Device and method for detecting defects of rolling body under operation condition

Abstract

The invention discloses a device and a method for detecting defects of a rolling body under an operation condition. Comprising a track, a rolling body, a high-speed moving camera, a linear moving body, a rolling body operation tread cleaning mechanism, a rolling body image detection controller, a high-frequency camera, a vibration sensor, a rolling body cleaning mechanism, a rolling body detection controller and a rolling body vibration detector, the rolling body image detection controller drives the rolling body operation tread cleaning mechanism to operate; the high-frequency camera, the vibration sensor and the rolling body cleaning mechanism are respectively mounted at preset fixed positions on the track; the rolling body detection controller monitors and judges the abnormal state of the rolling body; the rolling body vibration detector receives vibration data. The defects of the rolling body in the working state can be detected in real time, the problem that the defects of the rolling body are difficult to detect in the running process is effectively solved, and normal running of equipment is further guaranteed.

Description

Technical Field

[0001] The present invention relates to the technical field of material conveying, and more particularly to a device and method for detecting rolling element defects under operating conditions. Background Art

[0002] In modern industrial production, defect detection of individual parts (components) is an important step to ensure the quality of finished products. However, the lack of effective online detection devices for rolling element parts running at high speed has become a technical problem that needs to be solved urgently. Such parts play a vital role in key equipment such as baggage handling, and their performance directly affects the stability and safety of the entire system.

[0003] At present, many companies often rely on experience and judgment when maintaining rolling element parts, and adopt preventive maintenance replacement strategies or practical replacement strategies. Although this method can reduce the risk of failure to a certain extent, due to the lack of accurate data support, it often leads to premature or late replacement decisions. Premature replacement not only increases the user's replacement costs, but may also cause a waste of resources; while late replacement may result in the failure to replace parts in time before they wear out or fail, which in turn causes a comprehensive failure of the equipment and leads to greater losses.

[0004] In addition, the quality consistency of rolling element parts is also a pain point that cannot be ignored. Due to deviations in the production process, parts from different batches may have significant differences in performance. This inconsistency not only increases the instability of the overall operation of the equipment, but may also lead to actual damage, ultimately causing damage to other parts of the equipment, resulting in heavy economic losses.

[0005] Therefore, how to provide an advanced online detection device to detect the operating status and health status of rolling element components in real time is a problem that technical personnel in this field urgently need to solve. Summary of the invention

[0006] In view of this, the present invention provides a detection device and method for rolling element defects under operating conditions, which can realize real-time detection of defects (such as wear and cracks) of rolling elements under working conditions, effectively solving the problem that rolling element defects are difficult to monitor during operation, thereby further ensuring the normal operation of the equipment and improving the overall reliability. At the same time, the present invention also addresses the wear problem of rolling elements after long-term operation, significantly reduces the risk of collision and noise between each worn rolling element and the operating working surface, thereby extending the service life of the rolling element and reducing the operating cost of the equipment; it can not only provide data support for maintenance strategies, helping enterprises to replace parts at the appropriate time, thereby reducing costs and improving the operating efficiency of the equipment, but also effectively extend the service life of the equipment and reduce the chain reaction caused by the failure of parts.

[0007] In order to achieve the above object, the present invention adopts the following technical solution:

[0008] A device for detecting rolling element defects under operating conditions comprises a track, a rolling element, a high-speed moving camera, a linear motion element, a rolling element running tread cleaning mechanism, a rolling element image detection controller, a high-frequency camera, a vibration sensor, a rolling element cleaning mechanism, a rolling element detection controller and a rolling element vibration detector.

