Method, device, system, equipment and medium for determining tear size of conveyor belt

Abstract

The present application discloses a method, device, system, electronic device and readable storage medium for determining the tear size of a conveyor belt, which is applied to the field of material transportation technology. The method comprises determining the single-frame belt running distance of each frame image interval of the conveyor belt at the current moment based on the belt surface running speed of the belt conveyor at the current moment and the sampling frame rate of the image acquisition device. The number of tears in the conveyor belt is determined by comparing the tear characteristics of two adjacent frames of images of the conveyor belt. For each tear position, the tear size of each tear position of the conveyor belt is calculated in turn based on the tear width of each single-frame image belonging to the same tear position and the corresponding single-frame belt running distance, so that whether the conveyor belt has reached the maximum allowable tear size can be accurately and timely detected, which is beneficial to improving the safety and stability of the belt conveyor.

Description

Technical Field

[0001] The present application relates to the technical field of material transportation, and in particular to a method, device, system, electronic device, and readable storage medium for determining the tear size of a conveyor belt. Background Art

[0002] Belt conveyors are widely used in the transport of materials in ports, metallurgy, mining, chemicals, petroleum, power plants, building materials, and many other fields. They rely on conveyor belts to connect to drive devices and transport materials. During the material transport process, conveyor belts are inevitably punctured by sharp objects and may even deviate, causing longitudinal tears in the conveyor belt. As the tear size increases, the conveyor belt can easily cause cargo to spill, paralyzing the entire belt conveyor. In severe cases, it can cause casualties among inspection personnel and result in significant economic losses. To ensure that belt conveyors can transport materials safely and stably, it is necessary to monitor the tear status of the conveyor belt in real time.

[0003] After detecting a tear in a conveyor belt, the existing technology typically involves periodic manual inspections of the belt's tear condition, relying on experience to determine whether the tear will affect the normal operation of the belt conveyor. However, relying on manual inspections and judgments cannot accurately and promptly determine whether the conveyor belt has reached the maximum allowable tear size.

[0004] In view of this, accurately and timely detecting whether the conveyor belt has reached the maximum allowable tear size is a technical problem that needs to be solved by technicians in the field. Summary of the Invention

[0005] The present application provides a method, device, system, electronic device and readable storage medium for determining the tear size of a conveyor belt, which can accurately and timely detect whether the conveyor belt has reached the maximum allowable tear size, which is beneficial to improving the safety and stability of the belt conveyor.

[0006] To solve the above technical problems, this application provides the following technical solutions:

[0007] In one aspect, the present application provides a method for determining the tear size of a conveyor belt, comprising:

[0008] According to the current running speed of the belt conveyor and the sampling frame rate of the image acquisition device, the single-frame running distance of the conveyor belt between each frame of image at the current moment is determined;

[0009] Determining the number of tears in the conveyor belt by comparing tear features in two adjacent frames of images of the conveyor belt;

[0010] Based on the number of tears, the tear size of each tear position of the conveyor belt is calculated according to the tear width of each single-frame image belonging to the same tear position and the corresponding single-frame belt running distance.

[0011] Optionally, determining the number of tears in the conveyor belt by comparing tear features in two adjacent frames of images of the conveyor belt includes:

[0012] Acquire a binary image of a current frame image of the laser light projection area of ​​the conveyor belt, and remove an image block of the torn area of ​​the conveyor belt in the binary image;

[0013] Obtaining vertical projection data of the binary image after removing the image block, and using the coordinates corresponding to the first target value appearing in the vertical projection data as the tearing position of the current frame image; the target value is determined by the pixel value of the pixel point in the binary image that is not the laser light;

[0014] If the difference between the tearing positions of the current frame image and the previous frame image is less than a preset frame interval threshold, the tears in the current frame image and the previous frame image belong to the same tearing position;

[0015] The preset frame interval threshold is determined according to a single-frame belt running distance between the current frame image and the previous frame image.

[0016] Optionally, determining the number of tears in the conveyor belt by comparing tear features in two adjacent frames of images of the conveyor belt includes:

[0017] If the difference between the tear positions of the current frame image and the previous frame image is greater than or equal to a preset frame interval threshold, the tear positions of the current frame image and the previous frame image are different, and the current frame image is treated as a newly occurred tear;

[0018] The number of tears in the conveyor belt is determined by counting the number of newly occurring tears.

[0019] Optionally, the calculating, based on the number of tears, the tear size of each tear position of the conveyor belt according to the tear width of each single-frame image belonging to the same tear position and the corresponding single-frame belt running distance, includes:

[0020] For the same tearing position, counting the number of tearing width pixels of pixel values ​​of consecutive non-laser line pixel points appearing in the vertical projection data;

[0021] The tear width of the single-frame image is calculated according to the actual distance represented by each pixel and the number of the tear width pixels.

[0022] Optionally, the calculating, based on the number of tears, the tear size of each tear position of the conveyor belt according to the tear width of each single-frame image belonging to the same tear position and the corresponding single-frame belt running distance, includes:

[0023] For each tearing position on the conveyor belt, sequentially obtaining the tearing width of each frame image belonging to the current tearing position and the corresponding single-frame belt running distance;

[0024] The tear size calculation formula is called to calculate the tear size of the current tear position; the tear size calculation formula is:

[0025]

[0026] Where sw_area j is the tear size of the jth tear position, n is the total number of single-frame images belonging to the jth tear position, is the tear width of the i-th frame image at the j-th tear position, s i is the single-frame belt running distance of the i-th frame image.

