Method for measuring fatigue degree of conveying belt

Abstract

The invention discloses a method for measuring the fatigue degree of a conveying belt, and the method achieves the non-contact real-time monitoring of the surface condition of the conveying belt through the combination of a high-resolution camera and an advanced image processing technology, and can automatically recognize a potential problem region. A high-resolution camera is adopted to shoot cracks of 0.1 mm on the surface of the conveying belt, the surface of the conveying belt is shot in real time during normal operation of the conveying belt, and clear imaging in the high-speed 7m / s belt speed state is met; the shooting view field is 20 mm, and the minimum pixel is 0.01 mm; the collected data are synchronously and automatically analyzed, automatic resolving of 5000 lines of data per second is achieved, and end-side resolving is achieved; automatically resolving information such as crack width, length and distribution density in the image by adopting a crack detection method algorithm based on threshold segmentation, and carrying out grading judgment on the aging degree of the conveying belt according to the resolving information and GB / T 11206-2009 Surface Cracking Method for Rubber Aging Test; the method can be widely applied to the field of conveyor belt fatigue measurement.

Description

Technical Field

[0001] The invention relates to a conveyor belt fatigue measurement method and belongs to the technical field of conveyor belt fatigue measurement. Background Art

[0002] With the continuous improvement of industrial automation level, higher requirements are put forward for the safety and reliability of production equipment. As an indispensable part of the material handling system, the working condition of the conveyor belt is directly related to the normal operation of the entire production line. However, in the long-term use process, the conveyor belt will cause defects such as wear and cracks due to various factors, which will affect its service life and safety. Therefore, it is particularly important to develop an efficient and accurate method to detect the fatigue degree of the conveyor belt.

[0003] At present, research in this field mainly focuses on the following aspects: Non-destructive testing methods: In order to accurately assess the fatigue level of the conveyor belt without damaging it, researchers are developing and improving a variety of non-destructive testing methods, such as ultrasonic testing, electromagnetic non-destructive testing (such as eddy current testing), and X-ray imaging.

[0004] Sensor-based monitoring systems: By installing various types of sensors at key locations, such as stress and strain sensors, data can be collected and analyzed in real time to predict possible problems with the conveyor belt. With the application of IoT technology, these systems have become more intelligent and can be remotely monitored and managed.

[0005] Machine learning algorithms: Using big data analysis and machine learning techniques to process data collected from the field helps to build more accurate models to predict the life of conveyor belts and potential failure points. This approach can improve the predictability and efficiency of maintenance work.

[0006] Progress in materials science: Through the research and application of new materials, not only the durability and fatigue resistance of the conveyor belt itself are improved, but also new possibilities are provided for designing more efficient detection schemes. For example, self-healing materials can extend the service life of the product to a certain extent.

[0007] Image recognition and visual inspection: With the help of high-precision cameras and other optical equipment, combined with computer vision technology, the surface condition of the conveyor belt can be comprehensively and carefully observed from the appearance, and possible defects or damaged areas can be automatically identified. Summary of the invention

[0008] The present invention overcomes the shortcomings of the prior art and provides a conveyor belt fatigue measurement method. It utilizes a high-resolution camera combined with advanced image processing technology to achieve non-contact real-time monitoring of the conveyor belt surface condition and can automatically identify potential problem areas.

[0009] In order to solve the above technical problems, the technical solution adopted by the present invention is: a conveyor belt fatigue measurement method, which is implemented according to the following steps: The first step is to use a high-resolution camera to capture 0.1mm cracks on the conveyor belt surface. The conveyor belt surface is captured in real time during normal operation to ensure clear imaging at a high speed of 7m / s. A 2K linear array camera and a 121-07-106 lens are used to achieve a 20mm field of view and a minimum pixel of 0.01mm. In the second step, the computing host has an embedded card with 6T computing power built in, which can realize real-time acquisition of high-resolution cameras, automatically analyze the collected data simultaneously, and realize automatic calculation of 5,000 lines of data per second, thus realizing end-side calculation. In the third step, a crack detection method algorithm based on threshold segmentation is used to automatically calculate the crack width, length, distribution density and other information in the image, and the degree of aging of the conveyor belt is graded according to GB / T 11206-2009 "Surface Cracking Method for Rubber Aging Test" based on the calculated information.

[0010] Furthermore, the crack distribution and crack density can be automatically determined by using the algorithm in the host computer, and the conveyor belt fatigue level can be graded according to the cracking method.

[0011] Furthermore, the high-resolution camera is connected to a computing host via a network cable to acquire image data and transmit the image data to the computing host.

