Method and system for monitoring running state of film coating machine

Abstract

The invention discloses a film coating machine operation state monitoring method and system, and belongs to computer data processing, visual equipment configuration, acquisition of a first image and a second image before and after working of a film coating machine, establishment of a plane coordinate system, determination of a film coating area, mapping of the film coating area to the first image, acquisition of the boundary of the film coating area, and division of the film coating area into S identification areas. Calculating gray values of all pixel points of the third image and taking a mean value as a representative parameter to generate a trend chart; presetting a difference allowable range, extracting a wave crest and a wave trough in the trend chart, calculating the difference between the representative parameters corresponding to the wave crest and the wave trough to obtain a difference value, judging whether the difference value is within the difference allowable range, obtaining a deviation value between the representative parameters with adjacent numbers in the trend chart, and calculating an average deviation degree; whether the average deviation degree is larger than the consistency parameter or not is judged, and it is expected to improve the problem of misjudgment or missed judgment caused by the fact that visual equipment is prone to local obvious errors in the abnormal monitoring work process of the film coating machine.

Description

Technical Field

[0001] The present invention relates to computer data processing, and particularly to a method and system for monitoring the running state of a coating machine. Background Art

[0002] In modern industrial production, coating technology is widely used in the surface treatment of various products to improve the aesthetics, durability and functionality of the products. As a key device to achieve this process, the stability and reliability of the running state of the coating machine have a decisive impact on production efficiency and product quality. However, during long-term operation, the coating machine may have problems such as wear, aging or improper operation, resulting in unstable coating quality or even defects. Therefore, monitoring the running state of the coating machine and timely discovering and handling abnormal situations are crucial for ensuring production quality and efficiency. Traditional monitoring methods often rely on manual inspections, which are not only inefficient but also prone to missing subtle fault signals. Currently in industry, in addition to manual monitoring, the coating machine itself also uses various sensors to monitor its working state. Since there are various abnormal situations when the coating machine is working, such as problems with the coating itself (unequal coating color matching, too much air in the coating), or equipment problems (improper setting of the coating roller pressure, wear or damage of the coating roller), etc.

[0003] Based on this, most current coating machines are equipped with visual devices to cooperate, aiming to improve the recognition performance of equipment abnormalities. However, in the actual operation process, there are still insurmountable problems. For example, when the coating machine is working, the coating area usually overflows, and it is very difficult to make the boundary of each coating exactly the same; for example, when using a visual device for monitoring, due to environmental factors, obvious local errors may occur when the visual device captures and analyzes images, resulting in misjudgment or missed judgment of abnormal situations. Therefore, how to optimize the monitoring of the running state of the coating machine is worthy of research. Summary of the Invention

[0004] The purpose of the present invention is to provide a method and system for monitoring the running state of a coating machine, aiming to improve the problem that obvious local errors are likely to occur in the visual device during the abnormal monitoring process of the coating machine, resulting in misjudgment or missed judgment.

[0005] An embodiment of the present invention uses the form of referencing a data table for data transmission, aiming to improve the stability of data transmission from the local machine to the cloud platform and reduce the transmission resource consumption of the cloud platform.

[0006] To solve the above technical problems, the present invention adopts the following technical solutions: A method for monitoring the operating state of a coating machine, comprising the following steps. S100, Configure a vision device and obtain image data before the coating machine works to obtain a first image. The above first image is uploaded to a local machine, and the local machine establishes a plane coordinate system on the first image, extracts the execution data of the coating machine and determines the coating area; Map the coating area onto the first image, identify the boundary of the coating area and obtain the first coordinate parameters corresponding to the boundary.

[0007] S200, The above vision device obtains image data after the coating work to obtain a second image; The local machine establishes the same plane coordinate system on the second image as on the first image. The above second image identifies the coating area through the first coordinate parameters; Divide the coating area into S consecutive and rectangular recognition areas, and sequentially number the recognition areas; Wherein, S is a positive integer, and the value of S is greater than 2.

[0008] S300, Extract the image data corresponding to each recognition area as a third image, calculate the gray values of all pixel points of the third image and take the average value as a representative parameter; Generate a trend chart with the S representative parameters according to the sequential numbers of the corresponding recognition areas.

[0009] S400, The local machine presets a difference allowable range, extracts the peaks and valleys in the trend chart, calculates the difference between the representative parameters corresponding to the peaks and valleys to obtain a difference value, and determines whether the difference value is within the difference allowable range. Among them, if the difference value is within the difference allowable range, then execute S500; Among them, if the difference value is outside the difference allowable range, the coating machine works abnormally, and the local machine gives an abnormal alarm.