[0027] Another aspect of the present application provides a device for determining the tear size of a conveyor belt, comprising:

[0028] The running distance calculation module is used to determine the single-frame running distance of the conveyor belt at each frame interval of the current moment according to the belt surface running speed of the belt conveyor and the sampling frame rate of the image acquisition device;

[0029] a tearing number determining module, configured to determine the tearing number of the conveyor belt by comparing tearing features of two adjacent frames of images of the conveyor belt;

[0030] The tear size determination module is used to calculate the tear size of each tear position of the conveyor belt based on the tear number, the tear width of each single-frame image belonging to the same tear position and the corresponding single-frame belt running distance.

[0031] The present application also provides an electronic device, comprising a processor, wherein the processor is configured to implement the steps of the method for determining the tear size of a conveyor belt as described in any of the preceding items when executing a computer program stored in a memory.

[0032] The present application also provides a readable storage medium having a computer program stored thereon. When the computer program is executed by a processor, the steps of the method for determining the tear size of a conveyor belt as described in any of the above items are implemented.

[0033] Finally, the present application provides a conveyor belt tear size determination system, comprising a laser, an image acquisition component, a belt speed detection device, and an image processing server;

[0034] The belt speed detection device is installed on the conveyor belt, and is used to measure the belt surface running speed of the belt conveyor and transmit the belt surface running speed to the image processing server;

[0035] The laser and the image acquisition assembly are installed between the carrying belt and the return belt of the conveyor belt of the belt conveyor and face the back of the conveyor belt;

[0036] The laser is used to project laser light onto the return belt;

[0037] The image acquisition component is used to acquire the return belt image and transmit the return belt image to the image processing server;

[0038] The image processing server is used to implement the steps of the method for determining the tear size of the conveyor belt as described in any of the above items by executing a computer program.

[0039] Optionally, the image acquisition component includes an image acquisition device, a lighting board and a light shield;

[0040] The image acquisition device, the lighting plate and the laser are arranged inside the light shield, and the light shield is installed between the carrying belt and the return belt;

[0041] The image acquisition device and the lighting plate face the back side of the conveyor belt.

[0042] The advantage of the technical solution provided by the present application is that, since each frame image can only detect a tear within the range of a line laser width, the tear features of two adjacent frames of images of the conveyor belt can be compared to identify whether the tears in each frame image belong to the same tear position, and then the tear size of each tear position of the conveyor belt can be calculated based on the tear width of the single frame image combined with the running distance of the conveyor belt in each frame image interval. According to the calculated tear size, it is possible to accurately and timely detect whether the conveyor belt has reached the maximum allowable tear size, and timely deal with the conveyor belt with large-area tear to prevent accidents, which is conducive to improving the safety and stability of the belt conveyor.

[0043] In addition, the present application also provides corresponding implementation devices, systems, electronic devices and readable storage media for the method of determining the tear size of a conveyor belt, further making the method more practical, and the devices, systems, electronic devices and readable storage media have corresponding advantages.

[0044] It should be understood that the foregoing general description and the following detailed description are merely illustrative and are not restrictive of the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] In order to more clearly illustrate the technical solutions of the present application or related technologies, the following briefly introduces the drawings required for use in the embodiments or related technical descriptions. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0046] Figure 1 A schematic flow chart of a method for determining the tear size of a conveyor belt provided in this application;

[0047] Figure 2 A schematic diagram comparing the tearing characteristics of multiple tearing locations provided in this application;

[0048] Figure 3 A schematic flow chart of another method for determining the tear size of a conveyor belt provided in this application;

[0049] Figure 4 A structural diagram of a specific embodiment of the device for determining the tear size of a conveyor belt provided in this application;

[0050] Figure 5 A structural diagram of a specific embodiment of the electronic device provided in this application;

[0051] Figure 6 A structural diagram of a specific embodiment of the system for determining the tear size of a conveyor belt provided in this application;

[0052] Figure 7 Schematic diagram of monocular vision triangulation provided for this application;

[0053] Figure 8 This is a structural diagram of a specific embodiment of the system for determining the tear size of a conveyor belt provided in this application. DETAILED DESCRIPTION

[0054] In order to enable those skilled in the art to better understand the present application, the present application is further described in detail below in conjunction with the accompanying drawings and specific embodiments. Obviously, the embodiments described are only a part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without making any creative efforts are within the scope of protection of the present application.

[0055] The terms "including," "having," and any variations thereof in the specification and claims of this application, as well as in the accompanying drawings, are intended to cover non-exclusive inclusions. For example, a process, method, system, product, or apparatus comprising a series of steps or elements is not limited to the listed steps or elements and may include steps or elements that are not listed. Various non-limiting embodiments of the present application are described in detail below.

[0056] First see Figure 1 , Figure 1 This is a flow chart of a method for determining the tear size of a conveyor belt provided in this application. This application may include the following contents:

[0057] S101: Determine a single-frame belt running distance of each frame of the conveyor belt at the current moment according to the belt surface running speed of the belt conveyor and the sampling frame rate of the image acquisition device.