[0012] Furthermore, the high-resolution camera is fixed to an adjustable roller bracket by screws, the adjustable roller bracket is fixed to a belt frame by screws, the conveyor belt is movably arranged on the belt frame, the upper pressure roller is arranged on the upper side of the conveyor belt below, and the upper pressure roller realizes vibration suppression of the conveyor belt.

[0013] Furthermore, the two ends of the upper pressure roller are matched and connected with the adjustable roller brackets on both sides of the belt frame.

[0014] Furthermore, the structure of the adjustable roller bracket is: it includes a bracket body with a U-shaped structure, the bracket body is matched and hung on the belt frame, a plurality of adjustment holes are regularly distributed on the side of the bracket body, and the high-resolution camera is fixed to the adjustment holes by screws.

[0015] Compared with the prior art, the present invention has the following beneficial effects: the present invention realizes 0.1mm precision crack shooting and automatic identification, and at the same time realizes clear imaging of the high-speed 7m / s conveyor belt in operation, and realizes automatic judgment and grading of the aging degree of the conveyor belt and real-time judgment of the fatigue degree during the operation of the conveyor belt. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The present invention will be further described below in conjunction with the accompanying drawings.

[0017] Figure 1 It is a schematic diagram of the structure of the present invention.

[0018] Figure 2 It is a schematic diagram of the structure of the adjustable roller support in the present invention.

[0019] In the figure: 1 is a conveyor belt, 2 is an adjustable roller bracket, 21 is a bracket body, 22 is an adjustment hole, 23 is a groove, 3 is a computing host, 4 is a belt frame, 5 is a high-resolution camera, and 6 is an upper pressure roller. DETAILED DESCRIPTION

[0020] The present invention will be further described below in conjunction with specific embodiments.

[0021] like Figure 1 , Figure 2 As shown, a conveyor belt fatigue measurement method of the present invention is implemented according to the following steps: In the first step, a high-resolution camera 5 is used to photograph cracks of 0.1 mm on the surface of the conveyor belt. The surface of the conveyor belt 1 is photographed in real time during normal operation of the conveyor belt 1 to achieve clear imaging at a high speed of 7 m / s. A 2K linear array camera is selected and a 121-07-106 lens is used to achieve a shooting field of view of 20 mm and a minimum pixel of 0.01 mm. The laser emitter built into the high-resolution camera 5 adopts a line scanning mode. The laser emitter in the high-resolution camera 5 emits a fan-shaped laser line to form a strip-shaped conveyor belt profile surface on the lower surface of the conveyor belt 1. The difference between the points at adjacent positions on the surface of the conveyor belt 1 is calculated. After the conveyor belt 1 moves, a continuous surface profile value of the conveyor belt 1 can be obtained; Two cameras are arranged on the lower side of the conveyor belt 1. The laser lines irradiated by the two high-resolution cameras 5 to the surface of the conveyor belt 1 are connected and the sum of their lengths is equal to the width of the conveyor belt 1. The combination of visual imaging and laser ranging improves the accuracy of measurement and reduces the misjudgment rate. In the second step, the computing host 3 has an embedded board with 6T computing power built in, which can realize real-time acquisition of the high-resolution camera 5, automatically analyze the acquired data simultaneously, realize automatic calculation of 5000 lines of data per second, and realize end-side calculation; In the third step, a crack detection method algorithm based on threshold segmentation is used to automatically calculate the crack width, length, distribution density and other information in the image, and the aging degree of the conveyor belt 1 is graded and judged according to the calculated information in accordance with GB / T 11206-2009 "Surface Cracking Method for Rubber Aging Test".

[0022] The present invention realizes automatic determination of crack distribution and crack density by using an algorithm in the computing host 3, and realizes grading of fatigue degree of the conveyor belt 1 according to the cracking method.

[0023] In the present invention, the computing host 3 is located on one side of the belt frame 4 , and the high-resolution camera 5 is connected to the computing host 3 via a network cable to collect image data and transmit it to the computing host 3 .

[0024] The high-resolution camera 5 in the present invention is fixed to the adjustable roller bracket 2 by screws, the adjustable roller bracket 2 is fixed to the belt frame 4 by screws, the conveyor belt 1 is movably arranged on the belt frame 4, the upper pressure roller 6 is arranged on the upper side of the conveyor belt 1 below, and the upper pressure roller 6 realizes the vibration suppression of the conveyor belt 1.

[0025] The two ends of the upper pressure roller 6 in the present invention are matched and connected with the adjustable roller brackets 2 on both sides of the belt frame 4.

[0026] The structure of the adjustable roller bracket 2 described in the present invention is: it includes a U-shaped bracket body 21, the bracket body 21 is matched and hung on the belt frame 4, and a plurality of adjustment holes 22 are regularly distributed on the side of the bracket body 21. The high-resolution camera 5 is fixed to the adjustment holes 22 by screws, and a groove 23 is provided on one side of the bending part of the bracket body 21, and the groove 23 facilitates the installation of the upper pressure roller 6.

