Belt conveyor scattering height monitoring method and device, storage medium and terminal

Abstract

The invention discloses a belt conveyor scattering height monitoring method and device, a storage medium and a terminal, and the method comprises the steps: obtaining a target scattering pile image from a monitoring camera, carrying out the denoising of the target scattering pile image, and obtaining a denoised image; binarization processing is carried out on the de-noised image, and a material scattering pile contour map is obtained; obtaining a target spreading pile height in the spreading pile profile diagram based on a calibration coordinate conversion relation; wherein a target material scattering pile in the target material scattering pile image is located below the discharging end of the belt conveyor, the monitoring camera is located on one side of the target material scattering pile, a backlight source is arranged on the other side of the target material scattering pile, and the backlight source covers the view field of the monitoring camera. The height of the material scattering pile of the belt conveyor can be monitored in real time and early warned, the maintenance work efficiency is improved, the maintenance time is shortened, and economic losses caused by serious faults of the belt conveyor due to the fact that the height of the material scattering pile is too high are avoided.

Description

Technical Field

[0001] The invention relates to the technical field of belt conveyor monitoring, and in particular to a belt conveyor material spreading height monitoring method and device, a storage medium and a terminal. Background Art

[0002] Belt conveyors, also known as rubber belt conveyors, are widely used in various industries such as home appliances, electronics, electrical appliances, machinery, tobacco, coal, injection molding, post and telecommunications, printing, and food to transport objects of various shapes. Belt conveyors have strong conveying capacity, long conveying distance, simple structure and easy maintenance, and can easily implement programmed control and automatic operation. The continuous or intermittent movement of the conveyor belt is used to transport objects under 100KG or powdery or granular objects. It runs at high speed, smoothly, with low noise, and can be transported up and down slopes.

[0003] When the belt conveyor is conveying powdery or granular materials, the powdery or granular materials will form a pile below the belt conveyor discharge end, and the height of the pile is in a dynamic state. The height of the pile is closely related to the material transmission state of the belt conveyor, that is, when the height of the pile reaches a certain level, an alarm is required, and the working state of the belt conveyor is adjusted, and subsequent operations are taken on the pile.

[0004] Normally, the measurement of these material heights and their dynamic management require manual measurement and estimation, which is inefficient and has low measurement accuracy. Summary of the invention

[0005] The technical problem to be solved by the present invention is that the height of the material pile formed during the material transportation process of the existing belt conveyor needs to be measured and predicted manually, which has low efficiency and low measurement accuracy.

[0006] In order to solve the above technical problems, the present invention provides a method for monitoring the material spreading height of a belt conveyor, comprising:

[0007] Acquire a target material scattering pile image from a monitoring camera, and perform denoising on the target material scattering pile image to acquire a denoised image;

[0008] Binarizing the denoised image to obtain a material pile contour image;

[0009] Acquire the height of the target material spreading pile in the material spreading pile outline map based on the calibration coordinate conversion relationship;

[0010] The target material pile in the target material pile image is located below the discharging end of the belt conveyor, the monitoring camera is located on one side of the target material pile, and a backlight source is provided on the other side of the target material pile, and the backlight source covers the field of view of the monitoring camera.

[0011] Preferably, fixed columns are provided on both sides of the belt conveyor, and the monitoring camera is fixed on the fixed columns.

[0012] Preferably, the monitoring camera is set at a height at a cleaning threshold height of the target material scattering pile.

[0013] Preferably, the denoising process is a smoothing process.

[0014] Preferably, the calibration coordinate conversion relationship is obtained in the following manner:

[0015] Acquire a checkerboard image from a monitoring camera;

[0016] Obtaining the coordinates of corner points in the chessboard image, and obtaining a calibration coordinate conversion relationship based on the coordinates of the corner points and chessboard position information;

[0017] Wherein, the chessboard is placed at the location of the target material scattering pile.

[0018] Preferably, the belt conveyor material spreading height monitoring method further comprises:

[0019] Determine whether the target material spreading pile height is greater than the alarm threshold, if so, issue a material spreading pile alarm signal, otherwise determine whether the target material spreading pile height is greater than the cleaning threshold, if so, issue a material spreading pile cleaning reminder signal, otherwise re-determine whether the target material spreading pile height is greater than the alarm threshold.

[0020] Preferably, the belt conveyor material spreading height monitoring method further comprises:

[0021] The target scattering pile height is sent to a display interface for display.