[0058] In this embodiment, the belt speed is the distance per second traveled by the conveyor belt. This speed can be obtained using any speed-detecting belt speed detection device, such as a sensor. The belt speed detection device can be pre-installed on the conveyor belt to detect the conveyor belt speed. The conveyor belt speed can be fixed or variable. Accordingly, the current moment is the moment when the conveyor belt tear size needs to be calculated, or when conveyor belt image capture for determining the conveyor belt tear size begins. The sampling frame rate is the number of image frames captured per second by the image capture device and can be determined based on the physical parameters of the image capture device, such as a camera, installed on the conveyor belt. After obtaining the belt speed V and the sampling frame rate fps, the single-frame belt travel distance s of the conveyor belt at the current moment can be calculated based on s = V / fps. The single-frame belt travel distance is the distance the conveyor belt travels during each frame interval of the image capture device. When the conveyor belt speed is constant, a higher sampling frame rate value results in a more accurate statistical tear size.

[0059] S102: Determine the number of tears in the conveyor belt by comparing tear features in two adjacent frames of images of the conveyor belt.

[0060] It is understandable that analyzing each frame of laser imagery captured by the image acquisition device in the laser projection area on the conveyor belt can only detect a tear within the width of a single laser line. Calculating the size of each tear location on the conveyor belt requires identifying and counting the tear sizes of multiple frames of images that share the tear signature at the same tear location. Because there may be more than one tear location on the conveyor belt, and the tear width varies across frames, accurately determining the size of each tear location requires identifying whether the two preceding and subsequent frames of images that share the tear signature represent the same tear location, thereby calculating the total number of tear locations on the conveyor belt.

[0061] S103: Based on the number of tears, according to the tear widths of the single-frame images belonging to the same tear position and the corresponding single-frame belt running distance, the tear size of each tear position of the conveyor belt is calculated.

[0062] After determining in the previous step whether there is one or multiple tears in the conveyor belt, this step can count the tear width of each tear in all single-frame images of the tear, and convert pixel units and actual distance based on the belt running distance between each frame image to calculate the actual size of the tear position.

[0063] In the technical solution provided by this application, since each frame image can only detect a tear within the range of a line laser width, the tear characteristics of two adjacent frames of the conveyor belt are compared to identify whether the tears in each frame image belong to the same tear position. Then, based on the tear width of the single frame image and the running distance of the conveyor belt in each frame image interval, the tear size of each tear position of the conveyor belt can be calculated. Based on the calculated tear size, it is possible to accurately and timely detect whether the conveyor belt has reached the maximum allowable tear size, and timely handle the conveyor belt with large-area tear to prevent accidents, which is conducive to improving the safety and stability of the belt conveyor. The entire calculation process has little dependence on computing hardware and can effectively reduce the excessive use of computing resources.

[0064] In the above embodiment, whether the tear position is the same is determined based on the comparison of tear features of two adjacent frames of images of the conveyor belt. The tear features can be, but are not limited to, tear position, tear width, and tear shape. Different tear features are extracted and analyzed in different ways. In the above embodiment, there is no limitation on how to execute step S102. Technicians in the relevant field can choose a suitable method to identify whether a single frame image has a tear and extract the corresponding tear features according to the actual situation. For example, technicians in the relevant field can use any existing machine learning algorithm to train a tear recognition model and a tear position recognition model based on a large amount of labeled sample data. The present application also provides a method that can simply and efficiently identify whether two adjacent frames of images of a conveyor belt belong to the same tear position, which may include the following:

[0065] Obtain a binary image of the current frame image of the laser light projection area of ​​the conveyor belt, and remove the image block of the torn area of ​​the conveyor belt in the binary image; obtain the vertical projection data of the binary image after removing the image block, and use the coordinate corresponding to the first target value appearing in the vertical projection data as the tear position of the current frame image; the target value is determined by the pixel value of the non-laser light pixel point in the binary image; if the difference in the tear position between the current frame image and the previous frame image is less than a preset frame interval threshold, then the tears in the current frame image and the previous frame image belong to the same tear position; if the difference in the tear position between the current frame image and the previous frame image is greater than or equal to the preset frame interval threshold. The preset frame interval threshold is determined based on the single-frame belt running distance between the current frame image and the previous frame image. Of course, the tear feature of the previous frame image is also extracted according to the scheme provided in this embodiment.

