An intelligent monitoring mechanism for coal conveyor belts based on image recognition

Abstract

The present invention relates to the field of belt monitoring technology, and more specifically, to an intelligent coal conveyor belt monitoring mechanism based on image recognition. The mechanism comprises a high-speed industrial camera and a linear laser, which are connected above a stabilizing frame. Both ends of the stabilizing frame are provided with a clearance opening for inserting the high-speed industrial camera and the linear laser. The inner sidewall of the stabilizing frame is provided with an inner groove for guiding the high-speed industrial camera and the linear laser during movement. The top of the inner groove is provided with a power supply contact for providing electrical energy to the high-speed industrial camera and the linear laser. The bottom of the inner groove is provided with a floating guide rail for supporting the high-speed industrial camera and the linear laser. The coordination of the clearance opening and the support frame facilitates installation and removal of the housing of the high-speed industrial camera and the linear laser, and allows for prompt and rapid replacement of the high-speed industrial camera and the linear laser if damaged, providing a convenient and quick solution.

Description

Technical Field

[0001] The present invention relates to the technical field of belt monitoring, in particular to an intelligent monitoring mechanism for a coal conveying belt based on image recognition. Background Art

[0002] Coal conveyor belts are widely used in coal mining, processing, transportation, and material handling in the power and chemical industries. In power plants, they are key equipment for ensuring the continuous and reliable operation of the coal supply system. They utilize the principle of connecting conveyor belts end-to-end to form a closed loop, maintained in a tensioned state by a tensioning device. Driven by an active motor, friction is generated between the belt and the drive pulley, enabling power transmission and continuous coal conveyance.

[0003] The coal conveyor belt is subjected to the weight, humidity, and temperature of the coal for a long time, which can easily lead to aging and fatigue damage of the material itself, and then cracks. If the cracks are not treated in time, they may gradually expand and eventually cause the belt to break. The broken belt may splash and cause harm to surrounding workers.

[0004] Prolonged downtime not only causes production delays but can also affect the stability of the entire supply chain. Especially in critical industries such as power generation, downtime of coal conveyors can lead to insufficient energy supply, which in turn has a wider impact on the social economy.

[0005] If the belt continues to run after it is torn, it may cause damage to other parts of the belt conveyor, such as rollers, idlers, etc. This will further increase the cost and complexity of maintenance. Summary of the Invention

[0006] In response to the problems in the prior art, the present invention provides an intelligent monitoring mechanism for a coal conveyor belt based on image recognition.

[0007] The technical solution adopted by the present invention to solve the technical problem is: an intelligent monitoring mechanism for a coal conveyor belt based on image recognition, comprising a high-speed industrial camera and a linear laser, which are connected above a stabilizing frame;

[0008] There are openings at both ends of the stabilizing frame for plugging in high-speed industrial cameras and linear lasers.

[0009] The inner wall of the stabilizing frame is provided with an inner groove for guiding the high-speed industrial camera and the linear laser during movement, and the top of the inner groove is provided with a power supply contact for providing power to the high-speed industrial camera and the linear laser;

[0010] A floating guide rail for supporting a high-speed industrial camera and a linear laser is installed at the bottom of the inner groove.

[0011] Preferably, the floating guide rail is formed by splicing a plurality of track pieces, the thickness of the floating guide rail is 4-6 mm, and the splicing parts are plug-in settings; the bottom of each track piece of the floating guide rail is fixedly connected to the first cylinder.

[0012] Preferably, a support frame is provided on the outside of the high-speed industrial camera and the linear laser for supporting, and an adjustment motor is provided on one side of the support frame for driving the high-speed industrial camera and the linear laser to rotate.

[0013] Preferably, both sides of the upper side of the stabilizing frame are provided with sliding grooves, a bidirectional threaded rod is rotatably arranged in the sliding groove, and one end of the bidirectional threaded rod is fixedly connected to the regulating motor;

[0014] The outer wall of the bidirectional threaded rod is fixedly sleeved with a moving block, the outer wall of the support frame is fixedly provided with a guide block, and the guide block and the moving block are magnetically arranged.

