0145] S302, when only the discharge port appears to be blocked, control the mechanical arm to dredge the blocked part of the discharge port;

[0146] S303, when the inlet port and the discharge port appear to be blocked at the same time, then control the mechanical arm to dredge the inlet port and the discharge port at the same time and give a blocking alarm prompt.

[0147] The working principle of the above technical solution is: inlet port blocking treatment (S301): when the system detects that only the inlet port exists the blocking condition, control the mechanical arm to operate directionally, dredge the blocked part of the inlet port. Dredging treatment can include removing blockages, cleaning, or taking other appropriate measures to restore the smooth feeding.

[0148] Discharge port clogging processing (S302): When the system detects that only the discharge port is clogged, control the robotic arm to direct the operation to clear the clogged part of the discharge port. The clearing process can include removing the blockage, cleaning, or taking other appropriate measures to restore the discharge flow.

[0149] Simultaneous clogging processing and alarm of the feed port and the discharge port (S303): When the system detects that the feed port and the discharge port are simultaneously clogged, control the robotic arm to simultaneously clear the clogged part of the feed port and the discharge port. At the same time, the system triggers a clogging alarm to inform relevant personnel of the serious equipment clogging problem.

[0150] The effect of the above technical solution is: automatic processing: the system can automatically control the robotic arm to clear the clogging according to the location of the clogging, reducing the need for manual intervention and improving the processing efficiency.

[0151] Immediate response: the system can quickly detect the clogging and take action, which helps to reduce the possibility of production interruption.

[0152] Alarm prompt: when there is a clogging, the system can issue a clogging alarm to inform relevant personnel to take timely measures, improving equipment supervision and safety.

[0153] Reducing damage risk: by timely clearing the clogging, the damage risk of the coal crusher and related equipment can be reduced, prolonging the service life of the equipment.

[0154] The embodiment of the present application proposes an intelligent coal crusher monitoring system, as shown in Figure 2 The intelligent coal crusher monitoring system comprises:

[0155] A video data acquisition module for acquiring video data of the coal crusher in real time through a camera and performing video processing on the video data.

[0156] A clogging condition judgment module for judging whether the current coal crusher operation has a clogging condition according to the video image of the coal crusher operation.

[0157] A clogging alarm module for clearing the clogged part by controlling the robotic arm and issuing a clogging alarm when the coal crusher operation has a clogging condition.

[0158] The working principle of the above technical solution is: real-time video acquisition: real-time video data acquisition of the coal crusher operation through a camera.

[0159] Video processing: video processing of the collected video data, which may include image processing, feature extraction, and other analysis methods.

[0160] Blockage condition determination: Based on the processed video images, the algorithm determines whether the coal crusher currently has a blockage condition. This can be achieved by detecting abnormal or blocked parts of the material flow.

[0161] Blockage processing and alarm: If a blockage condition is found in the coal crusher, the system triggers the operation of the mechanical arm to clear the blocked part. This can be achieved by the action of the mechanical arm to remove or clear the blocked part, ensuring the normal operation of the equipment.

[0162] At the same time, the system also triggers a blockage alarm to notify the relevant operators or record the event.

[0163] The effect of the above technical solution is: real-time monitoring: through real-time video acquisition and image processing, the system can monitor the running state of the coal crusher in real time and find problems in time.

[0164] Blockage detection: The system can automatically determine whether the coal crusher has a blockage condition without human intervention.

[0165] Automatic dredging: Once a blockage is detected, the system can solve the problem by controlling the mechanical arm, improving the availability and efficiency of the equipment.

[0166] Alarm notification: The system can generate an alarm notification so that relevant operators can take action quickly to ensure the normal operation of the equipment.