[0009] The rolling body and the high-speed moving camera are installed on the linear motion body, the rolling body is rollingly connected to the track surface of the track, and the camera end of the high-speed moving camera corresponds to the plane of the rolling track surface of the rolling body;

[0010] The rolling body running tread cleaning mechanism is installed on the lower end surface of the linear motion body; the rolling body image detection controller is configured to receive the image information of the rolling track surface collected by the high-speed mobile camera, monitor and judge the abnormal state of the rolling track surface through image processing and YOLO neural network algorithm, and drive the rolling body running tread cleaning mechanism to operate according to whether there are foreign objects on the rolling track surface;

[0011] The high-frequency camera, the vibration sensor and the rolling body cleaning mechanism are respectively installed at preset fixed positions on the track; the rolling body detection controller is configured to collect and monitor the image data and operation status data of the rolling body in real time, and monitor and judge the abnormal state of the rolling body through image processing and YOLO neural network algorithm; the rolling body vibration detector is configured to receive the vibration data of the vibration sensor; the rolling body cleaning mechanism receives the data of the rolling body detection controller or the rolling body vibration detector to be controlled by it.

[0012] The beneficial effects of the above technical solution are: the high-speed camera moves rapidly with the linear motion body; the rolling body image detection controller and the high-speed camera monitor the image information of the track in real time through data interaction, and the rolling body running tread cleaning mechanism cleans the track to ensure the cleanliness of the rolling track surface of the rolling body and improve the detection accuracy of the rolling body; the high-frequency camera monitors the running status of the linear motion body in real time, the rolling body detection controller ensures the transmission of high-frequency camera data and monitors and judges the rolling body status; the vibration sensor monitors the vibration information of the linear motion body, the rolling body vibration detector collects and processes the vibration information, and the rolling body cleaning mechanism can clean foreign matter on the rolling body.

[0013] Preferably, there are multiple linear motion bodies, and the multiple linear motion bodies are connected head to tail using a chain structure, so as to form a high-speed rolling body conveying system through the chain structure.

[0014] Preferably, the rolling bodies include guide rolling bodies and traveling rolling bodies, the rolling planes of the guide rolling bodies and the traveling rolling bodies are arranged vertically, and the high-speed moving cameras are arranged in groups and correspond to the planes of the rolling track surfaces of the guide rolling bodies and the traveling rolling bodies, respectively. The guiding and high-speed movement of the linear motion body along the track is achieved by the rolling of the guide rolling bodies and the traveling rolling bodies.

[0015] Preferably, the high-frequency camera is located above the guide roller and the travel roller, or a plurality of high-frequency cameras are fixed on the guide roller and the travel roller respectively to simultaneously detect the running status of the linear motion body, the guide roller and the travel roller. The status of the linear motion body and the rolling body is monitored by the high-frequency camera on the track and the high-frequency camera on the rolling body, and the defects of the rolling body in the working state are monitored in real time.

[0016] Preferably, the rolling body detection controller is located at the terminal of the plurality of high-frequency cameras to receive and process the image data collected by the plurality of high-frequency cameras. The rolling body detection controller sequentially performs a series of image processing operations, including image processing, error calculation, contour visualization, and neural network defect detection, through the image data collected by the high-frequency camera. The image processing steps include background removal, grayscale processing, filtering and denoising, edge detection, contour tracking, contour screening, and outer circle fitting, aiming to obtain optimized rolling body contour information. Subsequently, the contour information is subjected to error analysis and visual display. Through the systematic collection and training of various defect data of existing rollers, an accurate neural network defect detection algorithm is further refined to realize real-time monitoring and judgment of abnormal roller conditions.

[0017] Preferably, the high-frequency camera and the vibration sensor are arranged alternately along the length direction of the track. When the linear motion body moves to a station where a vibration sensor is provided, the vibration sensor will collect raw vibration data in real time. In order to improve the detection accuracy, the number of vibration sensors can be appropriately increased at different positions, thereby achieving more accurate monitoring.

[0018] Preferably, the rolling body cleaning mechanism can be attached to the linear motion body and communicated with the rolling body detection controller and the rolling body vibration detector to clean the rolling body. The rolling body cleaning mechanism can respond to cleaning instructions at any time and efficiently complete the cleaning task of the rolling body.