[0015] Preferably, a movable wheel is rotatably provided on the bottom side wall of the support frame, and the movable wheel is cooperated with the floating guide rail. A storage groove is opened in the middle of the movable wheel, and a second cylinder is fixedly connected in the storage groove. The telescopic end of the second cylinder is fixedly connected to a conductive sheet.

[0016] Preferably, a micro air pump is provided on one side of the housing of the high-speed industrial camera and the linear laser, and a lens for preventing dust from entering is installed in the middle of the housing of the high-speed industrial camera and the linear laser;

[0017] A circle of air jet holes is arranged around the lens, and the air jet holes are connected to the air outlet end of the micro air pump.

[0018] Preferably, the housing surfaces of the high-speed industrial camera and the linear laser are provided with cleaning parts, and the cleaning parts are driven by a servo motor;

[0019] The output end of the micro air pump is connected to the cleaning piece through a first air pipe.

[0020] Preferably, the cleaning member includes a mounting shell, a control member is rotatably arranged in the mounting shell, the control member is hollow, and a plurality of through holes are arranged on the side wall.

[0021] Preferably, a sponge strip for cleaning the lens surface is slidably inserted into the bottom of the control member.

[0022] Preferably, side sealing sheets are fixedly provided on both sides of the control member, and cleaning holes are provided on both sides of the mounting shell; the side sealing sheets are provided in coordination with the cleaning holes.

[0023] Preferably, a control ring is rotatably provided in the housing of the high-speed industrial camera and the linear laser, and the control ring is placed in a ring corridor that passes through the air jet hole, and the control ring is arranged in coordination with the air jet hole.

[0024] Preferably, a slide rod is fixedly provided on the top of the control ring, a guide groove is provided on one side of the mounting shell, and one side of the slide rod is slidably connected to the guide groove.

[0025] Beneficial effects of the present invention:

[0026] (1) The present invention describes an intelligent monitoring mechanism for a coal conveyor belt based on image recognition. Compared with the prior art, this application can increase the effective working time by 10%-20%, reduce the downtime inspection time by 1%-2%, improve the equipment utilization efficiency by 2%-3%, save manpower for regular replacement and maintenance of equipment, monitor the tearing, overlapping, and misalignment of the coal conveyor belt, as well as the health assessment and accurate risk warning of the coal conveyor belt, thereby improving the safety production efficiency and risk hidden danger prevention and control capabilities of the coal conveyor belt.

[0027] (2) The image recognition-based intelligent monitoring mechanism for the coal conveyor belt described in the present invention can facilitate the installation and removal of the housings of the high-speed industrial camera and the linear laser by coordinating the clearance opening with the support frame. When the high-speed industrial camera and the linear laser are damaged, they can be replaced promptly and quickly, which is convenient and quick.

[0028] (3) The present invention describes an intelligent monitoring mechanism for a coal conveyor belt based on image recognition. During the rotation of the output end of the servo motor, the mounting shell is driven to rotate along the surface of the lens. When the lens surface rotates, the control ring is driven to rotate via the sliding rod. The control ring can block half of the air jet holes. The mounting shell can push the control ring to open more of the air jet holes on the uncleaned side of the lens, so that the gas can be blown more concentratedly to the uncleaned side of the lens, thereby improving the cleaning efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The present invention will be further described below with reference to the accompanying drawings and examples.