[0167] An embodiment of the present application, the video data acquisition module comprises:

[0168] Data acquisition module, for acquiring video data of coal crusher operation in real time through camera;

[0169] Image frame processing module, for frame processing of the video data, obtaining frame image data after frame processing, and image processing of the frame image data, obtaining frame image data after image processing;

[0170] Region image extraction module, for extracting feed inlet region and discharge outlet region image of coal crusher feed inlet for each frame image;

[0171] Primary screening module, for screening frame image data with primary occlusion in feed inlet region and primary occlusion in discharge outlet region, and taking the frame image data with primary occlusion in feed inlet region and primary occlusion in discharge outlet region as target image data;

[0172] Target image data storage module, for storing target image data into database;

[0173] The judgment standard of the primary blockage is that the blockage area of the inlet area and the outlet area reaches the first blockage area corresponding to the inlet and the outlet.

[0174] The first blockage area of the inlet is:

[0175]

[0176] Wherein, S 01 represents the first blockage area of the inlet; S c and S j respectively represent the area of the outlet and the inlet.

[0177] The first blockage area of the outlet is:

[0178]

[0179] Wherein, S 02 represents the first blockage area of the outlet.

[0180] The working principle of the above technical solution is as follows: video data acquisition: real-time acquisition of video data of the coal crusher through the camera.

[0181] Frame processing: frame processing is performed on the acquired video data, which is divided into one frame by one frame of image.

[0182] Region extraction: for each frame of image, the image of the inlet and outlet area of the coal crusher is extracted from it. These areas usually contain the information of the inlet and outlet.

[0183] Blockage detection: the extracted inlet area and outlet area image is analyzed to detect whether there is a primary blockage. The blockage can be caused by material or other obstacles. If the primary blockage is detected, the frame image is marked as target image data.

[0184] Data storage: the target image data is stored in the database for further processing and recording.

[0185] At the same time, the primary blockage judgment of the inlet is:

[0186] By obtaining the area of the inlet area and the outlet area, which are respectively represented as Sc (outlet area) and Sj (inlet area).

[0187] The first blockage area of the inlet is calculated by using the above formula, and the area is used to judge the primary blockage. The first blockage area of the inlet is related to the area Sj of the inlet. If the actual blockage area of the inlet exceeds the calculated first blockage area, it will be judged as the primary blockage.

[0188] The primary blockage judgment of the outlet is:

[0189] The first blocking area of the discharge port is calculated using the above formula, which is used to determine the primary blocking. The first blocking area of the discharge port is related to the area Sj of the feed port and the area Sc of the discharge port. If the actual blocking area of the discharge port exceeds this calculated first blocking area, it will be determined as primary blocking.

[0190] The effect of the above technical solution is: real-time monitoring: through real-time video data collection by the camera, the system can monitor the running state of the coal crusher in real time.

[0191] Primary blocking detection: the system analyzes the images of the feed port and discharge port area to detect whether there is primary blocking, which helps to find running problems early.

[0192] Automatic labeling: the frame image of the primary blocking detected is labeled as target image data for subsequent analysis and processing.

[0193] Data recording: target image data is stored in the database, which can be used for historical data analysis and problem tracking.

[0194] On the other hand, primary blocking detection: through this method, the system can quantitatively judge the primary blocking of the feed port and discharge port, not just rely on visual recognition, improving the accuracy of detection.

[0195] Automatic processing: once the primary blocking is detected, the system can take measures immediately, such as automatically notifying the operator or triggering the dredging mechanical arm, to reduce the risk of production interruption.

[0196] Improve production efficiency: by timely detection and processing of primary blocking, the system can ensure smooth feeding and discharging, thereby improving the production efficiency of the coal crusher.

[0197] In summary, this method can help improve the supervision and maintenance efficiency of the coal crusher, ensuring the normal operation of the equipment.