[0019] The present invention also provides a method for detecting rolling element defects under operating conditions, which uses the detection device in the above technical solution and adopts the height method to detect rolling element defects. The principle is that a linear motion body moves at high speed around a track and collects image data through a high-speed moving camera, and a rolling element image detection controller displays the track surface information of the track. When the track surface image is abnormal, a rolling element running tread cleaning mechanism cleans the track.

[0020] The high-frequency camera detects the rolling body contour and transmits the image data to the rolling body detection controller, and checks the detection height of the rolling body with the standard height. When the detection height is lower than the standard height, the rolling body is judged as defective; when the detection height is lower than the minimum limit of the standard height, the rolling body is judged as faulty; when the detection height is higher than the maximum limit of the standard height, the rolling body cleaning mechanism starts and cleans the foreign matter on the rolling body;

[0021] The vibration sensor receives the vibration information of the rolling body and extracts the vibration information through the rolling body vibration detector. When the vibration information is greater than the normal range, the rolling body is judged to be abnormal. When the vibration information exceeds the limit value, the rolling body is judged to be faulty. When the vibration information is less than the normal range, the rolling body cleaning mechanism starts and cleans the foreign matter on the rolling body.

[0022] The present invention also provides a method for detecting rolling element defects under operating conditions, which uses the detection device in the above technical solution and the center of circle method to detect rolling element defects. The principle is that a linear motion body moves at high speed around a track and collects image data through a high-speed moving camera, and a rolling element image detection controller displays the track surface information of the track. When the track surface image is abnormal, a rolling element running tread cleaning mechanism cleans the track.

[0023] The high-frequency camera detects the rolling body contour and transmits the image data to the rolling body detection controller, and calibrates the detection center point of the rolling body with the theoretical center point. When the detection center point is lower than the theoretical center point, the rolling body is judged to be defective; when the detection center point is lower than the lowest limit value of the theoretical center point, the rolling body is judged to be faulty; when the detection center point is higher than the limit value of the theoretical center point, the rolling body cleaning mechanism starts and cleans foreign matter on the rolling body.

[0024] It can be seen from the above technical solutions that, compared with the prior art, the present invention discloses a detection device and method for rolling element defects under operating conditions, which can realize real-time detection of defects (such as wear and cracks) of rolling elements under working conditions, effectively solving the problem of difficulty in detecting rolling element defects during operation, thereby further ensuring the normal operation of the equipment and improving the overall reliability. At the same time, the present invention also addresses the wear problem of rolling elements after long-term operation, significantly reduces the risk of collision and noise between each worn rolling element and the operating working surface, thereby extending the service life of the rolling element and reducing the operating cost of the equipment; it can not only provide data support for maintenance strategies, helping enterprises to replace parts at the appropriate time, thereby reducing costs and improving the operating efficiency of the equipment, but also effectively extend the service life of the equipment and reduce the chain reaction caused by the failure of parts. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the provided drawings without paying creative work.

[0026] Figure 1 A cross-sectional view of a linear motion body provided by the present invention;

[0027] Figure 2 A front view of the detection device provided by the present invention;

[0028] Figure 3 A top view of a linear motion body provided by the present invention;

[0029] Figure 4 A schematic diagram of the rolling body height detection method provided by the present invention;

[0030] Figure 5 A flow chart of the rolling element intelligent detection algorithm provided by the present invention;

[0031] Figure 6 A flow chart of a rolling element vibration detection algorithm provided by the present invention;

[0032] Figure 7 A schematic diagram of the rolling body center detection method provided by the present invention;

[0033] Figure 8 A schematic diagram of the center line of the rolling element provided by the present invention;

[0034] Fig. 9 A flow chart of the rolling element defect height detection method provided by the present invention;

[0035] Fig.10 This is a flow chart of the rolling body defect center method detection provided by the present invention.