[0066] The tearing feature of this embodiment is the tearing position. The laser will emit laser light to the conveyor belt, and the image acquisition device will capture the image of the conveyor belt. This embodiment is based on the phenomenon that the belt surface of the conveyor belt will be discontinuous after it is torn. By detecting whether the laser light is continuous, the tearing fault of the conveyor belt can be detected. Correspondingly, what is extracted is the image of the laser light projection area of ​​the conveyor belt. In order to facilitate the extraction of the laser light in the image, the image of the conveyor belt captured by the image acquisition device containing the laser light is binarized. In this way, the pixel values ​​of the image pixels of the binary image are of only two categories, one is the pixel value of the pixel point corresponding to the laser light, and the rest are the pixel values ​​corresponding to the non-laser light pixel points. In order to improve the accuracy of subsequent image processing, this step removes most of the background area in the binary image and the image area corresponding to the torn position of the conveyor belt, so that the image block retained is the image block corresponding to the laser light. As an optional implementation, since the laser light in the laser image is concentrated in a certain area in the horizontal direction, the binary image can be horizontally projected, and each row of pixels in the horizontal direction is accumulated to obtain horizontal projection data, that is, a column vector. The length of the column vector is equal to the height h of the image. The maximum value of the horizontal projection data is taken as the highest position value h of the laser light in the laser binary image. max The width h of the laser beam in the widest possible case is determined based on empirical values ​​or the slope of the horizontal projection image of the laser binary image. thresh When cropping the binary image of the laser, only the image with the height that meets [h max -h thresh ,h max +h thresh] image blocks, so that the image blocks of the torn area and the background area can be eliminated, and the image blocks retained are the image blocks of the laser light. That is, as an optional embodiment, the method of removing the image blocks of the torn area of ​​the conveyor belt in the binary image can be: horizontally projecting the binary image of the current frame image to obtain horizontal projection data, taking the maximum value in the horizontal projection data as the highest position value of the laser light in the binary image, determining the laser width threshold according to the width of the laser light, and determining the target height range according to the highest position value and the laser width threshold, extracting the pixel points in the target height range from the binary image, thereby removing the image blocks of the torn area of ​​the conveyor belt in the binary image and most of the background area. If the pixel values ​​of all pixels in a certain column of the target laser image are the pixel values ​​corresponding to the non-laser light pixels, then the pixels in this column correspond to the tear position of the conveyor belt. Therefore, this embodiment can identify the tear position based on the distribution of the target values. That is, the target value is determined by the pixel values ​​corresponding to the non-laser light pixels. For example, the target value can be the cumulative value of the pixel values ​​corresponding to multiple non-laser light pixels. The specific number can be determined according to the actual situation, as long as it can be ensured that the target value can reflect that the column is all non-laser light pixels. In order to facilitate calculation, the pixel values ​​corresponding to the non-laser light pixels are generally set to 0. The pixel values ​​corresponding to the laser light pixels are not 0. Accordingly, the target value can be 0. This step performs vertical projection on the binarized image after removing the image blocks. Since the horizontal projection process previously removed pixel values ​​from the belt's torn areas, if a target value appears in the vertical projection data after vertical projection, the pixel corresponding to that target value is the location where the laser light encounters a crack or split in the conveyor belt. Therefore, by determining whether a conveyor belt tear has occurred, the presence of a target value in the vertical projection data can be used to detect whether the conveyor belt has experienced a tear. If a tear has occurred, the location where the first target value appears is the tear location. The tear area and its size are then determined based on the distribution of target values ​​in the vertical projection data. For each tear location, the number of consecutive non-laser line pixel values ​​in the vertical projection data is counted. The tear width for a single frame is calculated based on the actual distance represented by each pixel and the number of tear width pixels. Alternatively, the number of consecutive target values ​​(e.g., 0) that appear is recorded as the tear width. When the image acquisition device is fixed in position, the actual distance represented by each pixel can be determined using any existing camera calibration method. The actual tear width can be determined by counting the number of tear width pixels.

[0067] It is understandable that since the tear width varies with its position, the tear position location and tear width sw detected by vertical projection of the previous and next frame images will vary to a certain extent, such as Figure 2What is displayed is the change in the tear position between the two frames when there are two tear faults in the same section. If there are multiple tear faults, it is necessary to judge the tear position of the previous and next frames. Assuming that the tear fault is first identified in the i-th frame and there are two positions, the value of tear 1 is obtained. Tear 2 value In the i+1th frame, since the tearing is not uniformly distributed, the tearing position and tearing width will vary after vertical projection, but and These are different locations of the same tear, and the degree of variation is relatively small, so a preset frame interval threshold, l_thresh, can be set. If the absolute difference in the tear locations between frame i+1 and frame i is less than l_thresh, they are considered the same tear. If the absolute difference in the tear locations between frame i+1 and frame i is greater than or equal to l_thresh, they are considered different tears. After comparing tear features in each frame of the conveyor belt, the current frame that is not the same tear as the previous frame is marked as a new tear. By counting the number of new tears, the number of tears in the conveyor belt can be determined.

[0068] Based on the above embodiment, the present application further provides a method for calculating the tear size of a boundary, which may include the following:

[0069] For each tear position on the conveyor belt, the same tear is continuous. When a tear is detected in the current frame image, the next frame image of the current frame is identified as a tear fault and whether it belongs to the same tear position. If the next frame image has a tear and belongs to the same tear position as the current frame image, the next frame image is used as the current frame image to perform the above steps until the next frame image has no tear or does not belong to the same tear position, then the current tear position ends. Obtain the tear width of each frame image belonging to the current tear position and the corresponding single-frame belt running distance; call the tear size calculation relationship to calculate the tear size of the current tear position; the tear size calculation relationship can be expressed as:

[0070]

[0071] Where sw_area j is the tear size of the jth tear position, n is the total number of single-frame images belonging to the jth tear position, is the tear width of the i-th frame image at the j-th tear position, s i is the single-frame belt running distance of the i-th frame image.

[0072] In order to make the technicians in the related field more clear about the method for determining the tear size of the conveyor belt of the present application, the present application also provides an illustrative example, such as Figure 3As shown, it may include the following:

[0073] A binary image of the current frame image of the laser light projection area on the conveyor belt is obtained. If the laser light in the binary image is tilted, the binary image is tilt-corrected according to the tilt angle determined by the fitting result of the binary image. The highest position value of the laser light in its image is determined based on the horizontal projection data of the binary image; the binary image is cropped based on the target height range determined by the highest position value and the laser width threshold to obtain a target laser image with the image block and background area corresponding to the torn area of ​​the conveyor belt removed from the binary image. Based on the distribution of target values ​​in the vertical projection data of the target laser image, it is determined whether the conveyor belt is torn. If torn, the tear position and tear width of the current frame image are calculated based on the position of the first target value and the number of multiple consecutive target values. The tear position of the current frame image is compared with the tear position of the previous frame image to determine whether the tear in the current frame image is a continuation of the tear in the previous frame image. If the absolute value of the difference is less than the preset frame interval threshold, the current frame image and the previous frame image belong to the same tear position. The tear width of the current frame image is added to the tear width of the previous frame image, and a new frame image is obtained as the current frame image and the above steps are repeated. If the absolute value of the difference is greater than or equal to the preset frame interval threshold, the current frame image and the previous frame image do not belong to the same tear position. The result of the tear end is output, and the tear size value of the tear position of the previous frame image is output at the same time. The tear position detected in the current frame image is marked as a new tear, and a new frame image is obtained as the current frame image and the above steps are repeated.