[0198] In one embodiment of the present application, the blockage condition judgment module comprises:

[0199] The first image data retrieval module is used to retrieve the feed port corresponding image in the target image data in the database in sequence;

[0200] The feed port blocking judgment module is used to compare the blocking area in the feed port corresponding image with the second blocking area of the feed port, and when the blocking area in the feed port corresponding image exceeds the second blocking area of the feed port, it is determined that the current feed port is in a blocked state;

[0201] The second image data retrieval module is used to retrieve the discharge port corresponding image in the target image data in the database in sequence;

[0202] The outlet clogging judgment module is configured to compare the occlusion area in the outlet corresponding image with the outlet second occlusion area, and determine that the current outlet is in a clogging state when the occlusion area in the outlet corresponding image exceeds the outlet second occlusion area.

[0203] The second occlusion area of the inlet is S

[0204]

[0205] The second occlusion area of the outlet is S 03 The second occlusion area of the inlet is S c The second occlusion area of the outlet is S j Sc and Sj respectively represent the areas of the outlet and the inlet, V1 represents the feeding speed of the coal crusher, and V2 represents the discharging speed of the coal crusher.

[0206] The second occlusion area of the inlet is S

[0207]

[0208] The second occlusion area of the outlet is S 04 The second occlusion area of the inlet is S c The second occlusion area of the outlet is S j Sc and Sj respectively represent the areas of the outlet and the inlet, V1 represents the feeding speed of the coal crusher, and V2 represents the discharging speed of the coal crusher.

[0209] The working principle of the above technical solution is as follows: Inlet occlusion detection: the inlet corresponding images in the target image data in the database are sequentially called. For each inlet corresponding image, the system compares the occlusion area in the image with the second occlusion area of the inlet. If the occlusion area in the image exceeds the second occlusion area threshold of the inlet, it is determined that the current inlet is in a clogging state.

[0210] Outlet occlusion detection: the outlet corresponding images in the target image data in the database are sequentially called. For each outlet corresponding image, the system compares the occlusion area in the image with the second occlusion area of the outlet. If the occlusion area in the image exceeds the second occlusion area threshold of the outlet, it is determined that the current outlet is in a clogging state.

[0211] Meanwhile, the second occlusion judgment of the inlet is as follows:

[0212] The areas of the inlet region and the outlet region are obtained and represented as Sc (outlet area) and Sj (inlet area).

[0213] The feeding speed V1 and the discharging speed V2 of the coal crusher are obtained.

[0214] The second shielding area of the feed inlet is calculated by the above formula, which is used to determine the second level shielding. The second shielding area of the feed inlet is related to the area of the feed inlet Sj, the area of the discharge outlet Sc, and the feed speed V1 and the discharge speed V2. If the actual shielding area of the feed inlet exceeds the calculated second shielding area, it will be judged as the second level shielding.

[0215] Second shielding judgment of the discharge outlet:

[0216] The second shielding area of the discharge outlet is calculated by the above formula, which is used to determine the second level shielding. The second shielding area of the discharge outlet is related to the area of the feed inlet Sj, the area of the discharge outlet Sc, and the feed speed V1 and the discharge speed V2. If the actual shielding area of the discharge outlet exceeds the calculated second shielding area, it will be judged as the second level shielding.

[0217] The effect of the above technical solution is: real-time monitoring of the blocking state: by comparing the shielding areas of the corresponding images of the feed inlet and the discharge outlet, the system can monitor whether the coal crusher is blocked in real time. The method of the embodiment considers the feed speed (V1) and the discharge speed (V2) of the coal crusher, which helps to more accurately determine the blocking state. Early detection of the blocking state of the coal crusher can take measures to prevent equipment failure and production interruption. When the system detects the blocking state, it can automatically generate an alarm to notify the operator to take necessary measures, improving the efficiency and safety of equipment supervision.

[0218] At the same time, by considering the feed speed, discharge speed, and the areas of the feed inlet and discharge outlet, the system can more accurately determine whether there is a second level shielding, not just relying on a single factor. This method can help the system improve the accuracy of detecting the shielding condition of the coal crusher, reducing the possibility of false positives or false negatives. Once the second level shielding is detected, the system can take appropriate measures, such as triggering the mechanical arm, to reduce the risk of production interruption.