[0036] in,

[0037] 1-linear motion body; 2-high-speed moving camera; 3-track; 4-rolling body; 5-link head; 6-link tail; 7-rolling body running tread cleaning mechanism; 8-high-frequency camera; 9-rolling body cleaning mechanism; 10-vibration sensor; 11-rolling body image detection controller; 12-rolling body detection controller; 13-rolling body vibration detector. DETAILED DESCRIPTION

[0038] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0039] Embodiment 1:

[0040] See attached Figures 1 to 3 The embodiment of the present invention discloses a device for detecting rolling body defects under operating conditions, including a track 3, a rolling body 4, a high-speed mobile camera 2, a linear motion body 1, a rolling body running tread cleaning mechanism 7, a rolling body image detection controller 11, a high-frequency camera 8, a vibration sensor 10, a rolling body cleaning mechanism 9, a rolling body detection controller 12 and a rolling body vibration detector 13.

[0041] The rolling body 4 and the high-speed moving camera 2 are installed on the linear motion body 1, the rolling body 4 is rollingly connected to the track surface of the track 3, and the camera end of the high-speed moving camera 2 corresponds to the plane of the rolling track surface of the rolling body 4;

[0042] The rolling body running tread cleaning mechanism 7 is installed on the lower end surface of the linear motion body 1; the rolling body image detection controller 11 is configured to receive the image information of the rolling track surface collected by the high-speed mobile camera 2, monitor and judge the abnormal state of the rolling track surface through image processing and YOLO neural network algorithm, and drive the rolling body running tread cleaning mechanism 7 to operate according to whether there are foreign objects on the rolling track surface;

[0043] The high-frequency camera 8, the vibration sensor 10 and the rolling body cleaning mechanism 9 are respectively installed at preset fixed positions on the track 3; the rolling body detection controller 12 is configured to collect and monitor the image data and operation status data of the rolling body 4 in real time, and monitor and judge the abnormal state of the rolling body 4 through image processing and YOLO neural network algorithm; the rolling body vibration detector 13 is configured to receive the vibration data of the vibration sensor 10; the rolling body cleaning mechanism 9 receives the data of the rolling body detection controller 12 or the rolling body vibration detector 13 to be controlled by it.

[0044] like Figure 1 As shown, the track has two track surfaces perpendicular to each other, the rolling body 4 includes a guide rolling body and a traveling rolling body, the rolling planes of the guide rolling body and the traveling rolling body are arranged vertically, and the high-speed moving cameras 2 are arranged in groups and correspond to the planes of the rolling track surfaces of the guide rolling body and the traveling rolling body respectively.

[0045] High-speed cameras can accurately and real-time collect image information of mutually perpendicular track surfaces, and present a complete track surface projection in the rolling body image detection controller. The algorithm carried by the rolling body image detection controller deeply analyzes and calculates the state of the track surface, and works in coordination with the rolling body running tread cleaning mechanism to successfully complete the track surface cleaning task, thereby ensuring that there is no interference from foreign matter on the track surface and ensuring the normal operation of the linear motion body.

[0046] In order to further optimize the above technical solution, there are multiple linear motion bodies 1, and the multiple linear motion bodies 1 are connected end to end using a chain structure. Figure 3 As shown, a link joint 5 is fixed at one end of the linear motion body 1, and a link tail 6 is fixed at the other end. Both the link joint 5 and the link tail 6 are provided with connecting holes with standard pitches. Two adjacent linear motion bodies 1 are connected by a chain structure. The guide rolling body is located on the side wall of the linear motion body 1, and the traveling rolling body is located at the bottom end of the linear motion body 1, and the two are arranged vertically to each other.

[0047] In order to further optimize the above technical solution, the high-frequency camera 8 is located above the guide roller and the traveling roller, or multiple high-frequency cameras 8 are respectively fixed on the guide roller and the traveling roller to simultaneously detect the operating status of the linear motion body 1 and the guide roller and the traveling roller.

[0048] See attached Figure 4The guide roller and the travel roller are equipped with four high-frequency cameras respectively, and the angles of these four high-frequency cameras relative to the guide roller or the travel roller are 90° respectively. According to the requirements of detection accuracy, the number of linear motion bodies carrying high-frequency cameras is adjusted to achieve a higher detection effect.