[0074] As can be seen from the above, this embodiment can accurately and timely detect whether the conveyor belt has reached the maximum allowable tear size, which is beneficial to improving the safety and stability of the belt conveyor.

[0075] It should be noted that there is no strict order in which the steps in this application are performed. As long as they comply with the logical order, these steps can be performed simultaneously or in a predetermined order. Figure 1 and Figure 3 This is just a schematic and does not mean that this is the only execution order.

[0076] The present application also provides a corresponding device for the method for determining the tear size of a conveyor belt, which further makes the method more practical. Among them, the device can be explained from the perspective of functional modules and hardware. The following is an introduction to the device for determining the tear size of a conveyor belt provided by the present application. The device is used to implement the method for determining the tear size of a conveyor belt provided by the present application. In this embodiment, the device for determining the tear size of a conveyor belt may include or be divided into one or more program modules, and the one or more program modules are stored in a storage medium and executed by one or more processors to complete the method for determining the tear size of a conveyor belt disclosed in Example 1. The program module referred to in this application refers to a series of computer program instruction segments that can complete specific functions, which is more suitable for describing the execution process of the device for determining the tear size of a conveyor belt in a storage medium than the program itself. The following description will specifically introduce the functions of each program module of this embodiment. The device for determining the tear size of a conveyor belt described below and the method for determining the tear size of a conveyor belt described above can be referenced to each other.

[0077] From the perspective of functional modules, see Figure 4 , Figure 4 This is a structural diagram of a device for determining the tear size of a conveyor belt provided in this application in a specific embodiment. The device may include:

[0078] The running distance calculation module 401 is used to determine the single-frame belt running distance of the conveyor belt at the current moment based on the belt surface running speed of the belt conveyor and the sampling frame rate of the image acquisition device.

[0079] a tear number determination module 402 for determining the number of tears on the conveyor belt by comparing tear features between two adjacent frames of images of the conveyor belt;

[0080] The tear size determination module 403 is used to calculate the tear size of each tear position of the conveyor belt based on the tear number, the tear width of each single-frame image belonging to the same tear position and the corresponding single-frame belt running distance.

[0081] Optionally, in some implementations of this embodiment, the above-mentioned tearing number determination module 402 can be further used to: obtain a binarized image of the current frame image of the laser light projection area of ​​the conveyor belt, and remove the image block of the tearing area of ​​the conveyor belt in the binarized image; obtain the vertical projection data of the binarized image after removing the image block, and use the coordinates corresponding to the first target value appearing in the vertical projection data as the tearing position of the current frame image; the target value is determined by the pixel value of the pixel point of the non-laser light in the binarized image; if the difference between the tearing position of the current frame image and the previous frame image is less than a preset frame interval threshold, the tears in the current frame image and the previous frame image belong to the same tearing position; wherein the preset frame interval threshold is determined based on the single-frame belt running distance of the current frame image and the previous frame image.

[0082] As an optional implementation of the above embodiment, the above-mentioned tear number determination module 402 can also be further used for: if the difference between the tear position of the current frame image and the previous frame image is greater than or equal to the preset frame interval threshold, the tear in the current frame image and the previous frame image are not in the same tear position, and the current frame image is regarded as a newly appeared tear; the number of tears in the conveyor belt is determined by counting the number of newly appeared tears.

[0083] As another optional implementation of the above embodiment, the above tear size determination module 403 can also be used to: for the same tear position, count the number of tear width pixels of the pixel values ​​of non-laser line pixel points that appear continuously in the vertical projection data; and calculate the tear width of a single frame image based on the actual distance represented by each pixel and the number of tear width pixels.

[0084] Optionally, in some implementations of this embodiment, the tear size determination module 403 may be further configured to: sequentially obtain the tear width of each frame image belonging to the current tear position and the corresponding single-frame belt running distance for each tear position on the conveyor belt; and call a tear size calculation formula to calculate the tear size of the current tear position; the tear size calculation formula is:

[0085]

[0086] Where sw_area j is the tear size of the jth tear position, n is the total number of single-frame images belonging to the jth tear position, is the tear width of the i-th frame image at the j-th tear position, s i is the single-frame belt running distance of the i-th frame image.

[0087] The functions of the various functional modules of the device for determining the tear size of a conveyor belt in the present application can be specifically implemented according to the method in the above-mentioned method embodiment. The specific implementation process can refer to the relevant description of the above-mentioned method embodiment, and will not be repeated here.

[0088] As can be seen from the above, this embodiment can accurately and timely detect whether the conveyor belt has reached the maximum allowable tear size, which is beneficial to improving the safety and stability of the belt conveyor.

