Automatic cleaning and calibration system for industrial visual monitoring equipment in high-dust environment

Abstract

The invention relates to an automatic cleaning and calibration system for industrial visual monitoring equipment in a high-dust environment, which is used for a longitudinal tearing detection device of a conveyor, and the longitudinal tearing detection device is provided with at least one infrared lens and at least one visible light lens; the automatic cleaning and calibration system comprises a controller and a cleaning device, and the controller is connected with the cleaning device and the longitudinal tearing detection device; the controller is a built-in controller of the longitudinal tearing detection device; the cleaning device comprises a cleaning assembly used for cleaning the infrared lens and the visible light lens and a driving mechanism used for driving the cleaning assembly to linearly move or swing. A calibration algorithm is loaded in the controller, and temperature compensation calibration is carried out on the infrared lens. The surface of the lens can be automatically cleaned, and infrared image temperature measurement is calibrated, so that reliable operation of the longitudinal tearing detection device of the conveyor is ensured.

Description

Technical Field

[0001] This invention relates to the field of industrial sensor equipment maintenance technology, specifically to an automatic cleaning and calibration system for industrial visual monitoring equipment in high-dust environments. Background Technology

[0002] Belt conveyors, with their strong continuous transport capacity, high operating efficiency, and ease of automation, are widely used in power plant fuel transportation. The conveyor belt is a crucial component of the conveyor, accounting for as much as 45% of the total cost. In recent years, longitudinal tearing accidents involving conveyor belts have occurred frequently. Conveyor belts worth hundreds of thousands (or even millions) of yuan can be completely destroyed within minutes due to longitudinal tears, causing significant economic losses. Even if repairs are possible, they require a considerable amount of time. During transportation, conveyor belt tearing is a highly destructive form of damage, with tearing caused most severely by foreign objects at the receiving and guide chute, affecting normal loading and unloading operations and resulting in substantial economic losses. Therefore, establishing a monitoring system to identify longitudinal tears in conveyor belts is of great significance for ensuring safe operation, improving production efficiency, and avoiding or reducing direct and indirect losses.

[0003] In one design, the tear detection device for conveyors uses both visible light and infrared lenses (infrared thermal imagers). This combination of visual judgment and infrared image temperature measurement provides dual protection. However, during conveyor operation, especially in dusty or humid environments, the image function of the tear monitoring device is affected by dust and moisture condensation (specifically, dust or moisture covering the lens), leading to data distortion. This necessitates frequent manual maintenance, affecting continuous operation, and the working environment for manual maintenance is also poor. Furthermore, within the infrared lens's field of view, ambient temperature and humidity also affect the accuracy of thermal imaging temperature measurement.

[0004] It should be noted that the above content is for the reader's convenience only and does not mean that the above content is existing technology. Summary of the Invention

[0005] To address the problems existing in the prior art, the purpose of this invention is to provide an automatic cleaning and calibration system for industrial visual monitoring equipment in high-dust environments. This system can automatically clean the lens surface and calibrate the infrared image temperature measurement, thereby ensuring the reliable operation of the longitudinal tear detection device of the conveyor.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: An automatic cleaning and calibration system for industrial visual monitoring equipment in high-dust environments, used for a longitudinal tear detection device of a conveyor, the longitudinal tear detection device having at least one infrared lens and at least one visible light lens; The automatic cleaning and calibration system includes a controller and a cleaning device. The controller is connected to the cleaning device and the longitudinal tear detection device. The controller is a built-in controller of the longitudinal tear detection device. The cleaning device is integrated into the longitudinal tear detection device, or the cleaning device is detachably connected to the longitudinal tear detection device. The cleaning device includes a cleaning assembly for cleaning infrared lenses and visible light lenses, and a drive mechanism for driving the cleaning assembly to move linearly or swing. The controller is loaded with a calibration algorithm to perform temperature compensation calibration on the infrared lens; when the temperature compensation calibration is triggered, the following operations are performed: (4) Acquire built-in shutter data: Control the shutter of the infrared lens to close, and read the shutter temperature in real time through the shutter temperature sensor and infrared detector. and the corresponding AD mean ; (5) Query the baseline curve: based on the current shutter temperature Retrieve theoretical benchmark values ​​from the lookup table ; (6) Calculate calibration parameters: calibration coefficients Calculated by the formula:

[0007] in, , These are two consecutive AD values ​​collected in real time. , This corresponds to the baseline value; (4) Correct target temperature: The original AD value of each pixel in the conveyor belt image. Make corrections:

[0008] Then, through the TX curve, Convert to actual temperature.