[0010] S500, The local machine sets a consistency parameter, obtains the deviation value between the representative parameters with adjacent numbers in the trend chart, calculates the average deviation degree of the coating area through the deviation value, and determines whether the average deviation degree is greater than the consistency parameter; If the average deviation degree is greater than the consistency parameter, the coating machine works abnormally, and the local machine gives an abnormal alarm; If the average deviation degree is less than or equal to the consistency parameter, it means normal, and the above local machine sends data to the cloud platform for recording.

[0011] Preferably, coordinate grids are set in the above coating area. When the difference value is outside the difference allowable range, the following steps are carried out: S401, Extract the third images corresponding to the peaks and valleys as fourth images, and enhance the contrast of the fourth images. S402, Align the two fourth images and convert them into a binary image through pixel-by-pixel subtraction, and determine the difference area from the binary image; The difference area represents the area with obvious coating abnormalities; S402, The local machine marks the coordinate grids in the difference area; Obtain the second coordinate parameters corresponding to the marked coordinate grids, and the local machine highlights and annotates the coordinate grids corresponding to the second coordinate parameters in the coating area.

[0012] A further technical solution is that the step of converting the fourth image into a binary image is as follows: calculate the pixel values of the fourth image after contrast enhancement, and its calculation formula is: ; In the formula, is the pixel value at the position of coordinates (x, y) after contrast enhancement of the fourth image; is the original pixel value at the position of coordinates (x, y) of the fourth image; L is the number of gray levels of the image, and CDF represents the cumulative distribution function of the original image.

[0013] Obtain the pixel values of two fourth images, and calculate the pixel value difference between the fourth images by pixel-by-pixel subtraction. The calculation formula of the pixel value difference is: ; In the formula, is the pixel value at the position of coordinates (x, y) of the difference image, and are respectively the pixel values at the position of coordinates (x, y) after alignment of the two fourth images.

[0014] Set a significant threshold T. When converting the fourth image into a binary image, the conversion conditions are as follows: ; Among them, represents the pixel value of the binary image at the position of coordinates (x, y); is the pixel value at the position of coordinates (x, y) of the difference image; T is the significant threshold, 255 is white in the binary image, indicating the area with significant difference; 0 is black in the binary image, indicating the area with no significant difference.

[0015] Preferably, the calculation representative parameter includes converting the third image into a grayscale image, traversing each pixel of the image, obtaining the grayscale value of each pixel, summing the grayscale values of all pixels of the third image, and calculating the average grayscale value, and taking the average grayscale value as the representative parameter; among them, the formula of the representative parameter is: ; In the formula, A is the representative parameter of the third image, M is the height of the image, N is the width of the image, and G(x, y) is the grayscale value at the position of coordinates (x, y) of the third image.

[0016] Preferably, the formula for calculating the difference value by calculating the difference between the representative parameters corresponding to the peak and the trough is: ; In the formula, is the difference value between the representative parameters corresponding to the peak and the trough, and the above difference value represents the maximum difference degree of the trend graph; is the representative parameter corresponding to the peak, It is the representative parameter corresponding to the wave trough.

[0017] Preferably, the calculation formula for the average deviation degree of the coating film area is: ; ; In the formula, P is the average deviation degree of the coating film area, is the average value of the representative parameters of all recognition areas in the coating film area, is the representative parameter of the i-th recognition area, and S is the number of set recognition areas.

[0018] Preferably, there are multiple coating machines, and each coating machine is configured with a local machine. The local machines are connected to the cloud platform through a server. One server corresponds to multiple local machines. The local machines send the generated data as working data to the server, and the server optimizes the working data and then uploads it to the cloud platform for unified recording.

[0019] A further technical solution is that when the server optimizes the working data, the following steps are executed: S501, the server obtains all the working data in the local machine to form a first data packet, identifies the types of duplicate data blocks in the first data packet, and makes a reference data table for the duplicate data blocks; wherein, the reference data table contains multiple types of duplicate data blocks, each type of duplicate data block corresponds to a unique identification code, and the same duplicate data blocks correspond to the same identification code; S502, transfer and store all the working data with duplicate data blocks to obtain a second data packet; classify and organize the second data packet into a first data set and a second data set, wherein, the first data set contains working data with completely duplicate data content; the second data set contains working data with partially duplicate data; S503, replace the duplicate data blocks in the second data set with the identification codes in the reference data table to obtain replacement data; eliminate the duplicate data in the first data set to obtain representative data; S504, mark the working data in the first data packet corresponding to the second data packet, write the replacement data and the representative data into the first data packet and replace the marked working data to obtain a third data packet; S505, send the third data packet and the reference data table to the cloud platform by remote transmission; after receiving the third data packet and the reference data table, the cloud platform replaces the identification codes in the replacement data with the original duplicate data blocks according to the identification codes in the reference data table to complete the recording of the working data.