[0089] The above-mentioned device for determining the tear size of the conveyor belt is described from the perspective of a functional module. Furthermore, the present application also provides an electronic device, which is described from the perspective of hardware. Figure 5 This is a schematic diagram of the structure of an electronic device provided in an embodiment of the present application in one embodiment. Figure 5 As shown, the electronic device includes a memory 50 for storing a computer program; and a processor 51 for implementing the steps of the method for determining the tear size of a conveyor belt as mentioned in any of the above embodiments when executing the computer program.

[0090] The processor 51 may include one or more processing cores, such as a 5-core processor or an 8-core processor. The processor 51 may also be a controller, a microcontroller, a microprocessor, or other data processing chip. The processor 51 may be implemented in at least one hardware form selected from the group consisting of a DSP (Digital Signal Processing), an FPGA (Field-Programmable Gate Array), and a PLA (Programmable Logic Array). The processor 51 may also include a main processor and a coprocessor. The main processor is a processor for processing data in the awake state, also known as a CPU (Central Processing Unit); the coprocessor is a low-power processor for processing data in the standby state. In some embodiments, the processor 51 may be integrated with a GPU (Graphics Processing Unit), which is responsible for rendering and drawing the content to be displayed on the display screen. In some embodiments, the processor 51 may also include an AI (Artificial Intelligence) processor, which is used to handle computing operations related to machine learning.

[0091] The memory 50 may include one or more computer-readable storage media, which may be non-transitory. The memory 50 may also include high-speed random access memory and non-volatile memory, such as one or more disk storage devices or flash memory storage devices. In some embodiments, the memory 50 may be an internal storage unit of an electronic device, such as a server's hard drive. In other embodiments, the memory 50 may also be an external storage device of the electronic device, such as a plug-in hard drive equipped on a server, a Smart Media Card (SMC), a Secure Digital (SD) card, a flash memory card, etc. Furthermore, the memory 50 may include both an internal storage unit and an external storage device of the electronic device. The memory 50 may be used not only to store application software installed on the electronic device and various types of data, such as the code of the program used to execute the method for determining the tear size of a conveyor belt, but also to temporarily store data that has been output or is about to be output. In this embodiment, the memory 50 is used to store at least the following computer program 501, wherein, after being loaded and executed by the processor 51, the computer program can implement the relevant steps of the method for determining the tear size of a conveyor belt disclosed in any of the aforementioned embodiments. In addition, the resources stored in memory 50 may also include an operating system 502 and data 503, which may be stored in a temporary or permanent manner. Operating system 502 may include Windows, Unix, Linux, etc. Data 503 may include, but is not limited to, data corresponding to the result of determining the tear size of the conveyor belt.

[0092] In some embodiments, the electronic device may further include a display screen 52, an input / output interface 53, a communication interface 54 or a network interface, a power supply 55 and a communication bus 56. Among them, the display screen 52 and the input / output interface 53, such as a keyboard, are user interfaces, and the optional user interface may also include a standard wired interface, a wireless interface, etc. Optionally, in some embodiments, the display may be an LED display, a liquid crystal display, a touch-sensitive liquid crystal display, and an OLED (Organic Light-Emitting Diode) touch device, etc. The display may also be appropriately referred to as a display screen or a display unit, which is used to display information processed in the electronic device and to display a visual user interface. The communication interface 54 may optionally include a wired interface and / or a wireless interface, such as a WI-FI interface, a Bluetooth interface, etc., which is generally used to establish a communication connection between the electronic device and other electronic devices. The communication bus 56 may be a peripheral component interconnect (PCI) bus or an extended industry standard architecture (EISA) bus, etc. The bus may be divided into an address bus, a data bus, a control bus, etc. For ease of representation, Figure 5 Only one thick line is used in the diagram, but this does not mean that there is only one bus or one type of bus.

[0093] Those skilled in the art will understand that Figure 5 The structure shown in the figure does not constitute a limitation on the electronic device, and may include more or fewer components than shown in the figure, for example, it may also include a sensor 57 to realize various functions.

[0094] The functions of each functional module of the electronic device of the present application can be specifically implemented according to the method in the above method embodiment. The specific implementation process can refer to the relevant description of the above method embodiment, which will not be repeated here.

[0095] As can be seen from the above, this embodiment can accurately and timely detect whether the conveyor belt has reached the maximum allowable tear size, which is beneficial to improving the safety and stability of the belt conveyor.

[0096] It is understandable that if the method for determining the tear size of the conveyor belt in the above embodiment is implemented in the form of a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present application, or the part that contributes to the relevant technology, or all or part of the technical solution can be embodied in the form of a software product, and the computer software product is stored in a storage medium and executes all or part of the steps of the various embodiments of the present application. The aforementioned storage medium includes: U disk, mobile hard disk, read-only memory (ROM), random access memory (RAM), electrically erasable programmable ROM, register, hard disk, multimedia card, card-type memory (such as SD or DX memory, etc.), magnetic memory, removable disk, CD-ROM, magnetic disk or optical disk, etc. Various media that can store program codes.

[0097] Based on this, the present application also provides a readable storage medium storing a computer program. When the computer program is executed by a processor, the steps of the method for determining the tear size of a conveyor belt in any of the above embodiments are performed.