[0022] In order to solve the above technical problems, the present invention also provides a belt conveyor material spreading height monitoring device, including an image acquisition module, a contour map acquisition module and a target material spreading pile height acquisition module;

[0023] The image acquisition module is used to acquire an image of a target material scattering pile from a monitoring camera, and to perform denoising on the image of the target material scattering pile to acquire a denoised image;

[0024] The contour image acquisition module is used to perform binarization processing on the denoised image to obtain a contour image of the scattering pile;

[0025] The target material scattering pile height acquisition module is used to acquire the target material scattering pile height in the material scattering pile outline map based on the calibration coordinate conversion relationship;

[0026] The target material pile in the target material pile image is located below the discharging end of the belt conveyor, the monitoring camera is located on one side of the target material pile, and a backlight source is provided on the other side of the target material pile, and the backlight source covers the field of view of the monitoring camera.

[0027] In order to solve the above technical problems, the present invention further provides a storage medium on which a computer program is stored, and when the program is executed by a processor, the method for monitoring the material spreading height of a belt conveyor is implemented.

[0028] In order to solve the above technical problem, the present invention further provides a terminal, comprising: a processor and a memory, wherein the memory is communicatively connected to the processor;

[0029] The memory is used to store a computer program, and the processor is used to execute the computer program stored in the memory, so that the terminal executes the belt conveyor material spreading height monitoring method as described above.

[0030] Compared with the prior art, one or more embodiments of the above scheme may have the following advantages or beneficial effects:

[0031] The belt conveyor material spreading height monitoring method provided in the embodiment of the present invention can realize real-time monitoring and early warning of the belt conveyor material spreading pile height, improve maintenance work efficiency, shorten maintenance time, and avoid economic losses caused by serious belt conveyor failures due to excessively high material spreading pile height.

[0032] Other features and advantages of the present invention will be described in the following description, and partly become apparent from the description, or understood by practicing the present invention. The purpose and other advantages of the present invention can be realized and obtained by the structures particularly pointed out in the description, claims and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The accompanying drawings are used to provide a further understanding of the present invention and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation of the present invention. In the accompanying drawings:

[0034] Figure 1 A schematic diagram of the process of a method for monitoring the material spreading height of a belt conveyor according to an embodiment of the present invention is shown;

[0035] Figure 2 The diagram shows a belt conveyor material spreading height monitoring architecture in the first embodiment of the present invention;

[0036] Figure 3 It shows a schematic structural diagram of a device for monitoring the material spreading height of a belt conveyor according to a second embodiment of the present invention;

[0037] Figure 4A schematic diagram showing the structure of a terminal in accordance with a fourth embodiment of the present invention is shown;

[0038] Among them, 1 is the monitoring camera, 2 is the target scattering pile, 3 is the discharging end of the belt conveyor, and 4 is the backlight source. DETAILED DESCRIPTION

[0039] The following will describe the implementation methods of the present invention in detail with reference to the accompanying drawings and embodiments, so that the implementation process of how the present invention applies technical means to solve technical problems and achieve technical effects can be fully understood and implemented accordingly. It should be noted that as long as there is no conflict, the various embodiments of the present invention and the various features in the embodiments can be combined with each other, and the technical solutions formed are all within the protection scope of the present invention.

[0040] When a belt conveyor is conveying powdery or granular materials, some materials will stick to the conveyor belt surface and not be thrown out from the belt conveyor discharge end due to the stickiness or moisture of the materials themselves. Instead, a pile of materials will be formed below the belt conveyor discharge end, and the height of the pile of materials is in a dynamic state of change. The height of the pile of materials is closely related to the material transmission state of the belt conveyor, that is, when the height of the material pile reaches a certain level, an alarm is required, and the working state of the belt conveyor is adjusted, and subsequent operations are taken on the material pile. Usually, the measurement of these material heights and their dynamic management need to rely on manual measurement and estimation, which is inefficient and has low measurement accuracy.

[0041] Embodiment 1

[0042] In order to solve the technical problems existing in the prior art, an embodiment of the present invention provides a method for monitoring the material spreading height of a belt conveyor.

[0043] Figure 1 FIG. 1 is a flow chart showing a method for monitoring the material spreading height of a belt conveyor according to an embodiment of the present invention; Figure 1 As shown, the method for monitoring the material spreading height of a belt conveyor according to an embodiment of the present invention includes the following steps.