[0009] The cleaning components include rubber scrapers and / or brushes.

[0010] The cleaning assembly includes a mounting rod, a rubber scraper, and a brush. The driving mechanism drives the mounting rod to rotate, and the rubber scraper and the brush are respectively arranged on both sides of the central axis of rotation of the mounting rod.

[0011] A rotating cap is provided at the middle position of the mounting rod. The rotating cap is located outside the longitudinal tear detection device. The driving mechanism is located inside the longitudinal tear detection device. The driving mechanism has an output shaft that extends to the outside of the longitudinal tear detection device and is connected to the rotating cap. The output shaft rotates synchronously with the rotating cap.

[0012] The drive mechanism includes a drive motor and a gear set, and the drive motor is connected to the cleaning component through the gear set.

[0013] The controller triggers temperature compensation calibration at regular intervals or when there is a sudden temperature change.

[0014] The lookup table is pre-stored in the controller and is obtained by performing blackbody reference calibration.

[0015] The blackbody reference calibration is as follows: Using a high-precision blackbody radiation source, multiple known temperature points were set; An infrared camera is aimed at the blackbody to collect the average AD value and temperature reading at each temperature point.

[0016] The TX curve is established by fitting a quadratic function, using the following formula:

[0017] Where T is temperature and X is the mean of AD. These are the fitting coefficients; Store the TX curve parameters in the controller's lookup table as a baseline.

[0018] By adopting the above solution, this invention can automatically clean the lens surface by setting up a cleaning device, and the structure is simple. At the same time, the infrared image temperature measurement is calibrated by the controller, thereby ensuring the reliable operation of the longitudinal tear detection device of the conveyor. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the cleaning device (in non-operating state). Figure 2 This is a schematic diagram of the cleaning device (at a certain moment during its operation). Figure 3 This is a schematic diagram of the cleaning device installed on the longitudinal tear detection device.

[0020] Explanation of key figure labels: Tear detection device 10, infrared lens 11, visible light lens 12; Drive motor 21, gear set 22, output shaft 23, mounting rod 24, rotating cap 25, rubber scraper 26, brush 27. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings.

[0022] This invention discloses an automatic cleaning and calibration system for industrial visual monitoring equipment in high-dust environments, specifically for a longitudinal tear detection device on a conveyor. This device includes an infrared lens and a visible light lens. The automatic cleaning and calibration system comprises a controller and a cleaning device, preferably with the controller integrated into the longitudinal tear detection device to reduce equipment costs. The controller connects the cleaning device and the longitudinal tear detection device.

[0023] The cleaning device is integrated into the longitudinal tear detection device, or the cleaning device can be detachably connected to the longitudinal tear detection device; the former is preferred. Figure 1-3 As shown, the cleaning device includes a cleaning component for cleaning infrared lenses and visible light lenses, and a drive mechanism for driving the cleaning component to move linearly or swing. Preferably, the cleaning component swings, which simplifies the design of the drive mechanism.

[0024] Specifically, the drive mechanism is housed inside the casing of the tear detection device to provide good dust protection. The drive mechanism includes a drive motor and a gear set, which has an output shaft. The drive motor is connected to the cleaning component via the gear set.