[0030] Figure 1 It is a schematic diagram of the overall structure of the present invention;

[0031] Figure 2 This is a diagram showing the connection between the linear laser and the stabilizing frame of the present invention;

[0032] Figure 3 This is a schematic diagram of the three-dimensional structure of the stabilizing frame of the present invention;

[0033] Figure 4 This is a cross-sectional view of the stabilizer frame of the present invention;

[0034] Figure 5 This is a schematic diagram of the three-dimensional structure of the support frame of the present invention;

[0035] Figure 6 For the present invention Figure 5 Enlarged view of point A in the middle;

[0036] Figure 7 This is a schematic diagram of the three-dimensional structure of the control ring of the present invention;

[0037] Figure 8 This is an exploded view of the cleaning part of the present invention;

[0038] Figure 9 Obtaining a picture processing graph for the present invention;

[0039] Figure 10 This is a crack diagram of the coal conveyor belt of the present invention.

[0040] In the figure: 100, high-speed industrial camera; 200, linear laser; 201, air jet; 202, lens; 204, servo motor; 300, stabilizing frame; 301, bidirectional threaded rod; 302, yielding port; 303, floating guide rail; 306, first cylinder; 310, adjusting motor; 400, supporting frame; 401, guide block; 406, control ring; 407, sliding rod; 430, moving wheel; 431, conductive sheet; 432, second cylinder; 500, micro air pump; 501, first air pipe; 600, cleaning part; 601, cleaning air hole; 606, guide groove; 607, control part; 608, side sealing sheet; 609, sponge strip. DETAILED DESCRIPTION

[0041] In order to make the technical means, creative features, objectives and effects achieved by the present invention easier to understand, the present invention is further described below in conjunction with specific implementation methods.

[0042] Example 1:

[0043] like Figures 1-10 As shown, an intelligent monitoring mechanism for a coal conveyor belt based on image recognition of the present invention includes a high-speed industrial camera 100 and a linear laser 200, which are connected above a stabilizing frame 300;

[0044] A clearance opening 302 is provided at both ends of the stabilizing frame 300 for plugging in the high-speed industrial camera 100 and the linear laser 200. An inner groove is provided on the inner side wall of the stabilizing frame 300 for guiding the high-speed industrial camera 100 and the linear laser 200 during movement. A power supply contact is provided at the top of the inner groove for providing electrical energy to the high-speed industrial camera 100 and the linear laser 200; a floating guide rail 303 is installed at the bottom of the inner groove for supporting the high-speed industrial camera 100 and the linear laser 200.

[0045] The monitoring mechanism is suitable for conveyor belt width: ≤1400mm, suitable belt speed: 0~5m / s, minimum tear detection accuracy: 4mm, working environment: 0-40℃.

[0046] The parameters of the high-speed industrial camera 100 are: resolution 2448 (H) × 2048 (V), frame rate 79fps, sensor type 2 / 3" SONY IMX264 CMOS, pixel size 3.45μm × 3.45μm, image data format Mono8 / Mono10, signal-to-noise ratio 39dB, resolution >1661 lines, data interface Gigabit Ethernet (1000Mbit / s), power consumption <3W@12VDC, operating temperature 0℃ ~ 45℃, and operating humidity 10% ~ 80%.

[0047] One side of the high-speed industrial camera 100 is equipped with a mining explosion-proof fill light. The parameters of the mining explosion-proof fill light are as follows:

[0048] The optimal fill light distance is 16m~25m, the luminous angle is 40°, the light source type is an original imported high-power white light LED, the number of LED lamp beads is ≥16, the response time is ≤20us, the design life is ≥50,000 hours, the maximum power is 36W, the operating temperature is -40℃~+70℃, the operating humidity is 10%~90%, and the overall dimensions shall not exceed 160mm(W)×220mm(H)×130mm(D).

[0049] Installation method: side mounting (bracket rotation angle -90°~+90°), linear laser 200: 110° 100~150MW continuous laser.

[0050] The monitoring data is collected and processed through the computing platform and transmitted through the network switch. The accuracy of longitudinal tear detection during the monitoring agency's operation is: 100%; the accuracy of alarm for existing wounds and injuries is higher than 99%; the false alarm rate of all wounds and injuries is no more than 1%, which includes false alarms of wounds and misjudgments of injury levels.