[0044] Step S101, obtaining a target material scattering pile image from a monitoring camera, and performing denoising processing on the target material scattering pile image to obtain a denoised image.

[0045] Figure 2 FIG. 1 shows a diagram of a belt conveyor material spreading height monitoring architecture in the first embodiment of the present invention; Figure 2As shown, during the material transmission process of the belt conveyor, multiple material piles may appear below. Usually, the material pile below the belt conveyor discharge end 3 is the largest. In this embodiment, the material pile below the belt conveyor discharge end 3 is used as the target material pile 2. A monitoring camera 1 is fixedly arranged on one side of the target material pile 2 to obtain image information of the target material pile; at the same time, a backlight source 4 is arranged on the other side of the target material pile 2 to provide uniform background light for the monitoring camera 1, thereby providing a calculation basis for calculating the height of the target material pile 2. It should be noted that the size of the backlight source 4 needs to be set to completely cover the shooting field of view of the monitoring camera 1. For example, its size can be set to 800mm*500mm or other reasonable values, so as to further ensure that uniform background light is provided for the monitoring camera 1.

[0046] Furthermore, an industrial camera with a lens can be selected as the monitoring camera 1, and the specifications of the monitoring camera 1 can be determined according to the accuracy of the target material pile height to be identified. For example, a 1000W pixel array industrial camera with a 25mm lens can be used, and the recognition accuracy of the detection camera can reach 1mm. In order to avoid damage or displacement of the monitoring camera 1 due to on-site collision, the monitoring camera 1 can be fixed to a fixed column in this embodiment, wherein the fixed column is used to fix the belt conveyor, and is usually a fixing tool set on both sides of the belt conveyor. The monitoring camera 1 can be further set in the groove of the fixed column.

[0047] Preferably, when the height of the target material pile 2 is monitored, it is determined whether it is above the cleaning threshold, and then it is determined whether the material pile needs to be cleaned. In order to better obtain the height value of the target material pile and avoid the height error of the material pile due to angle problems, the embodiment of the present invention can also set the height of the monitoring camera 1 at the cleaning threshold height of the target material pile 2.

[0048] After the monitoring camera 1 and the backlight source 4 are set, the target material pile 2 can be photographed in real time by the detection camera to obtain the target material pile image in real time. That is, the belt conveyor material height monitoring architecture method of the embodiment of the present invention is implemented under the belt conveyor material height monitoring architecture, and the obtained target material pile image must also be a target material pile image that meets the above design requirements.

[0049] After the monitoring camera 1 acquires the target material pile image, the target material pile image can be read from the monitoring camera 1 in real time, and the acquired target material pile image can be analyzed and processed. Preferably, the imread function in OpenCV can be used in this embodiment to read the target material pile image from the monitoring camera 1. After acquiring the target material pile image, the GaussianBlur or blur function in OpenCV can be used to smooth the target material pile image to obtain a denoised image, so as to achieve denoising of the target material pile image, so that the image can be better extracted and analyzed later.

[0050] Step S102, binarization processing is performed on the denoised image to obtain a contour image of the scattering pile.

[0051] Specifically, after the target pile image is denoised, it is necessary to perform a binarization process to obtain the outline of the pile. Furthermore, the denoised image is first log-transformed: for the gray value x of each pixel in the denoised image, the result after log-transformation is y=log(1+x), where log is the natural logarithm with base e. Since the pixel value after log-transformation may exceed the range of 0 to 255, it needs to be normalized.

[0052] Then, the grayscale features of the normalized image surface are statistically analyzed, and the threshold segmentation is performed to realize pixel binarization to obtain the outline of the material pile. For example, the grayscale value 150 can be used as the threshold segmentation line, and the pixel points below 150 are considered as the pile, and the pixel content of the pile is closed and filled to obtain the outline of the pile, and the pixel points above or equal to 150 are considered as the background; thus, the outline of the material pile can be obtained.

[0053] Step S103, obtaining the height of the target material spreading pile in the material spreading pile outline map based on the calibration coordinate conversion relationship.