[0020] The present invention also discloses a monitoring system for the operating state of a coating machine. The system includes a coating machine, a vision device, a local machine, and a cloud platform. The above-mentioned vision device is arranged above the working surface of the coating machine. The vision device interacts with the local machine in terms of signals. The vision device collects image data on the working surface of the coating machine and uploads it to the local machine. The local machine is signal-connected to the cloud platform, and the local machine executes the above-mentioned method for monitoring the operating state of the coating machine.

[0021] Preferably, the system further includes a server. The local machine is signal-connected to the cloud platform through the server. The server is used to obtain data from the local machine and send data to the server.

[0022] Compared with the prior art, the beneficial effects of the present invention are as follows: By setting the difference allowable range and consistency parameters, this method comprehensively and meticulously monitors the output second image of the coating machine, and judges whether there is an abnormality in the operating state of the coating machine by judging the coating quality of the second image. By acquiring images before and after the coating machine works, and establishing a unified plane coordinate system on these images, the changes before and after coating are objectively expressed by calculating the pixel values and comparing the gray levels, so as to reduce the errors brought by traditional visual judgment. By identifying the boundary of the coating area and obtaining the corresponding coordinate parameters, and through the collaborative analysis of generating a trend chart, the concurrent pressure during image processing is avoided as much as possible, especially in the case where the equipment works continuously and is monitored in real time.

[0023] The present invention can also make the coating abnormal area clear at a glance through the highlighted annotation of the coordinate grid, which is convenient for the staff to quickly locate and solve problems.

[0024] The present invention transfers data by referring to data tables, significantly improving the stability of data transmission and reducing the misjudgment or missed judgment phenomena caused by data transmission errors. In addition, the optimized working data function of the server further improves the data transmission efficiency, reduces data redundancy, and provides a support basis for the intelligent management of the coating machine. Brief Description of the Drawings

[0025] Figure 1 It is a schematic flowchart of the present invention. Detailed Embodiments

[0026] In order to make the objectives, technical solutions and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0027] It should be noted that all directional indications (such as up, down, left, right, front, back...) in the embodiments of the present invention are only used to explain the relative position relationship, motion conditions, etc. under a certain specific working state. If the specific posture changes, the directional indications will also change accordingly. In the present invention, unless otherwise clearly specified and limited, terms such as "connection" should be understood in a broad sense. For example, "connection" can be an electrical signal connection or a signal connection; it can also be the communication inside two components or the interaction relationship between two components, unless otherwise clearly limited. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations.

[0028] If there are descriptions involving "first", "second", etc. in the embodiments of the present invention, the descriptions of "first", "second", etc. are only for descriptive purposes and cannot be understood as indicating or implying their relative importance or implicitly indicating the quantity of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include at least one of such features. In addition, the meaning of "and / or" appearing throughout the text includes three parallel scenarios. Taking "A and / or B" as an example, it includes scenario A, or scenario B, or the scenario where both A and B are satisfied simultaneously. In addition, the technical solutions between various embodiments can be combined with each other, but it must be based on the ability of those of ordinary skill in the art to implement. When the combination of technical solutions results in contradictions or cannot be implemented, it should be considered that such a combination of technical solutions does not exist and is not within the protection scope required by the present invention.

[0029] Reference Figure 1 One embodiment of the present invention is a method for monitoring the operating state of a coating machine, including the following steps: S100, configuring a vision device and obtaining image data before the coating machine works to obtain a first image. The above first image is uploaded to a local machine, and the local machine establishes a plane coordinate system on the first image, extracts the execution data of the coating machine and determines the coating area; maps the coating area onto the first image, identifies the boundary of the coating area and obtains the first coordinate parameters corresponding to the boundary. By configuring and installing a high-resolution vision device to capture the image before the coating machine works, the image is then uploaded to the local machine. On the local machine, an image processing software is used to establish a plane coordinate system on the first image, and the coating area is determined in combination with the execution data of the coating machine. After mapping the coating area onto the first image, the boundary of the coating area is identified through image recognition technology, and the corresponding first coordinate parameters are obtained.

[0030] Among them, when establishing the plane coordinate system, the existing image processing software OpenCV can be used to establish the plane coordinate system on the first image. The execution data of the coating machine includes at least the coating speed, pressure, and coating type, and the execution data determines the approximate position and range of the coating area.