[0049] In order to further optimize the above technical solution, the rolling body detection controller 12 is located at the terminal of the multiple high-frequency cameras 8 to receive and process the image data collected by the multiple high-frequency cameras 8.

[0050] like Figure 5 As shown, the rolling body detection controller is located at the terminal of the high-frequency camera. Through the image data collected by the high-frequency camera, a series of image processing operations are performed in sequence, including image processing, error calculation, contour visualization and neural network defect detection. The image processing link uses background subtraction to remove background, OpenCV color conversion, Gaussian filtering denoising, Canny edge detection, OpenCV outer circle search, contour screening and outer circle fitting, aiming to obtain optimized rolling body contour information. Subsequently, the contour information is analyzed and visualized. Through the systematic collection and training of various defect data of existing rolling bodies, including 500 training data sets, 100 defect data sets and 50 verification data sets, an accurate YOLO neural network defect detection algorithm is further refined to achieve real-time monitoring and judgment of abnormal states of rolling bodies.

[0051] In order to further optimize the above technical solutions, the YOLO neural network defect detection algorithm not only covers the automatic recognition and timely judgment of the rolling element profile, but also can accurately identify various defects of the rolling element, such as cracks, pits and damage. The data set trained by the YOLO neural network defect detection algorithm is derived from the real-time extraction of high-frequency cameras, which can effectively improve the accuracy of detection.

[0052] The algorithm has been tested on the validation set and its accuracy rate can reach 98%. No misjudgment has been found after specific experiments. In addition, for the results of the algorithm's misjudgment, the staff can manually modify the labels to further optimize the detection accuracy.

[0053] In order to further optimize the above technical solution, the high-frequency camera 8 and the vibration sensor 10 are arranged alternately along the length direction of the track 3. When the linear motion body runs to the station where the vibration sensor is installed, the vibration sensor will collect the original vibration data in real time. In order to improve the detection accuracy, the number of vibration sensors can be appropriately increased at different positions to achieve more accurate monitoring.

[0054] like Figure 6As shown, the rolling element vibration detector receives the vibration data collected by the vibration sensor in real time, and performs a series of operations such as data collection, filtering processing, data standardization, time domain analysis, frequency domain analysis, anomaly detection, fault mode recognition, decision model construction and comprehensive evaluation in sequence, so as to accurately obtain the vibration information of each component and effectively judge its fault status.

[0055] In order to further optimize the above technical solution, the rolling body cleaning mechanism 9 can be attached to the linear motion body 1 and communicated with the rolling body detection controller 12 and the rolling body vibration detector 13 to clean the rolling body 4. The rolling body cleaning mechanism can respond to the cleaning instruction at any time and efficiently complete the cleaning task of the rolling body.

[0056] Embodiment 2:

[0057] like Figures 1 to 6 and Fig. 9 As shown, the embodiment of the present invention discloses a method for detecting rolling element defects under operating conditions, and the rolling element defects are detected by using the device for detecting rolling element defects under operating conditions in embodiment 1, using a height method;

[0058] This embodiment takes two groups of identical structures as an example, namely, two groups of linear motion bodies carrying rolling body tread cleaning mechanisms and two groups of linear motion bodies carrying high-speed moving cameras, two groups of high-frequency cameras fixed at preset positions on the track, and two groups of vibration sensors fixed at preset positions on the track.

[0059] In this embodiment, the rolling body image detection controller 11 is located at the terminal of the high-speed mobile camera 2; the rolling body detection controller 12 is located at the terminal of the high-frequency camera 8; the rolling body vibration detector 13 is located at the terminal of the vibration sensor 10, and the three are integrated in one terminal.

[0060] The detection principle is:

[0061] The linear motion body 1 moves at high speed around the track 3 and collects image data through the high-speed moving camera 2. The rolling body image detection controller 11 displays the track surface information of the track 3. When the track surface image is abnormal (convex, concave), the linear motion body carrying the rolling body running tread cleaning mechanism 7 cleans the track 3 until the rolling body image detection controller 11 detects a normal track.