[0051] Real-time images can be acquired through a high-speed industrial camera 100 and a linear laser 200. The computing host runs a longitudinal tear recognition algorithm, processes the original image and calculates the result, and outputs the video and alarm results to the back-end platform. The processing process is referenced in Figure 9 shown.

[0052] The provision of the clearance opening 302 facilitates the installation and removal of the housings of the high-speed industrial camera 100 and the linear laser 200. When the high-speed industrial camera 100 and the linear laser 200 are damaged, they can be replaced promptly and quickly, which is convenient and quick. At the same time, the provision of the floating guide rail 303 enables the high-speed industrial camera 100 and the linear laser 200 to maintain continuous contact with the power supply contacts, ensuring their normal operation.

[0053] Specifically, the floating guide rail 303 is formed by splicing multiple rail pieces. The thickness of the floating guide rail 303 is 4-6 mm, and the splicing parts are plug-in settings. The bottom of each rail piece of the floating guide rail 303 is fixedly connected to the first cylinder 306.

[0054] The floating guide rail 303 is made up of multiple track pieces. When one of them is damaged, it can be replaced in time to save replacement costs. The thickness of the floating guide rail 303 is 4-6mm, which can achieve the preset rigidity and at the same time be lightweight. The first cylinder 306 can support the track piece. During installation, different lengths of the first cylinder 306 can be selected according to different specifications for installation, which has a wider adaptability.

[0055] Specifically, a support frame 400 is provided outside the high-speed industrial camera 100 and the linear laser 200 for supporting. A driving motor for driving the high-speed industrial camera 100 and the linear laser 200 to rotate is provided on one side of the support frame 400.

[0056] The rotation of the driving motor can drive the high-speed industrial camera 100 and the linear laser 200 to rotate at a certain angle, so as to achieve all-round monitoring of the transmission process of the coal conveyor belt and avoid blind spots in monitoring. The support frame 400 can move along the stabilizing frame 300, and at the same time drive the high-speed industrial camera 100 and the linear laser 200 to move synchronously, and further adjust the positions of the high-speed industrial camera 100 and the linear laser 200.

[0057] Specifically, a sliding groove is provided on both sides of the upper side of the stabilizing frame 300, and a bidirectional threaded rod 301 is rotatably provided in the sliding groove. One end of the bidirectional threaded rod 301 is fixedly connected to an adjustment motor 310;

[0058] The outer wall of the bidirectional threaded rod 301 is fixed with a moving block, and the outer wall of the support frame 400 is fixed with a guide block 401, and the guide block 401 is magnetically attracted to the moving block;

[0059] A moving wheel 430 is rotatably provided on the bottom side wall of the support frame 400. The moving wheel 430 is cooperated with the floating guide rail 303. A storage groove is opened in the middle of the moving wheel 430. A second cylinder 432 is fixedly connected in the storage groove. The telescopic end of the second cylinder 432 is fixedly connected to a conductive sheet 431.

[0060] By adjusting the output end of the motor 310 to rotate, the bidirectional threaded rod 301 is driven to rotate. At this time, the moving block will move along the outer wall of the bidirectional threaded rod 301 in the direction of approaching or moving away from each other. The moving block and the guide block 401 are magnetically arranged to facilitate the disassembly and separation of the support frame 400 and the stabilizing frame 300. At the same time, the setting of the moving wheel 430 can increase the pressure between the guide block 401 and the moving block, thereby achieving the effect of increasing the friction between them, ensuring that the high-speed industrial camera 100 and the linear laser 200 can be driven to move during the movement of the moving block, which is convenient and fast.

[0061] Example 2:

[0062] Basically the same as the first embodiment, Figure 1 、 Figure 2 、 Figure 5-9 As shown, the difference is that a micro air pump 500 is provided on one side of the housing of the high-speed industrial camera 100 and the linear laser 200, and a lens 202 for preventing dust from entering is installed in the middle of the housing of the high-speed industrial camera 100 and the linear laser 200; a circle of air jet holes 201 is provided around the lens 202, and the air jet holes 201 are connected to the air outlet end of the micro air pump 500.