[0098] This application also provides a conveyor belt tear size determination system, see Figure 6 , which may include the following:

[0099] The conveyor belt tear size determination system is applied to a belt conveyor, and may include a laser 601, an image acquisition component 602, an image processing server 603, and a belt speed detection device 604. Inevitably, for normal operation, the laser 601, the image acquisition component 602, the image processing server 603, and the belt speed detection device 604 need to be connected to a distribution box 600. Figure 7 As shown, laser light emitted by laser 601 reaches the surface of the conveyor belt, perpendicular to both sides of the conveyor belt. Image acquisition device 6021, such as a camera, in image acquisition assembly 602 forms a certain angle with laser 601, which can be anywhere between 16° and 90°. Using the principle of monocular vision triangulation, the position of the image captured by the camera changes as the height of the object changes. Similarly, when a conveyor belt is torn, the gap created by the tear causes the position of the laser light on the conveyor belt plane to change. Therefore, the continuity of the laser light can be used to identify a tear in the conveyor belt.

[0100] In this embodiment, the laser 601 and the image acquisition component 602 are both installed between the carrier belt and the return belt of the conveyor belt of the belt conveyor, and face the back of the conveyor belt. The laser 601 is used to project laser light onto the return belt. The laser 601 can be any type of laser emitter, for example, a line laser. The image acquisition component 602 is used to capture images of the return belt and transmit the images of the return belt to the image processing server 603. The image acquisition component 602 includes at least one image acquisition device 6021, such as a camera or a webcam. In order to improve the image acquisition effect, it can also be equipped with components that can improve the image imaging effect or improve the image acquisition effect. The image processing server 603 is used to implement the steps of the method for determining the tear size of the conveyor belt as described in any of the above embodiments by executing a computer program. The processor of the image processing server 603 includes a built-in computer program that implements the steps of the method for determining the tear size of a conveyor belt as described in any of the above embodiments. Alternatively, a chip or readable storage medium storing the computer program that implements the steps of the method for determining the tear size of a conveyor belt as described in any of the above embodiments may be directly integrated into the image processing server 603, without affecting the implementation of the present application. The belt speed detection device 604 is installed on the conveyor belt. The installation position can be determined based on the actual structure and spatial layout of the conveyor belt. For example, it can be installed near the roller 605. It is used to measure the belt surface running speed of the belt conveyor and transmit the belt surface running speed to the image processing server 603.

[0101] In this embodiment, the tear detection system of the entire conveyor belt can be installed in the middle of the belt conveyor. The laser 601 and the image acquisition device 6021 in the image acquisition assembly 602, such as a camera, are installed from top to bottom. Figure 8 As shown. Considering that image acquisition assembly 602's downward shooting reduces the amount of material falling onto the image acquisition assembly 602 and laser 601 during belt operation, it does not affect the operation of the entire system and also avoids increasing the maintenance workload of the entire system. Furthermore, considering the imaging of the laser beam, and the fact that the accuracy of the entire tear size determination method is related to the straightness of the laser line, the return belt is flat because it is not allowed to be loaded with material. Therefore, image acquisition assembly 602 captures the image of the return belt surface.

[0102] Furthermore, in order to improve the quality of the captured image, the image capture component 602 may further include a lighting plate 6022. Similarly, the lighting plate 6022 faces downward, that is, toward the back of the conveyor belt. Figure 8As shown. If the lighting plate 6022 is not added, the image captured by the camera will mostly be black, with only the laser line area being highlighted. Adding a lighting plate allows the image captured by the camera to clearly see the laser line and the surface texture of the belt, making it easier for the operator to view the saved fault image after the system detects an alarm and can intuitively observe the torn area. Furthermore, in order to improve the stability of image acquisition quality and reduce the complexity of image processing, the image acquisition component 602 can be provided with a light shield 6023, and the lighting plate 6022, the image acquisition device 6021 and the laser 601 are all arranged inside the light shield 6023. The light shield 6023 is installed between the loading belt and the return belt. The light shield 6023 can reduce interference from external light sources.

[0103] The functions of the various functional modules of the system for determining the tear size of a conveyor belt in an embodiment of the present invention can be specifically implemented according to the method in the above method embodiment. The specific implementation process can refer to the relevant description of the above method embodiment and will not be repeated here.

[0104] As can be seen from the above, this embodiment can accurately and timely detect whether the conveyor belt has reached the maximum allowable tear size, which is beneficial to improving the safety and stability of the belt conveyor.

[0105] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from the other embodiments. References to the same or similar parts between the various embodiments will be sufficient. The hardware disclosed in the embodiments, including devices and electronic devices, is described briefly because it corresponds to the methods disclosed in the embodiments. For relevant details, refer to the method description.

[0106] Professionals may further appreciate that the units and algorithm steps of each example described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of the two. In order to clearly illustrate the interchangeability of hardware and software, the above description has generally described the components and steps of each example according to their functions. Whether these functions are performed in hardware or software depends on the specific application and design constraints of the technical solution. Professionals and technicians may use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0107] The above describes in detail the method, device, system, electronic device, and readable storage medium for determining the tear size of a conveyor belt provided by this application. This article uses specific examples to illustrate the principles and implementation methods of this application. The description of the above embodiments is only intended to help understand the method and core concept of this application. It should be noted that for ordinary technicians in this technical field, without departing from the principles of this application, various improvements and modifications can be made to this application, and these improvements and modifications also fall within the scope of protection of the claims of this application.