[0054] This embodiment uses a chessboard method to calibrate the monitoring camera 1, that is, to determine the calibration coordinate conversion relationship of the image captured by the monitoring camera 1. The specific process of obtaining the calibration coordinate conversion relationship is as follows: place the chessboard at the location of the target scattering pile 2 to ensure that the chessboard plane is perpendicular to the optical axis direction of the monitoring camera 1; secondly, use the monitoring camera 1 to capture the chessboard image and transfer it to the computer; then use the findChessboardCorners function in OpenCV to automatically detect the coordinates of the corner points of the chessboard in the chessboard image; finally, based on the distance information between the chessboard and the monitoring camera 1 (that is, the chessboard position information), and the size information of each grid in the chessboard, obtain the calibration coordinate conversion relationship of the image captured by the monitoring camera 1. Further, the camera coordinate system is transformed into the actual world coordinate system, thereby realizing operations such as geometric correction and three-dimensional reconstruction in image processing.

[0055] The height of the material scattering pile image in the target material scattering pile outline image is obtained, and then the material scattering pile is converted into the actual height of the target material scattering pile 2, that is, the target material scattering pile height, based on the calibration coordinate conversion relationship.

[0056] Step S104, monitoring the target material spreading pile height.

[0057] Specifically, after obtaining the target material pile height, it is necessary to determine whether the target material pile height is greater than the alarm threshold. If so, it means that the user needs to clean the material pile immediately, otherwise the material pile is too high and will seriously affect the operation of the equipment, so a material pile alarm signal needs to be issued; and when the target material pile height is not greater than the alarm threshold, it is necessary to further determine whether the target material pile height is greater than the cleaning threshold. If so, it means that the current target material pile height has reached the cleaning threshold, and the user needs to be reminded to clean the material pile in time, and a material pile cleaning reminder signal can be issued at this time.

[0058] Step S105, sending the target material spreading pile height to the display interface for display.

[0059] Specifically, after obtaining the target material spreading pile height, the target material spreading pile height can also be sent to the display interface for display. At the same time, the alarm information issued according to the target material spreading pile height in step S104 can also be sent to the display interface for display, so that the alarm information can be displayed through the display interface.

[0060] The belt conveyor material spreading height monitoring method provided in the embodiment of the present invention can realize real-time monitoring and early warning of the belt conveyor material spreading pile height, improve maintenance work efficiency, shorten maintenance time, and avoid economic losses caused by serious failure of the belt conveyor due to excessive height of the material spreading pile.

[0061] Embodiment 2

[0062] In order to solve the technical problems existing in the prior art, an embodiment of the present invention provides a belt conveyor material spreading height monitoring device.

[0063] Figure 3 FIG. 2 shows a schematic diagram of a belt conveyor material spreading height monitoring device according to a second embodiment of the present invention; Figure 3 As shown, the belt conveyor material spreading height monitoring device according to the embodiment of the present invention includes an image acquisition module, a contour map acquisition module and a target material spreading pile height acquisition module.

[0064] The image acquisition module is used to acquire a target material scattering pile image from a monitoring camera, and to perform denoising processing on the target material scattering pile image to acquire a denoised image.

[0065] The contour map acquisition module is used to perform binarization processing on the denoised image to obtain a contour map of the scattering pile.

[0066] The target material scattering pile height acquisition module is used to acquire the target material scattering pile height in the material scattering pile outline map based on the calibration coordinate conversion relationship.

[0067] The target material pile in the target material pile image is located below the discharging end of the belt conveyor, the monitoring camera is located on one side of the target material pile, and a backlight source is provided on the other side of the target material pile, and the backlight source covers the field of view of the monitoring camera.

[0068] The belt conveyor material spreading height monitoring device provided in the embodiment of the present invention can realize real-time monitoring and early warning of the belt conveyor material spreading pile height, improve maintenance work efficiency, shorten maintenance time, and avoid economic losses caused by serious failure of the belt conveyor due to excessive height of the material spreading pile.

[0069] Embodiment 3

[0070] In order to solve the above technical problems existing in the prior art, an embodiment of the present invention further provides a storage medium storing a computer program, which can implement all the steps in the belt conveyor material spreading height monitoring method in embodiment 1 when executed by a processor.

[0071] The specific steps of the belt conveyor material spreading height monitoring method and the beneficial effects obtained by applying the readable storage medium provided by the embodiment of the present invention are the same as those in the first embodiment, and will not be described in detail here.

[0072] It should be noted that the storage medium includes various media that can store program codes, such as ROM, RAM, magnetic disk or optical disk.

[0073] Embodiment 4

[0074] In order to solve the above technical problems existing in the prior art, an embodiment of the present invention further provides a terminal.