[0063] Specifically, a cleaning member 600 is provided on the housing surface of the high-speed industrial camera 100 and the linear laser 200 , and the cleaning member 600 is driven by the servo motor 204 ; the output end of the micro air pump 500 is connected to the cleaning member 600 through the first air pipe 501 .

[0064] The micro air pump 500 is connected to the cleaning part 600 through the first air pipe 501, and can continuously pump gas into the cleaning part 600. The lens 202 is cleaned through the setting of the cleaning part 600. The cleaning part 600 can not only clean by wiping, but also by blowing. During the process of transporting coal, a large amount of coal dust will adhere to the lens 202. The dust on the surface of the lens 202 can be cleaned through the air jet hole 201.

[0065] Specifically, the cleaning member 600 includes a mounting shell, in which a control member 607 is rotatably arranged. The control member 607 is hollow and has a plurality of through holes on its side wall.

[0066] A sponge strip 609 for cleaning the surface of the lens 202 is slidably inserted at the bottom of the control member 607. Side sealing sheets 608 are fixedly provided on both sides of the control member 607, and cleaning holes 601 are opened on both sides of the mounting housing; the side sealing sheets 608 are provided in conjunction with the cleaning holes 601.

[0067] The servo motor 204 drives the mounting shell to rotate during the rotation process. During the rotation process, the mounting shell drives the control part 607 to rotate, which can drive the side sealing piece 608 to rotate synchronously. The friction between the sponge strip 609 and the surface of the lens 202 will cause the housing control part 607 to tilt. The side sealing piece 608 rotates to open the cleaning air hole 601 on the side close to the lens 202 to be cleaned, and the other side sealing piece 608 rotates to block the corresponding cleaning air hole 601, which can concentrate the gas to clean the uncleaned lens 202. The control part 607 is hollow and has multiple groups of through holes on the side wall. At the same time, the control part 607 is made of lightweight plastic material to achieve a lightweight setting of the components. The setting of the through holes can facilitate the flow of gas.

[0068] Specifically, a control ring 406 is rotatably mounted within the housing of the high-speed industrial camera 100 and the linear laser 200. The control ring 406 is positioned within a circular corridor extending through the air jet 201 and is configured to cooperate with the air jet 201. A slide bar 407 is fixedly mounted on the top of the control ring 406. A guide groove 606 is defined on one side of the mounting housing, and one side of the slide bar 407 is slidably connected to the guide groove 606.

[0069] During the rotation of the output end of the servo motor 204, the mounting shell is driven to rotate along the surface of the lens 202. When the surface of the lens 202 rotates, the control ring 406 is driven to rotate through the slide bar 407. The control ring 406 can block half of the air injection holes 201. The mounting shell can push the control ring 406 to open more of the air injection holes 201 on the uncleaned side of the lens 202, so that the gas can be blown more concentratedly to the uncleaned side of the lens 202, thereby improving the cleaning efficiency.