[0062] The high-frequency camera 8 on the track 3 detects the contour of the rolling body 4 and transmits the image data to the rolling body detection controller 12. The highest point of the rolling body 4 is found by the algorithm installed in the rolling body detection controller 12 ( Figure 4 8A, 8D, 8G, 8E) and the lowest point ( Figure 4 8B, 8C, 8H, 8F), automatically calculate the height difference between two opposing high-frequency cameras ( Figure 4H1, H2, H3, H4 in the figure), and check the detected height of the rolling element 4 with the standard height (H1, H2, H3, H4 and H in the figure are compared). When the detected height is lower than the standard height, the rolling element 4 is judged to be defective, and it is allowed to continue to be used within a certain range and the height information of the rolling element 4 is marked; when the detected height is lower than the minimum limit value of the standard height, the rolling element 4 is judged to be faulty, especially when the same rolling element 4 is higher than the marked height information three times at different heights (lower than the standard range and not lower than the minimum limit height of the rolling element 4), the rolling element 4 is judged to be faulty; when the detected height is higher than the maximum limit value of the standard height, the rolling element cleaning mechanism 9 is started and foreign matter on the rolling element 4 is cleaned;

[0063] At the same time, the vibration sensor 10 receives the vibration information of the rolling body 4 and extracts the vibration information through the rolling body vibration detector 13. When the detected vibration information is greater than the normal range, the rolling body 4 is judged to be abnormal and is allowed to continue to be used within a certain range; when the vibration information exceeds the limit range, the rolling body 4 is judged to be faulty. In particular, when the abnormal vibration information detected by the same rolling body 4 occurs more than five times in different situations, the rolling body 4 is judged to be faulty; when the vibration information is less than the normal range and there is slight abnormal information, the rolling body cleaning mechanism 9 starts and cleans foreign matter on the rolling body 4.

[0064] In order to further optimize the above technical solution, when the same rolling element 4 is determined to be both defective and abnormal, the rolling element 4 will be re-determined to be faulty.

[0065] The detection accuracy in this embodiment is closely related to the number and layout of high-frequency cameras and vibration sensors in the entire system. In terms of number, it is recommended to use an even number as much as possible to reduce the randomness of the system; in terms of layout, high-frequency cameras should be reasonably configured along the circumference of the rolling element to avoid repeated detection points as much as possible.

[0066] Embodiment 3:

[0067] See attached Figures 1 to 5 and Figure 7 , Figure 8 , Fig.10 The embodiment of the present invention discloses a method for detecting rolling element defects under operating conditions, wherein the rolling element defects are detected by using the device for detecting rolling element defects under operating conditions in embodiment 1, using the center of circle method;

[0068] In this embodiment, the rolling body image detection controller 11 is located at the terminal of the high-speed mobile camera 2; the rolling body detection controller 12 is located at the terminal of the high-frequency camera 8; the rolling body vibration detector 13 is located at the terminal of the vibration sensor 10, and the three are integrated in one terminal.

[0069] This embodiment takes two groups of identical structures as an example, namely, two groups of linear motion bodies carrying rolling body tread cleaning mechanisms and two groups of linear motion bodies carrying high-speed moving cameras, two groups of high-frequency cameras fixed at preset positions on the track, and two groups of vibration sensors fixed at preset positions on the track.

[0070] The detection principle is:

[0071] The linear motion body 1 moves at high speed around the track 3 and collects image data through the high-speed moving camera 2. The rolling body image detection controller 11 displays the track surface information of the track 3. When the track surface image is abnormal (convex, concave), the linear motion body carrying the rolling body running tread cleaning mechanism 7 cleans the track 3 until the rolling body image detection controller 11 detects a normal track.