[0075] Figure 4 The schematic diagram of the terminal structure of the fourth embodiment of the present invention is shown. Figure 4 In this embodiment, the terminal includes a processor and a memory connected to each other; the memory is used to store computer programs, and the processor is used to execute the computer programs stored in the memory, so that when the terminal executes, all steps in the belt conveyor material spreading height monitoring method described in Example 1 can be implemented.

[0076] The specific steps of the belt conveyor material spreading height monitoring method and the beneficial effects obtained by applying the terminal provided by the embodiment of the present invention are the same as those in the first embodiment, and will not be described in detail here.

[0077] It should be noted that the memory may include random access memory (RAM) and may also include non-volatile memory, such as at least one disk storage. Similarly, the processor may also be a general-purpose processor, including a central processing unit (CPU), a network processor (NP), etc.; it may also be a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic devices, discrete gates or transistor logic devices, discrete hardware components.

[0078] Although the embodiments disclosed in the present invention are as above, the contents described are only embodiments adopted for facilitating the understanding of the present invention and are not intended to limit the present invention. Any technician in the technical field to which the present invention belongs can make any modifications and changes in the form and details of the implementation without departing from the spirit and scope disclosed in the present invention, but the protection scope of the present invention shall still be subject to the scope defined in the attached claims.

Claims

1. A method for monitoring the material spreading height of a belt conveyor, comprising: Acquire a target material scattering pile image from a monitoring camera, and perform denoising on the target material scattering pile image to acquire a denoised image; Binarizing the denoised image to obtain a material pile contour image; Acquire the height of the target material spreading pile in the material spreading pile outline map based on the calibration coordinate conversion relationship; The target material pile in the target material pile image is located below the discharging end of the belt conveyor, the monitoring camera is located on one side of the target material pile, and a backlight source is provided on the other side of the target material pile, and the backlight source covers the field of view of the monitoring camera.

2. The monitoring method according to claim 1, characterized in that: Fixed columns are arranged on both sides of the belt conveyor, and the monitoring camera is fixed on the fixed columns.

3. The monitoring method according to claim 1, characterized in that: The monitoring camera is set at a height at a cleaning threshold height of the target material scattering pile.

4. The monitoring method according to claim 1, characterized in that: The denoising processing method is smoothing processing.

5. The monitoring method according to claim 1, characterized in that: The calibration coordinate conversion relationship is obtained in the following way: Acquire a checkerboard image from a monitoring camera; Obtaining the coordinates of corner points in the chessboard image, and obtaining a calibration coordinate conversion relationship based on the coordinates of the corner points and chessboard position information; Wherein, the chessboard is placed at the location of the target material scattering pile.

6. The monitoring method according to claim 1, characterized in that: Also includes: Determine whether the target material spreading pile height is greater than the alarm threshold, if so, issue a material spreading pile alarm signal, otherwise determine whether the target material spreading pile height is greater than the cleaning threshold, if so, issue a material spreading pile cleaning reminder signal, otherwise re-determine whether the target material spreading pile height is greater than the alarm threshold.

7. The monitoring method according to claim 1, characterized in that: Also includes: The target material spreading pile height is sent to a display interface for display.

8. A belt conveyor material spreading height monitoring device, characterized in that: It includes an image acquisition module, a contour map acquisition module and a target scattering pile height acquisition module; The image acquisition module is used to acquire an image of a target material scattering pile from a monitoring camera, and to perform denoising on the image of the target material scattering pile to acquire a denoised image; The contour image acquisition module is used to perform binarization processing on the denoised image to obtain a contour image of the scattering pile; The target material scattering pile height acquisition module is used to acquire the target material scattering pile height in the material scattering pile outline map based on the calibration coordinate conversion relationship; The target material pile in the target material pile image is located below the discharging end of the belt conveyor, the monitoring camera is located on one side of the target material pile, and a backlight source is provided on the other side of the target material pile, and the backlight source covers the field of view of the monitoring camera.

9. A storage medium having a computer program stored thereon, characterized in that: When the program is executed by a processor, the belt conveyor material spreading height monitoring method described in any one of claims 1 to 7 is implemented.

10. A terminal, characterized in that: include: A processor and a memory, wherein the memory is communicatively connected to the processor; The memory is used to store a computer program, and the processor is used to execute the computer program stored in the memory, so that the terminal executes the method for monitoring the material spreading height of a belt conveyor according to any one of claims 1 to 7.

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