[0031] To reflect the actual effect after the coating operation, in S200, the above visual device acquires the image data after the coating operation to obtain a second image; the second image is the image data acquired by the visual device after the coating operation is completed; the local machine establishes the same plane coordinate system on the second image as on the first image. Since the same visual device samples the same coating machine, the sizes and coordinate parameters of the second image and the first image are consistent.

[0032] The above second image identifies the coating area through the first coordinate parameter; it is presented on the second image through the first coordinate parameter, so that a boundary matching the coating area on the first image can be formed on the second image; the coating area is divided into S consecutive and rectangular recognition areas, and the recognition areas are sequentially numbered. By sequentially numbering the recognition areas, the numbers range from 1 to S, and the adjacent two coded recognizers are adjacent to each other on the second image. Among them, S is a positive integer, and the value of S is greater than 2.

[0033] In S300, the image data corresponding to each recognition area is extracted as a third image, the gray values of all pixel points of the third image are calculated and the mean value is taken as a representative parameter; the S representative parameters are used to generate a trend chart according to the sequential numbering of the corresponding recognition areas.

[0034] Extract the corresponding image data from each recognition area and use it as the third image. For each third image, the system calculates the gray values of all its pixel points and takes the mean value as the representative parameter of this area. Finally, the S representative parameters are used to generate a trend chart according to the sequential numbering of the recognition areas. Through the trend Figure 1 On the one hand, it can intuitively reflect the continuity and uniformity of the coating; on the other hand, by observing the shape of the trend line, it can be intuitively judged whether the coating is abnormal. Generally speaking, if the trend line is about flat, the coating is about uniform; if there are obvious fluctuations, it means that the coating quality is affected to a certain extent.

[0035] It should be noted that calculating the gray values of all pixel points of the third image is to establish a unified quality standard. The gray value directly reflects the brightness and darkness of the third image. Combining with the coating process, there is a corresponding relationship between the gray value and the coating thickness. Therefore, the gray value is used as the quantitative parameter of the coating in the recognition area, and the representative parameter uses the mean value in order to reflect the overall coating condition of the entire area of the third image.

[0036] To better judge whether there is an abnormality. In S400, the local machine presets a difference allowable range, extracts the peaks and valleys in the trend chart, calculates the difference between the representative parameters corresponding to the peaks and valleys to obtain a difference value, and judges whether the difference value is within the difference allowable range. The peak usually represents the thicker situation of the coating, and the valley represents the thinner situation of the coating; by calculating the difference between the representative parameters corresponding to the peaks and valleys, the coating difference between the recognition areas in the coating area is expressed; Among them, when the difference value is within the allowable difference range, it is generally considered that the coating film difference between the recognition areas will not affect the qualified rate of the coating film. The difference may be caused by inevitable tolerances or other uncontrollable factors. Therefore, S500 is executed; Among them, when the difference value is outside the allowable difference range, it is generally considered that the coating film difference will affect the qualified rate of the coating film. Therefore, it is considered that the coating machine is operating abnormally, and an abnormal alarm needs to be sent through the local machine.

[0037] S500: The local machine sets the consistency parameter and obtains the deviation value between the representative parameters of adjacent numbers in the trend chart. The deviation value is mainly used to present the abnormal conditions in the continuous coating process, mainly to identify the situations of discontinuous or uneven coating, so as to quickly discover the mutations in the coating process and adjust the working conditions in a timely manner.

[0038] Calculate the average deviation degree of the coating area through the deviation value, and judge whether the average deviation degree is greater than the consistency parameter; if the average deviation degree is greater than the consistency parameter, the coating machine is operating abnormally, and the local machine sends an abnormal alarm; if the average deviation degree is less than or equal to the consistency parameter, it indicates normal, and the above-mentioned local machine sends data to the cloud platform for recording.

[0039] Based on the foregoing embodiments, another embodiment of the present invention is that a coordinate grid is set in the above-mentioned coating area. When the difference value is outside the allowable difference range, the following steps are performed: S401, extract the third image corresponding to the wave peak and wave valley as the fourth image, and enhance the contrast of the fourth image. Enhancing the contrast can improve the image processing efficiency and better identify the difference area.

[0040] S402, align the two fourth images and convert them into a binary image through pixel-by-pixel subtraction, and determine the difference area from the binary image; the difference area represents the area with obvious coating film abnormalities; the obvious abnormal grid can be more intuitively obtained through the binary image.

[0041] S402, the local machine marks the coordinate grid in the difference area; obtains the second coordinate parameter corresponding to the marked coordinate grid, and the local machine highlights and annotates the coordinate grid corresponding to the second coordinate parameter in the coating area. This method is mainly used to quickly identify the differences between the fourth images.