[0219] An embodiment of the present application, the blocking alarm module comprises:

[0220] The first dredging control module is used to control the mechanical arm to dredge the blocked part of the feed inlet when only the feed inlet is blocked;

[0221] The second dredging control module is used to control the mechanical arm to dredge the blocked part of the discharge outlet when only the discharge outlet is blocked;

[0222] The third dredging control module is used to control the mechanical arm to dredge the feed inlet and the discharge outlet at the same time when the feed inlet and the discharge outlet are blocked at the same time, and to give a blocking alarm prompt.

[0223] The working principle of the above technical solution is as follows: feed inlet blockage treatment: when the system detects that only the feed inlet is blocked, the mechanical arm is controlled to operate in a targeted manner to dredge the blocked part of the feed inlet. The dredging treatment can include removing the blockage, cleaning, or taking other appropriate measures to restore the smoothness of the feed.

[0224] Discharge outlet blockage treatment: when the system detects that only the discharge outlet is blocked, the mechanical arm is controlled to operate in a targeted manner to dredge the blocked part of the discharge outlet. The dredging treatment can include removing the blockage, cleaning, or taking other appropriate measures to restore the smoothness of the discharge.

[0225] Feed inlet and discharge outlet blockage treatment and alarm: when the system detects that the feed inlet and the discharge outlet are simultaneously blocked, the mechanical arm is controlled to simultaneously dredge the blocked parts of the feed inlet and the discharge outlet. At the same time, the system triggers a blockage alarm to notify relevant personnel of the serious equipment blockage problem.

[0226] The effect of the above technical solution is: automatic treatment: the system can automatically control the mechanical arm to dredge according to the position of the blockage, reducing the need for manual intervention and improving the processing efficiency.

[0227] Immediate response: the system can quickly detect blockage and take action, which helps to reduce the possibility of production interruption.

[0228] Alarm prompt: when there is a blockage, the system can issue a blockage alarm to notify relevant personnel to take timely measures, improving equipment supervision and safety.

[0229] Reducing damage risk: by dredging the blockage in time, the damage risk of the coal crusher and related equipment can be reduced, prolonging the service life of the equipment.

[0230] Obviously, those skilled in the art can make various modifications and variations to the present application without departing from the spirit and scope of the present application. Thus, if these modifications and variations of the present application fall within the scope of the claims of the present application and their equivalents, the present application also intends to include these modifications and variations.

Claims

1. A method for monitoring an intelligent coal crusher, characterized in that, The intelligent coal crusher monitoring method includes: The video data of the coal crusher in operation is collected in real time by a camera, and the video data is processed. Determine whether there is a blockage in the current operation of the coal crusher based on the video images of the coal crusher's operation; When the coal crusher experiences blockages, the robotic arm is controlled to clear the blockages. Block alarm; This involves using cameras to collect real-time video data of the coal crusher's operation and then processing that video data. include: Real-time video data of the coal crusher's operation is collected via camera; The video data is subjected to frame processing to obtain frame image data after frame processing, and the frame image data is subjected to image processing to obtain frame image data after image processing. For each frame of image, extract the inlet and outlet areas of the coal crusher's feed inlet; Frame image data with primary occlusion in the inlet area and primary occlusion in the outlet area are selected, and the frame image data with primary occlusion in the inlet area and primary occlusion in the outlet area are used as target image data. Store the target image data in the database; The criterion for determining the primary obstruction is: the obstruction area of ​​the inlet area and the outlet area reaches the first obstruction area corresponding to the inlet and the outlet. The first obstruction area of ​​the feed inlet is: in, S 01 This indicates the first area of ​​obstruction at the feed inlet; S c and S j These represent the areas of the discharge port and the inlet port, respectively. The first shielding area of ​​the discharge port is: in, S 02 Indicates the first obstruction area of ​​the discharge port; The image processing includes: The area of ​​the inlet and outlet regions in the processed frame image data is extracted to determine the area of ​​the image region in the frame image data. The target contrast of the frame image data is obtained based on the area of ​​the image region in the frame image data; wherein, the target contrast is obtained by the following formula: in, D Indicates target contrast; D 0 indicates the original target contrast corresponding to the frame image data after frame processing; S The area of ​​the image in a frame; S tc and S tj These represent the areas corresponding to the inlet and outlet regions in the frame image data, respectively. λ 01 and λ 02 Let represent the first adjustment coefficient and the second adjustment coefficient, respectively, and the first and second adjustment coefficients are obtained by the following formula: in, Q rc and Q rj Indicates the ambient light level at the discharge and inlet ports; b This indicates the brightness value that the camera can still capture in a completely dark environment; k This represents the scaling factor, which is obtained using the following formula: in, K This represents a numerical value indicating the theoretical ratio between the image brightness and the ambient brightness under ideal conditions; ξ This indicates the camera's exposure compensation factor; L min and L max These represent the brightness values ​​of the brightest and darkest areas that the camera can capture, respectively. The frame image data is contrast-adjusted according to the target contrast to obtain contrast-adjusted frame image data, wherein the contrast-adjusted frame image data is the frame image data after image processing.