[0027] The present invention is composed of a high-resolution camera 5, a computing host 3 and an adjustable roller bracket 2, wherein the high-resolution camera 5 can capture cracks of 0.1 mm on the surface of the conveyor belt 1, and automatically determine the crack distribution and crack density through the algorithm in the computing host 3, and classify the fatigue level of the conveyor belt 1 according to the cracking method.

[0028] In the present invention, the adjustable roller bracket 2 is fixed to the belt frame 4 by screws, the high-resolution camera 5 is fixed to the adjustable roller bracket 2 by screws, the upper pressure roller 6 realizes the jitter suppression of the conveyor belt 1, and the high-resolution camera 5 is connected to the computing host 3 by a network cable to realize image data acquisition and transmission to the computing host 3.

[0029] Working principle of the present invention: The present invention adopts a high-resolution camera to realize the capture of 0.1mm cracks on the surface of the conveyor belt 1, and performs real-time capture of the surface of the conveyor belt 1 during normal operation of the conveyor belt 1, which can adapt to clear imaging at a high-speed belt speed of 7m / s; the solution selects a 2K linear array camera and adopts a 121-07-106 lens to achieve a shooting field of view of 20mm and a minimum pixel of 0.01mm.

[0030] The computing host of the present invention has an embedded board with 6T computing power, which realizes real-time acquisition of the camera, automatically analyzes the acquired data simultaneously, realizes automatic calculation of 5000 lines of data per second, and realizes end-side calculation.

[0031] The present invention adopts a crack detection method algorithm based on threshold segmentation to realize automatic solution of information such as crack width, length, distribution density, etc. in the image, and performs graded judgment of the aging degree of the conveyor belt 1 according to GB / T 11206-2009 "Surface Cracking Method for Rubber Aging Test" based on the solution information.

[0032] The embodiments of the present invention are described in detail above in conjunction with the accompanying drawings, but the present invention is not limited to the above embodiments, and various changes can be made within the knowledge scope of ordinary technicians in this field without departing from the purpose of the present invention.

Claims

1. A conveyor belt fatigue measurement method, characterized in that: Follow these steps to implement: In the first step, a high-resolution camera (5) is used to photograph cracks of 0.1 mm on the surface of the conveyor belt. The surface of the conveyor belt (1) is photographed in real time during normal operation of the conveyor belt (1), so as to achieve clear imaging at a high speed of 7 m / s. A 2K linear array camera is selected and a 121-07-106 lens is used to achieve a shooting field of view of 20 mm and a minimum pixel of 0.01 mm. In the second step, the computing host (3) has an embedded board with 6T computing power built in, which can realize real-time acquisition of high-resolution cameras (5), and automatically analyze the collected data simultaneously, realizing automatic calculation of 5,000 lines of data per second, and realizing end-side calculation; In the third step, a crack detection method algorithm based on threshold segmentation is used to automatically calculate the crack width, length, distribution density and other information in the image, and the aging degree of the conveyor belt (1) is graded and judged according to GB / T 11206-2009 "Surface Cracking Method for Rubber Aging Test" based on the calculated information.

2. A conveyor belt fatigue measurement method according to claim 1, characterized in that: The crack distribution and crack density are automatically determined by the algorithm in the computing host (3), and the fatigue level of the conveyor belt (1) is graded according to the cracking method.

3. A conveyor belt fatigue measurement method according to claim 1, characterized in that: The high-resolution camera (5) is connected to the computing host (3) via a network cable to acquire image data and transmit the image data to the computing host (3).

4. A conveyor belt fatigue measurement method according to claim 3, characterized in that: The high-resolution camera (5) is fixed to the adjustable roller bracket (2) by screws, the adjustable roller bracket (2) is fixed to the belt frame (4) by screws, the conveyor belt (1) is movably arranged on the belt frame (4), the upper pressure roller (6) is arranged on the upper side of the conveyor belt (1) below, and the upper pressure roller (6) suppresses the vibration of the conveyor belt (1).

5. A conveyor belt fatigue measurement method according to claim 4, characterized in that: The two ends of the upper pressure roller (6) are matched and connected with the adjustable roller brackets (2) on both sides of the belt frame (4).

6. A conveyor belt fatigue measurement method according to claim 4, characterized in that: The structure of the adjustable roller support (2) is as follows: it comprises a support body (21) of a U-shaped structure, the support body (21) is matched and hung on the belt frame (4), a plurality of adjustment holes (22) are regularly distributed on the side of the support body (21), and the high-resolution camera (5) is fixed to the adjustment hole (22) by means of screws.

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