[0042] A further technical solution is that the step of converting the fourth image into a binary image is: calculate the pixel value of the fourth image after contrast enhancement, and its calculation formula is: ; In the formula, is the pixel value at the position of coordinates (x, y) of the fourth image after contrast enhancement; is the original pixel value at the position of the fourth image coordinates (x, y); L is the number of gray levels of the image, and CDF represents the cumulative distribution function of the original image.

[0043] Obtain the pixel values of two fourth images, and calculate the pixel value difference between the fourth images pixel by pixel. The calculation formula for the pixel value difference is: ; In the formula, is the pixel value at the position of the difference image with coordinates (x, y), and are the pixel values at the position of coordinates (x, y) after alignment of the two fourth images respectively.

[0044] Set the significant threshold T. When converting the fourth image into a binary image, the conversion conditions are as follows: ; Among them, represents the pixel value of the binary image at the position of coordinates (x, y); is the pixel value of the difference image at the position of coordinates (x, y); T is the significant threshold, 255 is white in the binary image, representing the area with significant difference; 0 is black in the binary image, representing the area without significant difference.

[0045] Preferably, the calculation representative parameter includes converting the third image into a grayscale image, traversing each pixel of the image, obtaining the grayscale value of each pixel, summing the grayscale values of all pixels of the third image, and calculating the average grayscale value, and taking the average grayscale value as the representative parameter; among them, the formula for the representative parameter is: ; In the formula, A is the representative parameter of the third image, M is the height of the image, N is the width of the image, and G(x, y) is the grayscale value at the position of coordinates (x, y) of the third image.

[0046] Preferably, the formula for calculating the difference value by calculating the difference between the representative parameters corresponding to the peak and the trough is: ; In the formula, is the difference value between the representative parameters corresponding to the peak and the trough, and the above difference value represents the maximum difference degree of the trend graph; is the representative parameter corresponding to the peak, is the representative parameter corresponding to the trough.

[0047] Based on the foregoing embodiments, another embodiment of the present invention is that the calculation formula for the average deviation degree of the coating film area is: ; ; Wherein, P is the average deviation degree of the coating film area, is the average value of the representative parameters of all identification areas in the coating film area, is the representative parameter of the i-th identification area, and S is the number of set identification areas.

[0048] Based on the foregoing embodiments, another embodiment of the present invention is that there are multiple coating machines as described above, and each coating machine is configured with a local machine. The local machines are connected to the cloud platform through a server. One server corresponds to multiple local machines. The local machines send the generated data as working data to the server, and the server optimizes the working data and then uploads it to the cloud platform for unified recording. In actual operation, since multiple coating machines are required to work in batches, a local machine is set for each coating machine to perform basic anomaly judgment, and the relevant conditions of the data coating machine are sent to the server through the Internet. After being sorted by the server and sent to the cloud platform for summary, when necessary, the user can connect to the API interface reserved by the cloud platform through a mobile phone or other means to view the relevant data.

[0049] Based on the foregoing embodiments, another embodiment of the present invention is that when considering the local machine obtaining the data of the local machine, the data structure and content are usually determined. In a frequently updated scenario, the current server can already capture only the data that has changed since the last data occurrence, that is, applying a log mechanism, which is commonly used in the way of change data capture, to record each addition and modification operation of the data, and only record these changes in the data to reduce the amount of data. Although the current coating machine is a continuous data collection and there is a possibility of data change, during the process of changing from normal to abnormal, usually only the change of local fields of the data may be involved. Therefore, a further technical solution is that when the server optimizes the working data, the following steps are performed: S501, the server obtains all the working data in the local machine to form a first data packet, identifies the types of duplicate data blocks in the first data packet, and makes the duplicate data blocks into a reference data table; wherein, the reference data table contains multiple types of duplicate data blocks, each type of duplicate data block corresponds to a unique identification code, and the same duplicate data blocks correspond to the same identification code.

[0050] Wherein, the working data is the relevant data used by the local machine, and the first data includes the execution data of the coating machine and the data generated during the operation of the local machine; wherein, the first data packet is a data set formed after the server obtains a number of working data and intends to send it to the cloud platform.

[0051] Exemplarily, the process by which the above server obtains working data mainly involves sequentially generating data and identifying data blocks of the working data; if an identified data block appears repeatedly in one or more pieces of working data (for example, a large number of repeated working condition data are likely to occur when a coating machine is working), then this data block is defined as a repeated data block and recorded. It should be noted that there may be multiple repeated data blocks in the working data, and a reference data table is created to correspond to these repeated data blocks. Each repeated data block corresponds to a unique identification code, and the same repeated data blocks share the same identification code. By establishing the reference data table, it is expected that the redundancy of the generated data can be significantly reduced subsequently.