2. The intelligent coal crusher monitoring method according to claim 1, characterized in that, Determining whether there is a blockage in the current operation of the coal crusher based on the video images of its operation includes: Retrieve the corresponding images of the feed inlet from the target image data in the database in sequence; The occlusion area in the image corresponding to the feed inlet is compared with the second occlusion area of ​​the feed inlet. When the occlusion area in the image corresponding to the feed inlet exceeds the second occlusion area of ​​the feed inlet, the feed inlet is determined to be blocked. Retrieve the corresponding images of the discharge port from the target image data in the database in sequence; The obstructed area in the image corresponding to the discharge port is compared with the second obstructed area of ​​the discharge port. When the obstructed area in the image corresponding to the discharge port exceeds the second obstructed area of ​​the discharge port, the current discharge port is determined to be blocked.

3. The intelligent coal crusher monitoring method according to claim 2, characterized in that, The second shielding area of ​​the feed inlet is: in, S 03 Indicates the second obstruction area of ​​the feed inlet; S c and S j These represent the areas of the discharge port and the inlet port, respectively. V 1 indicates the feed rate of the coal crusher; V 2 indicates the discharge speed of the coal crusher; The second shielding area of ​​the discharge port is: in, S 04 Indicates the second obstruction area of ​​the discharge port; S c and S j These represent the areas of the discharge port and the inlet port, respectively. V 1 indicates the feed rate of the coal crusher; V 2 indicates the discharge speed of the coal crusher.

4. The intelligent coal crusher monitoring method according to claim 1, characterized in that, When the coal crusher is blocked, the robotic arm is controlled to clear the blockage and trigger a blockage alarm, including: When only the feed inlet is blocked, the robotic arm is controlled to clear the blockage. When only the discharge port is blocked, the robotic arm is controlled to clear the blockage. When both the feed inlet and the discharge outlet become blocked, the robotic arm is controlled to clear the blockage while simultaneously issuing a blockage alarm.