[0025] The cleaning assembly is located outside the tear detection device. The cleaning assembly includes a mounting rod, a rubber scraper, and a brush. A rotating cap is located at the middle of the mounting rod. An output shaft extends outside the tear detection device and connects to the rotating cap, rotating synchronously with it. The end of the output shaft connecting to the rotating cap can be shaped as a regular hexagon, and a regular hexagonal insertion hole is provided on the rotating cap. The connection between the two is achieved by inserting the hexagonal end of the output shaft into the insertion hole. The rubber scraper and the brush are respectively located on both sides of the rotating central axis of the mounting rod.

[0026] Normally, the mounting rod is placed horizontally or between the infrared and visible light lenses to avoid interfering with image acquisition. When cleaning is required (regular cleaning or remote-controlled cleaning; when the system requires remote control, the controller should communicate with a remote terminal, such as via wired or wireless means), the controller controls the drive motor to rotate, causing the rubber scraper and brush to alternately brush across the lens. The brush is beneficial for cleaning stubborn stains on the lens, while the rubber scraper is better at cleaning stains with a certain degree of moisture. Of course, the cleaning component can also consist of only a rubber scraper or a brush.

[0027] To ensure the accuracy of longitudinal tear detection on conveyor belts, the infrared lens needs to undergo temperature calibration to eliminate measurement errors caused by equipment drift and environmental interference. The following calibration scheme, based on automation and real-time requirements, combines built-in component self-calibration and blackbody calibration technology to ensure high-precision temperature measurement in industrial settings. Specifically, the controller of this invention incorporates a calibration algorithm to perform temperature-compensated calibration of the infrared lens.

[0028] The controller can trigger temperature compensation calibration at regular intervals or when there is a sudden temperature change. Once temperature compensation calibration is triggered, the following operations are performed: (7) Acquire built-in shutter data: Control the shutter of the infrared lens to close, and read the shutter temperature in real time through the shutter temperature sensor and infrared detector. and the corresponding AD mean .

[0029] (8) Query the baseline curve: based on the current shutter temperature Retrieve theoretical benchmark values ​​from the lookup table (Expected AD value under initial calibration).

[0030] (9) Calculate calibration parameters: calibration coefficients Calculated by the formula:

[0031] in, , These are two consecutive AD values ​​collected in real time. , This corresponds to the baseline value.

[0032] (4) Correct target temperature: The original AD value of each pixel in the conveyor belt image. Make corrections:

[0033] Then, through the TX curve, Convert to actual temperature.

[0034] The aforementioned lookup table is pre-stored in the controller and is obtained through blackbody calibration. A blackbody is an object in which all incident electromagnetic waves are absorbed, with neither reflection nor transmission; the radiation of a blackbody depends only on its temperature and is independent of its constituent materials. A true blackbody does not exist; the blackbody model described here is an idealized model, approximating a blackbody. Furthermore, the blackbody model used in this invention is a temperature-adjustable blackbody model.

[0035] The blackbody reference calibration is as follows: Using a high-precision blackbody radiation source (temperature range covering -20°C to 150°C, matching the surface temperature range of the conveyor belt), multiple known temperature points (such as 30°C, 50°C, and 80°C) are set.

[0036] An infrared camera is aimed at the blackbody to collect the average AD value (raw digital signal) and temperature reading at each temperature point.

[0037] The TX curve (temperature-AD value curve) is established by fitting a quadratic function, and the formula is as follows:

[0038] Where T is temperature and X is the mean of AD. represents the fitting coefficient.

[0039] Store the TX curve parameters in the controller's lookup table as a baseline.

[0040] In summary, this invention effectively addresses the core challenges of longitudinal tear detection in industrial settings—environmental interference and measurement drift—through a dual design of automatic cleaning and intelligent calibration. On one hand, the integrated cleaning device automatically removes dust and dirt from the lens surface periodically or as needed, ensuring consistently clear and usable infrared and visible light images. This proactive maintenance strategy avoids image quality degradation and recognition failure caused by lens contamination, guaranteeing detection reliability from the data source. On the other hand, this invention utilizes a built-in shutter and blackbody reference calibration to dynamically calculate the calibration coefficient K, effectively compensating for measurement drift caused by equipment heating and ambient temperature fluctuations. This ensures long-term accuracy of infrared thermometry, stabilizing the error within an acceptable range for industrial applications (e.g., within ±2℃). The above description is merely an embodiment of the present invention and does not constitute any limitation on the technical scope of the present invention. Therefore, any minor modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention shall still fall within the scope of the technical solution of the present invention.