[0052] S502, transfer and store all the working data with repeated data blocks to obtain a second data packet; classify and organize the second data packet into a first data set and a second data set. Among them, the first data set contains the working data with completely identical data content; the second data set contains the working data with partial data repetition.

[0053] Organize the working data corresponding to the repeated data blocks to obtain a second data packet; among them, the second data packet encompasses all the working data with repeated data blocks.

[0054] Among them, when the server obtains the working data in the local machine, it is necessary to determine the repeated data blocks, then identify the repeated data blocks and the corresponding working data, and organize the data into a second data packet in the local environment.

[0055] Identify and classify the second data packet into a first data set and a second data set. Among them, the first data set contains the working data with completely identical data content; since the working data with completely identical data content usually represents the same situation of a coating machine, in principle, the repeated data does not need to be frequently transmitted to the cloud platform, and only one representative is usually required for its data in the cloud platform. For example, if the coating machine equipment has a constant working condition (the settings of various parameters are constant), its working data can usually be directly represented as, for example, mode 1, mode 2, mode 3, etc. In principle, the cloud platform only needs to record the parameters of the constant working condition once, and when the working data is uploaded, the part representing the parameter settings can be expressed in the form of mode 1, mode 2, mode 3.

[0056] Among them, the second data packet is mainly obtained through local replication. On the one hand, the replication process of the second data packet occurs within the local area network, without being restricted by external network conditions, reducing the impact caused by network latency and instability.

[0057] S503, replace the repeated data blocks in the second data set with the identification codes in the reference data table to obtain substitute data; remove the repeated data in the first data set to obtain representative data.

[0058] Among them, the representative data contains non-repetitive and unique working data. Although the alternative data still contains working data with partially repetitive content, the repetitive data blocks in the alternative data have been replaced with corresponding identification codes.

[0059] Therefore, by referring to the identification codes corresponding to the repetitive data blocks to replace some overlapping data content, the amount of data that needs to be stored additionally can be significantly reduced. At the same time, when using the reference data table to restore data on the cloud platform, the complete data structure can be assembled and accessed faster, improving the availability and recovery speed of the data.

[0060] It should also be noted that the method of replacing repetitive data blocks with identification codes in the reference data table is beneficial to reducing potential error hazards and security risks during the data transmission process.

[0061] S504, mark the working data in the first data packet corresponding to the second data packet, write the alternative data and the representative data into the first data packet and replace the marked working data to obtain a third data packet.

[0062] Among them, find the part in the first data packet corresponding to all the working data in the second data packet and mark it. Through the marking, the data blocks that need to be updated or replaced can be quickly identified. Determine the part that needs to be deleted or replaced in the marking to obtain a new third data packet.

[0063] Among them, the third data packet is the final version after all data updates and optimizations, and is ready to be sent to the cloud platform through remote transmission. There are no repetitive data blocks and repetitive working data in the third data packet. It is beneficial to use the third data packet as the sending data subsequently, and during the remote data sending process, the amount of data that needs to be transmitted through the network is reduced, thereby accelerating the data synchronization speed and reducing the occupation of network resources.

[0064] S505, send the third data packet and the reference data table to the cloud platform through remote transmission; after the cloud platform receives the third data packet and the reference data table, the cloud platform replaces the identification codes in the alternative data back to the original repetitive data blocks according to the identification codes in the reference data table to complete the recording of the working data.

[0065] Send the third data packet and the reference data table to the cloud platform through remote transmission; after the cloud platform receives the third data packet and the reference data table, the cloud platform replaces the identification codes in the alternative data back to the original repetitive data blocks according to the identification codes in the reference data table to complete the generation of the valid data. Among them, after the cloud platform first receives the third data packet and the reference data table, the cloud platform will search for the corresponding identification codes in the alternative data according to the identification codes therein and replace them back to the original repetitive data blocks to complete the recording of the working data.

[0066] For reference, in order to guide the correct restoration of the substituted data block to the original data block by referring to the data table, specific symbols or marks can usually be set when adding the identification code to the substituted data to avoid incorrect replacement behavior and effectively ensure the integrity and consistency of the data. When the cloud platform replaces all the identification codes in the third data packet, the data set of the cloud platform obtains a complete copy of the source data.

[0067] For reference, considering that the third data packet contains all the working data for which data needs to occur, in order to ensure that the data is effectively transmitted from the local machine to the cloud platform securely through the network and the complete content of the data can be correctly restored on the cloud platform, the remote transmission method selected for the third data packet can be existing FTP, HTTP, or HTTPS transmission. When necessary, the third data packet and the reference data table can also be encrypted and transmitted through a secure encryption protocol (such as TLS / SSL) to further reduce the risk of the third data packet being stolen or tampered with during transmission.