5. An intelligent coal crusher monitoring system, characterized in that, The intelligent coal crusher monitoring system includes: The video data acquisition module is used to acquire video data of the coal crusher in real time through a camera and to process the video data. The blockage determination module is used to determine whether there is a blockage in the current operation of the coal crusher based on the video images of the coal crusher's operation. The blockage alarm module is used to control the robotic arm to clear the blockage when a blockage occurs during the operation of the coal crusher. The system will be divided into sections for clearing blockages and issuing blockage alarms. The video data acquisition module includes: The data acquisition module is used to collect video data of the coal crusher in real time via a camera; The image frame processing module is used to perform frame processing on the video data to obtain frame-processed frame image data, and to perform image processing on the frame image data to obtain image-processed frame image data. The region image extraction module is used to extract images of the feed inlet and discharge outlet regions of the coal crusher for each frame image; The primary filtering module is used to filter out frame image data where the inlet area and the outlet area have primary occlusion, and to use the frame image data where the inlet area and the outlet area have primary occlusion as target image data. The target image data storage module is used to store target image data in the database; The criterion for determining the primary obstruction is: the obstruction area of ​​the inlet area and the outlet area reaches the first obstruction area corresponding to the inlet and the outlet. The first obstruction area of ​​the feed inlet is: in, S 01 This indicates the first area of ​​obstruction at the feed inlet; S c and S j These represent the areas of the discharge port and the inlet port, respectively. The first shielding area of ​​the discharge port is: in, S 02 Indicates the first obstruction area of ​​the discharge port; The image processing includes: The area of ​​the inlet and outlet regions in the processed frame image data is extracted to determine the area of ​​the image region in the frame image data. The target contrast of the frame image data is obtained based on the area of ​​the image region in the frame image data; wherein, the target contrast is obtained by the following formula: in, D Indicates target contrast; D 0 indicates the original target contrast corresponding to the frame image data after frame processing; S The area of ​​the image in a frame; S tc and S tj These represent the areas corresponding to the inlet and outlet regions in the frame image data, respectively. λ 01 and λ 02 Let represent the first adjustment coefficient and the second adjustment coefficient, respectively, and the first and second adjustment coefficients are obtained by the following formula: in, Q rc and Q rj Indicates the ambient light level at the discharge and inlet ports; b This indicates the brightness value that the camera can still capture in a completely dark environment; k This represents the scaling factor, which is obtained using the following formula: in, K This represents a numerical value indicating the theoretical ratio between the image brightness and the ambient brightness under ideal conditions; ξ This indicates the camera's exposure compensation factor; L min and L max These represent the brightness values ​​of the brightest and darkest areas that the camera can capture, respectively. The frame image data is contrast-adjusted according to the target contrast to obtain contrast-adjusted frame image data, wherein the contrast-adjusted frame image data is the frame image data after image processing.

6. The intelligent coal crusher monitoring system according to claim 5, characterized in that, The blockage status determination module includes: The first image data retrieval module is used to sequentially retrieve the image corresponding to the feed port from the target image data in the database; The feed inlet blockage detection module is used to compare the occlusion area in the image corresponding to the feed inlet with the second occlusion area of ​​the feed inlet. When the occlusion area in the image corresponding to the feed inlet exceeds the second occlusion area of ​​the feed inlet, the feed inlet is determined to be blocked. The second image data retrieval module is used to sequentially retrieve the images corresponding to the discharge port from the target image data in the database. The discharge port blockage detection module is used to compare the obstruction area in the image corresponding to the discharge port with the second obstruction area of ​​the discharge port. When the obstruction area in the image corresponding to the discharge port exceeds the second obstruction area of ​​the discharge port, the current discharge port is determined to be blocked.

7. The intelligent coal crusher monitoring system according to claim 6, characterized in that, The second shielding area of ​​the feed inlet is: in, S 03 Indicates the second obstruction area of ​​the feed inlet; S c and S j These represent the areas of the discharge port and the inlet port, respectively. V 1 indicates the feed rate of the coal crusher; V 2 indicates the discharge speed of the coal crusher; The second shielding area of ​​the discharge port is: in, S 04 Indicates the second obstruction area of ​​the discharge port; S c and S j These represent the areas of the discharge port and the inlet port, respectively. V 1 indicates the feed rate of the coal crusher; V 2 indicates the discharge speed of the coal crusher.

8. The intelligent coal crusher monitoring system according to claim 5, characterized in that, The congestion alarm module includes: The first unblocking control module is used to control the robotic arm to unblock the part of the feed inlet when only the feed inlet is blocked. The second unblocking control module is used to control the robotic arm to unblock the part of the discharge port when only the discharge port is blocked. The third unblocking control module is used to control the robotic arm to unblock the inlet and outlet while simultaneously issuing a blockage alarm when both the inlet and outlet are blocked.

Images