[0072] The high-frequency camera 8 detects the contour of the rolling element 4 and transmits the image data to the rolling element detection controller 12. The highest point of the rolling element 4 is found by the algorithm installed in the rolling element detection controller 12 ( Figure 7 8A, 8D, 8G, 8E) and the lowest point ( Figure 7 8B, 8C, 8H, 8F), the detection center point of the rolling element 4 is checked with the theoretical center point, and the center point of the highest point and the lowest point between the two opposite high-frequency cameras 8 on the rolling element 4 is automatically calculated ( Figure 7 R1, R2, R3, R4, R5, R6) in the figure, and the theoretical center point of rolling element 4 ( Figure 7 R in the figure); when the detected center point (R3, R4) is lower than the theoretical center point (R), the rolling element 4 is judged to be defective, and it is allowed to continue to be used within a certain range (R~Rmin) and the position information of the center point (R3 and R4) of the rolling element is marked; when the detected center point (R5, R6) is lower than the lowest limit value (Rmin) of the theoretical center point, the rolling element 4 is judged to be faulty, in particular, when the center points of the same rolling element 4 are higher than the marked position information three times (lower than the standard range (R~Rmin) and not lower than the lowest limit height (Rmin) of the rolling element), the rolling element 4 is judged to be faulty; when the detected center point (R7, R8) is higher than the theoretical center point limit value (R~Rmax), the rolling element cleaning mechanism 9 is started and cleans the foreign matter on the rolling element 4.

[0073] In order to further optimize the above technical solution, Figure 8 As shown, by detecting the center point of each rolling body (R1, R2, R3, R4, R5, R6, R7, R8), the actual center point running trajectory of each rolling body can be generated. By combining the track image, the theoretical center point image of the rolling body (R01) and the actual center point (R) trajectory of the rolling body, the running status of each rolling body can be obtained. If there are rolling bodies with obvious defect trends, further monitoring and control can be implemented.

[0074] The detection accuracy in this embodiment is closely related to the number and layout of high-frequency cameras and vibration sensors in the entire system. In terms of number, it is recommended to use an even number as much as possible to reduce the randomness of the system; in terms of layout, high-frequency cameras should be reasonably configured along the circumference of the rolling element to avoid repeated detection points as much as possible.

[0075] In this specification, each embodiment is described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between the embodiments can be referred to each other. For the device disclosed in the embodiment, since it corresponds to the method disclosed in the embodiment, the description is relatively simple, and the relevant parts can be referred to the method part.

[0076] The above description of the disclosed embodiments enables one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but rather to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A device for detecting rolling element defects under operating conditions, characterized in that: The invention comprises a track (3), a rolling body (4), a high-speed moving camera (2), a linear motion body (1), a rolling body running tread cleaning mechanism (7), a rolling body image detection controller (11), a high-frequency camera (8), a vibration sensor (10), a rolling body cleaning mechanism (9), a rolling body detection controller (12) and a rolling body vibration detector (13). The rolling body (4) and the high-speed moving camera (2) are mounted on the linear motion body (1); the rolling body (4) is rollingly connected to the track surface of the track (3); and the camera end of the high-speed moving camera (2) corresponds to the plane of the rolling track surface of the rolling body (4); The rolling body running tread cleaning mechanism (7) is installed on the lower end surface of the linear motion body (1); the rolling body image detection controller (11) is configured to receive the image information of the rolling track surface collected by the high-speed mobile camera (2), monitor and judge the abnormal state of the rolling track surface through image processing and YOLO neural network algorithm, and drive the rolling body running tread cleaning mechanism (7) to operate according to whether there are foreign objects on the rolling track surface; The high-frequency camera (8), the vibration sensor (10) and the rolling body cleaning mechanism (9) are respectively installed at preset fixed positions on the track (3); the rolling body detection controller (12) is configured to collect and monitor in real time the image data and operation status data of the rolling body (4), and monitor and judge the abnormal state of the rolling body (4) through image processing and YOLO neural network algorithm; the rolling body vibration detector (13) is configured to receive the vibration data of the vibration sensor (10); the rolling body cleaning mechanism (9) receives the data of the rolling body detection controller (12) or the rolling body vibration detector (13) to be controlled by it for operation.