[0068] An embodiment of the present invention is a monitoring system for the operating state of a coating machine. The system includes a coating machine, a vision device, a local machine, and a cloud platform. The vision device is arranged above the working surface of the coating machine. The vision device interacts with the local machine in terms of signals. The vision device collects image data on the working surface of the coating machine and uploads it to the local machine. The local machine is signal-connected to the cloud platform, and the local machine executes any of the above-mentioned methods for monitoring the operating state of the coating machine. It consists of four core parts: an existing coating machine, a vision device, a local machine, and a cloud platform. Among them, the vision device is installed above the working surface of the coating machine and is responsible for collecting image data of the working surface of the coating machine. A signal interaction is established between the vision device and the local machine to ensure that the image data can be uploaded to the local machine in a timely manner for processing. A signal connection is established between the local machine and the cloud platform to execute the method for monitoring the operating state of the coating machine and transmit the processing result to the cloud platform.

[0069] An embodiment of the present invention is that the system further includes a server. The local machine is signal-connected to the cloud platform through the server. The server is used to obtain data from the local machine and send data to the server. The system adds a server as an intermediate layer. The local machine no longer directly connects to the cloud platform but establishes a signal connection with the cloud platform through the server. The main role of the server is to obtain data from the local machine and forward the data to the cloud platform. This architecture design improves the stability and scalability of the system.

[0070] As used herein, the terms "one embodiment", "another embodiment", "an embodiment", "a preferred embodiment", etc. refer to specific features, structures, or characteristics described in connection with that embodiment being included in at least one embodiment generally described in this application. The same expression occurring in multiple places in the specification does not necessarily refer to the same embodiment. Further, when describing a specific feature, structure, or characteristic in connection with any one embodiment, it is intended that such feature, structure, or characteristic be implemented in combination with other embodiments and also fall within the scope of the present invention.

[0071] Although the present invention has been described herein with reference to various illustrative embodiments, it should be understood that those skilled in the art can devise many other modifications and embodiments that will fall within the scope of the principles of this application as disclosed. More specifically, within the scope of the disclosure, the drawings, and the claims, various variations and improvements can be made to the components and / or arrangements of the subject combination layout. In addition to the variations and improvements to the components and / or arrangements, other uses will also be apparent to those skilled in the art.

Claims

1. A method for monitoring the operating status of a coating machine, characterized in that: The steps include: S100, configuring a visual device and acquiring image data of the coating machine before operation to obtain a first image, uploading the first image to a local machine, and establishing a plane coordinate system for the first image by the local machine; Extract the execution data of the coating machine and determine the coating area; Mapping the coating area onto the first image, identifying the boundary of the coating area and obtaining first coordinate parameters corresponding to the boundary; S200, the visual device acquires image data after the coating operation to obtain a second image; the local machine establishes the same plane coordinate system as the first image on the second image, and the second image identifies the coating area through the first coordinate parameter; The coating area is divided into S continuous and rectangular identification areas, and the identification areas are numbered sequentially; wherein S is a positive integer, and the value of S is greater than 2; S300, extracting image data corresponding to each identification area as a third image, calculating the grayscale values ​​of all pixels of the third image and taking the average as a representative parameter; numbering the S representative parameters in order of the corresponding identification areas to generate a trend graph; S400, the local machine presets the difference allowable range, extracts the peaks and troughs in the trend graph, calculates the difference between the representative parameters corresponding to the peaks and troughs to obtain a difference value, and determines whether the difference value is within the difference allowable range; If the difference value is within the allowable difference range, S500 is executed; If the difference value is outside the allowable range, the coating machine is working abnormally, and the local machine will issue an abnormal alarm; S500, the local machine sets consistency parameters, obtains deviation values ​​between representative parameters with adjacent numbers in the trend graph, calculates the average deviation degree of the coating area through the deviation value, and determines whether the average deviation degree is greater than the consistency parameter; If the average deviation is greater than the consistency parameter, the coating machine is working abnormally, and the local machine will issue an abnormal alarm; If the average deviation is less than or equal to the consistency parameter, it is normal, and the local machine sends data to the server for recording.

2. The method for monitoring the operating status of a coating machine according to claim 1, characterized in that: A coordinate grid is set in the coating area, and when the difference value is outside the allowable difference range, the following steps are performed: S401, extracting the third image corresponding to the peaks and troughs as the fourth image, and performing contrast enhancement on the fourth image; S402, aligning the two fourth images and converting the binary images by pixel-by-pixel subtraction, and determining the difference area by the binary images; The area of ​​obvious coating abnormality is indicated by the difference area; S402, the local machine marks the coordinate grid in the difference area; obtains the second coordinate parameter corresponding to the marked coordinate grid, and the local machine highlights the coordinate grid corresponding to the second coordinate parameter in the coating area.