Claims

1. A method for determining the tear size of a conveyor belt, characterized in that: include: According to the current running speed of the belt conveyor and the sampling frame rate of the image acquisition device, the single-frame running distance of the conveyor belt between each frame of image at the current moment is determined; Determining the number of tears in the conveyor belt by comparing tear features in two adjacent frames of images of the conveyor belt; Based on the number of tears, the tear size of each tear position of the conveyor belt is calculated according to the tear width of each single-frame image belonging to the same tear position and the corresponding single-frame belt running distance; The step of determining the number of tears on the conveyor belt by comparing tear features between two adjacent frames of images of the conveyor belt comprises: Acquire a binary image of a current frame image of the laser light projection area of ​​the conveyor belt, and remove an image block of the torn area of ​​the conveyor belt in the binary image; Obtaining vertical projection data of the binary image after removing the image block, and using the coordinates corresponding to the first target value appearing in the vertical projection data as the tearing position of the current frame image; the target value is determined by the pixel value of the pixel point in the binary image that is not the laser light; If the difference between the tearing positions of the current frame image and the previous frame image is less than a preset frame interval threshold, the tears in the current frame image and the previous frame image belong to the same tearing position; The preset frame interval threshold is determined according to a single-frame belt running distance between the current frame image and the previous frame image.

2. The method for determining the tear size of a conveyor belt according to claim 1, characterized in that: The determining the number of tears of the conveyor belt by comparing the tearing features of two adjacent frames of images of the conveyor belt comprises: If the difference between the tear positions of the current frame image and the previous frame image is greater than or equal to a preset frame interval threshold, the tear positions of the current frame image and the previous frame image are different, and the current frame image is treated as a newly occurred tear; The number of tears in the conveyor belt is determined by counting the number of newly occurring tears.

3. The method for determining the tear size of a conveyor belt according to claim 1, wherein: The method of calculating the tear size of each tear position of the conveyor belt based on the tear number and the tear width of each single-frame image belonging to the same tear position and the corresponding single-frame belt running distance includes: For the same tearing position, counting the number of tearing width pixels of pixel values ​​of consecutive non-laser line pixel points appearing in the vertical projection data; The tear width of the single-frame image is calculated according to the actual distance represented by each pixel and the number of the tear width pixels.

4. The method for determining the tear size of a conveyor belt according to any one of claims 1 to 3, characterized in that: The method of calculating the tear size of each tear position of the conveyor belt based on the tear number and the tear width of each single-frame image belonging to the same tear position and the corresponding single-frame belt running distance includes: For each tearing position on the conveyor belt, sequentially obtaining the tearing width of each frame image belonging to the current tearing position and the corresponding single-frame belt running distance; The tear size calculation formula is called to calculate the tear size of the current tear position; the tear size calculation formula is: ； Where, is the tear size of the jth tear position, n is the total number of single-frame images belonging to the jth tear position, is the tear width of the i-th frame image at the j-th tear position, is the single-frame belt running distance of the i-th frame image.

5. A device for determining the tear size of a conveyor belt, characterized in that: include: The running distance calculation module is used to determine the single-frame running distance of the conveyor belt at each frame interval of the current moment according to the belt surface running speed of the belt conveyor and the sampling frame rate of the image acquisition device; a tearing number determining module, configured to determine the tearing number of the conveyor belt by comparing tearing features of two adjacent frames of images of the conveyor belt; a tear size determination module for calculating the tear size of each tear position of the conveyor belt based on the tear number, according to the tear width of each single-frame image belonging to the same tear position and the corresponding single-frame belt running distance; Wherein, the tearing quantity determination module is further used for: Obtain a binarized image of the current frame image of the laser light projection area of ​​the conveyor belt, and remove the image block of the tear area of ​​the conveyor belt in the binarized image; obtain vertical projection data of the binarized image after removing the image block, and use the coordinates corresponding to the first target value appearing in the vertical projection data as the tear position of the current frame image; the target value is determined by the pixel value of the pixel point other than the laser light in the binarized image; if the difference between the tear position of the current frame image and the previous frame image is less than a preset frame interval threshold, then the tears in the current frame image and the previous frame image belong to the same tear position; wherein the preset frame interval threshold is determined according to the single-frame belt running distance of the current frame image and the previous frame image.

6. An electronic device, characterized in that: The method comprises a processor and a memory, wherein the processor is configured to implement the steps of the method for determining the tear size of a conveyor belt according to any one of claims 1 to 4 when executing a computer program stored in the memory.

7. A readable storage medium, characterized in that: The readable storage medium stores a computer program, which, when executed by a processor, implements the steps of the method for determining the tear size of a conveyor belt according to any one of claims 1 to 4.

8. A system for determining the tear size of a conveyor belt, characterized in that: It includes a laser, an image acquisition component, a belt speed detection device and an image processing server; The belt speed detection device is installed on the conveyor belt, and is used to measure the belt surface running speed of the belt conveyor and transmit the belt surface running speed to the image processing server; The laser and the image acquisition assembly are installed between the carrying belt and the return belt of the conveyor belt of the belt conveyor and face the back of the conveyor belt; The laser is used to project laser light onto the return belt; The image acquisition component is used to acquire the return belt image and transmit the return belt image to the image processing server; The image processing server is used to implement the steps of the method for determining the tear size of a conveyor belt according to any one of claims 1 to 4 by executing a computer program.

9. The conveyor belt tear size determination system according to claim 8, characterized in that: The image acquisition assembly includes an image acquisition device, a lighting plate and a light shield; The image acquisition device, the lighting plate and the laser are arranged inside the light shield, and the light shield is installed between the carrying belt and the return belt; The image acquisition device and the lighting plate face the back side of the conveyor belt.

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