Claims

1. An automatic cleaning and calibration system for industrial visual monitoring equipment in high-dust environments, used for a longitudinal tear detection device on a conveyor, the longitudinal tear detection device having at least one infrared lens and at least one visible light lens; characterized in that: The automatic cleaning and calibration system includes a controller and a cleaning device, wherein the controller is connected to the cleaning device and the longitudinal tear detection device; the controller is a built-in controller of the longitudinal tear detection device. The cleaning device is integrated into the longitudinal tear detection device, or the cleaning device is detachably connected to the longitudinal tear detection device. The cleaning device includes a cleaning assembly for cleaning infrared lenses and visible light lenses, and a drive mechanism for driving the cleaning assembly to move linearly or swing. The controller is loaded with a calibration algorithm to perform temperature compensation calibration on the infrared lens; when the temperature compensation calibration is triggered, the following operations are performed: (1) Acquiring built-in shutter data: Controlling the shutter of the infrared lens to close, and reading the shutter temperature in real time through the shutter temperature sensor and infrared detector. and the corresponding AD mean ; (2) Query the baseline curve: based on the current shutter temperature Retrieve theoretical benchmark values ​​from the lookup table ; (3) Calculate calibration parameters: calibration coefficients Calculated by the formula: in, , These are two consecutive AD values ​​collected in real time. , This corresponds to the baseline value; (4) Correct target temperature: The original AD value of each pixel in the conveyor belt image. Make corrections: Then, through the TX curve, Convert to actual temperature.

2. The automatic cleaning and calibration system for industrial visual monitoring equipment in a high-dust environment according to claim 1, characterized in that: The cleaning components include rubber scrapers and / or brushes.

3. The automatic cleaning and calibration system for industrial visual monitoring equipment in a high-dust environment according to claim 2, characterized in that: The cleaning assembly includes a mounting rod, a rubber scraper, and a brush. The driving mechanism drives the mounting rod to rotate, and the rubber scraper and the brush are respectively arranged on both sides of the central axis of rotation of the mounting rod.

4. The automatic cleaning and calibration system for industrial visual monitoring equipment in a high-dust environment according to claim 3, characterized in that: A rotating cap is provided at the middle position of the mounting rod. The rotating cap is located outside the longitudinal tear detection device. The driving mechanism is located inside the longitudinal tear detection device. The driving mechanism has an output shaft that extends to the outside of the longitudinal tear detection device and is connected to the rotating cap. The output shaft rotates synchronously with the rotating cap.

5. The automatic cleaning and calibration system for industrial visual monitoring equipment in a high-dust environment according to claim 1, characterized in that: The drive mechanism includes a drive motor and a gear set, and the drive motor is connected to the cleaning component through the gear set.

6. The automatic cleaning and calibration system for industrial visual monitoring equipment in a high-dust environment according to claim 1, characterized in that: The controller triggers temperature compensation calibration at regular intervals or when there is a sudden temperature change.

7. The automatic cleaning and calibration system for industrial visual monitoring equipment in a high-dust environment according to claim 1, characterized in that: The lookup table is pre-stored in the controller and is obtained by performing blackbody reference calibration.

8. The automatic cleaning and calibration system for industrial visual monitoring equipment in a high-dust environment according to claim 7, characterized in that: The blackbody reference calibration is as follows: Using a high-precision blackbody radiation source, multiple known temperature points were set; An infrared camera is aimed at the blackbody to collect the average AD value and temperature reading at each temperature point. The TX curve is established by fitting a quadratic function, using the following formula: Where T is temperature and X is the mean of AD. These are the fitting coefficients; Store the TX curve parameters in the controller's lookup table as a baseline.

Images