2. The device for detecting rolling element defects under operating conditions according to claim 2, characterized in that: The number of the linear motion bodies (1) is multiple, and the multiple linear motion bodies (1) are connected head to tail using a chain structure.

3. The device for detecting rolling element defects under operating conditions according to claim 2, characterized in that: The rolling bodies (4) include guide rolling bodies and traveling rolling bodies, the rolling planes of the guide rolling bodies and the traveling rolling bodies are arranged vertically, and the high-speed moving cameras (2) are arranged in groups and correspond to the planes of the rolling track surfaces of the guide rolling bodies and the traveling rolling bodies respectively.

4. The device for detecting rolling element defects under operating conditions according to claim 3, characterized in that: The high-frequency camera (8) is located above the guide roller and the travel roller, or a plurality of high-frequency cameras (8) are respectively fixed on the guide roller and the travel roller to simultaneously detect the operating status of the linear motion body (1) and the guide roller and the travel roller.

5. The device for detecting rolling element defects under operating conditions according to claim 4, characterized in that: The rolling body detection controller (12) is located at the terminal of the plurality of high-frequency cameras (8) to receive and process the image data collected by the plurality of high-frequency cameras (8).

6. The device for detecting rolling element defects under operating conditions according to claim 1, characterized in that: The high-frequency cameras (8) and the vibration sensors (10) are arranged alternately along the length direction of the track (3).

7. The device for detecting rolling element defects under operating conditions according to claim 1, characterized in that: The rolling body cleaning mechanism (9) can be attached to the linear motion body (1) and is communicatively connected with the rolling body detection controller (12) and the rolling body vibration detector (13) to clean the rolling body (4).

8. A method for detecting rolling element defects under operating conditions, using a rolling element defect detection device under operating conditions as claimed in any one of claims 1 to 7 to perform rolling element defect detection, the principle of which is that a linear motion body (1) moves at high speed around a track (3) and collects image data through a high-speed moving camera (2), a rolling element image detection controller (11) displays track surface information of the track (3), and when the track surface image is abnormal, a rolling element running tread cleaning mechanism (7) cleans the track (3); The high-frequency camera (8) detects the contour of the rolling body (4) and transmits the image data to the rolling body detection controller (12), and checks the detection height of the rolling body (4) with the standard height. When the detection height is lower than the standard height, the rolling body (4) is judged to be defective; when the detection height is lower than the minimum limit value of the standard height, the rolling body (4) is judged to be faulty; when the detection height is higher than the maximum limit value of the standard height, the rolling body cleaning mechanism (9) is activated to clean foreign matter on the rolling body (4); The vibration sensor (10) receives vibration information of the rolling body (4) and extracts the vibration information through the rolling body vibration detector (13); when the vibration information is greater than a normal range, the rolling body (4) is judged to be abnormal; when the vibration information exceeds a limit value, the rolling body (4) is judged to be faulty; when the vibration information is less than a normal range, the rolling body cleaning mechanism (9) is activated to clean foreign matter on the rolling body (4).

9. A method for detecting rolling element defects under operating conditions, using a rolling element defect detection device under operating conditions as claimed in any one of claims 1 to 7 to perform rolling element defect detection, the principle of which is that a linear motion body (1) moves at high speed around a track (3) and collects image data through a high-speed moving camera (2), a rolling element image detection controller (11) displays track surface information of the track (3), and when the track surface image is abnormal, a rolling element running tread cleaning mechanism (7) cleans the track (3); A high-frequency camera (8) detects the contour of the rolling body (4) and transmits image data to a rolling body detection controller (12), and calibrates the detection center point of the rolling body (4) with the theoretical center point. When the detection center point is lower than the theoretical center point, the rolling body (4) is judged to be defective; when the detection center point is lower than the lowest limit value of the theoretical center point, the rolling body (4) is judged to be faulty; when the detection center point is higher than the limit value of the theoretical center point, the rolling body cleaning mechanism (9) is activated to clean foreign matter on the rolling body (4).

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