3. The method for monitoring the operating status of a coating machine according to claim 2, characterized in that: The step of converting the fourth image into a binary image is: The pixel value of the fourth image after contrast enhancement is calculated using the following formula: ； In the formula, is the pixel value at the position with coordinates (x, y) after contrast enhancement of the fourth image; is the original pixel value at the position (x, y) of the fourth image coordinate; L is the grayscale level of the image, and CDF represents the cumulative distribution function of the original image; The pixel values ​​of the two fourth images are obtained, and the pixel value difference between the fourth images is calculated by pixel-by-pixel subtraction. The calculation formula of the pixel value difference is: ； In the formula, is the pixel value of the difference image at coordinate (x, y), and are the pixel values ​​at the position with coordinates (x, y) after the two fourth images are aligned; When the significant threshold T is set and the fourth image is converted into a binary image, the conversion conditions are as follows: ； in, Represents the pixel value of a binary image at the coordinate (x, y); is the pixel value of the difference image at the coordinate (x, y); T is the significant threshold, 255 is white in the binary image, indicating the area with significant difference; 0 is black in the binary image, indicating the area with no significant difference.

4. The method for monitoring the operating status of a coating machine according to claim 1, characterized in that: Calculating the representative parameter includes converting the third image into a grayscale image, traversing each pixel of the image, obtaining the grayscale value of each pixel, summing the grayscale values ​​of all pixels of the third image, and calculating the average grayscale value, and using the average grayscale value as the representative parameter; wherein the formula of the representative parameter is: ； Where A is the representative parameter of the third image, M is the image height, N is the image width, and G(x, y) is the grayscale value of the position (x, y) of the third image.

5. The method for monitoring the operating status of a coating machine according to claim 1, characterized in that: The formula for calculating the difference between the representative parameters corresponding to the peak and the trough to obtain the difference value is: ； In the formula, is the difference between the corresponding representative parameters of the peak and the trough, and the difference represents the maximum difference degree of the trend graph; is the representative parameter corresponding to the peak, is the representative parameter corresponding to the trough.

6. The method for monitoring the operating status of a coating machine according to claim 1, characterized in that: The formula for calculating the average degree of deviation of the coating area is: ； ； Where P is the average deviation of the coating area, is the average value of the representative parameters of all identification areas in the coating area, is the representative parameter of the i-th identification zone, and S is the number of set identification zones.

7. The method for monitoring the operating status of a coating machine according to claim 1, characterized in that: There are multiple coating machines, and each coating machine is configured with a local machine. The local machine is connected to the server through the server, and one server corresponds to multiple local machines. The local machine sends the generated data as working data to the server, and the server optimizes the working data and uploads it to the server for unified recording.

8. The method for monitoring the operating status of a coating machine according to claim 7, characterized in that: When the server optimizes the working data, the following steps are performed: S501, the server obtains all working data in the local machine to form a first data packet, identifies the types of repeated data blocks in the first data packet, and forms a reference data table with the repeated data blocks; wherein the reference data table contains multiple types of repeated data blocks, each type of repeated data block corresponds to a unique identification code, and the same repeated data blocks correspond to the same identification code; S502, transferring all the working data with duplicate data blocks to obtain a second data packet; classifying and arranging the second data packet into a first data set and a second data set, The first data set contains working data with completely repeated data content; the second data set contains working data with partial data duplication; S503, replacing the repeated data blocks in the second data set with the identification codes in the reference data table to obtain replacement data; removing the repeated data in the first data set to obtain representative data; S504, marking the working data in the first data packet corresponding to the second data packet, writing the replacement data and the representative data into the first data packet and replacing the marked working data, to obtain a third data packet; S505, sending the third data packet and the reference data table to the server via remote transmission; after the server receives the third data packet and the reference data table, the server replaces the identification code in the replacement data with the original repeated data block according to the identification code in the reference data table, thereby completing the recording of the working data.

9. A coating machine operation status monitoring system, characterized in that: The system includes a coating machine, a visual device, a local machine and a server. The visual device is arranged above the working surface of the coating machine. The visual device interacts with the local machine signals. The visual device collects image data on the working surface of the coating machine and uploads it to the local machine. The local machine is connected to the server signals. The local machine executes the coating machine operation status monitoring method described in any one of claims 1 to 8.

10. The coating machine operation status monitoring system according to claim 9, characterized in that: The system also includes a server, and the local machine is connected to the server signal through the server. The server is used to obtain data of the local machine and send the data to the server.

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