[0070] The basic principles, main features, and advantages of the present invention are shown and described above. Those skilled in the art should understand that the present invention is not limited to the above-described embodiments. The above-described embodiments and descriptions are merely illustrative of the principles of the present invention. Various changes and modifications may be made to the present invention without departing from the spirit and scope of the present invention. Such changes and modifications are intended to fall within the scope of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. An intelligent monitoring mechanism for a coal conveyor belt based on image recognition, comprising a high-speed industrial camera (100) and a linear laser (200), characterized in that: The high-speed industrial camera (100) and the linear laser (200) are connected above the stabilizing frame (300); A clearance opening (302) is provided at both ends of the stabilizing frame (300) for plugging in a high-speed industrial camera (100) and a linear laser (200). An inner groove for guiding the high-speed industrial camera (100) and the linear laser (200) during movement is provided on the inner side wall of the stabilizing frame (300), and a power supply contact for providing electrical energy to the high-speed industrial camera (100) and the linear laser (200) is provided on the top of the inner groove; A floating guide rail (303) for supporting a high-speed industrial camera (100) and a linear laser (200) is installed at the bottom of the inner groove; The floating guide rail (303) is formed by splicing a plurality of rail pieces. The thickness of the floating guide rail (303) is 4-6 mm, and the splicing portion is plug-in-place. The bottom of each rail piece of the floating guide rail (303) is fixedly connected to a first cylinder (306). A support frame (400) is provided outside the high-speed industrial camera (100) and the linear laser (200) for supporting the camera, and an adjustment motor (310) for driving the high-speed industrial camera (100) and the linear laser (200) to rotate is provided on one side of the support frame (400); Sliding grooves are provided on both sides of the upper side of the stabilizing frame (300), and a bidirectional threaded rod (301) is rotatably arranged in the sliding groove, and one end of the bidirectional threaded rod (301) is fixedly connected to an adjusting motor (310); A moving block is fixedly provided on the outer wall of the bidirectional threaded rod 301, and a guide block (401) is fixedly provided on the outer wall of the support frame (400), and the guide block (401) and the moving block are magnetically attracted.

2. The intelligent monitoring mechanism for coal conveyor belt based on image recognition according to claim 1, characterized in that: A movable wheel (430) is rotatably provided on the side wall of the bottom of the support frame (400), and the movable wheel (430) is arranged in cooperation with the floating guide rail (303). A receiving groove is provided in the middle of the movable wheel (430), and a second cylinder (432) is fixedly connected in the receiving groove. A conductive sheet (431) is fixedly connected to the telescopic end of the second cylinder (432).

3. The intelligent monitoring mechanism for coal conveyor belt based on image recognition according to claim 1, characterized in that: A micro air pump (500) is provided on one side of the housing of the high-speed industrial camera (100) and the linear laser (200), and a lens (202) for preventing dust from entering is installed in the middle of the housing of the high-speed industrial camera (100) and the linear laser (200); A circle of air jet holes (201) is provided around the lens (202), and the air jet holes (201) are connected to the air outlet end of the micro air pump (500).

4. The intelligent monitoring mechanism for coal conveyor belt based on image recognition according to claim 3, characterized in that: A cleaning member (600) is provided on the housing surfaces of the high-speed industrial camera (100) and the linear laser (200), and the cleaning member (600) is driven by a servo motor (204); The output end of the micro air pump (500) is connected to the cleaning piece (600) via a first air pipe (501).

5. The intelligent monitoring mechanism for coal conveyor belt based on image recognition according to claim 4, characterized in that: The cleaning member (600) comprises a mounting shell, in which a control member (607) is rotatably arranged. The control member (607) is hollow and has a plurality of through holes on its side wall.

6. The intelligent monitoring mechanism for coal conveyor belt based on image recognition according to claim 5, characterized in that: A sponge strip (609) for cleaning the surface of the lens (202) is slidably inserted into the bottom of the control member (607).

7. The intelligent monitoring mechanism for coal conveyor belt based on image recognition according to claim 6, characterized in that: Side sealing sheets (608) are fixedly provided on both sides of the control member (607), and cleaning air holes (601) are provided on both sides of the mounting shell; the side sealing sheets (608) are arranged in coordination with the cleaning air holes (601).

8. The intelligent monitoring mechanism for coal conveyor belt based on image recognition according to claim 7, characterized in that: A control ring (406) is rotatably provided in the housing of the high-speed industrial camera (100) and the linear laser (200), and the control ring (406) is placed in a ring corridor that is connected to the air jet hole (201). The control ring (406) is arranged in coordination with the air jet hole (201).

9. The intelligent monitoring mechanism for coal conveyor belt based on image recognition according to claim 8, characterized in that: A slide rod (407) is fixedly provided on the top of the control ring (406), a guide groove (606) is provided on one side of the mounting shell, and one side of the slide rod (407) is slidably connected to the guide groove (606).

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