Method and system for detecting and cleaning accumulated materials on material sliding plate of disc pelletizer

Abstract

The invention discloses an accumulated material detecting and cleaning method and system for a material sliding plate of a disc pelletizer, and the method comprises the steps: obtaining a background image containing a material sliding plate body, and dividing a plurality of cleaning regions to obtain a background grid image; a continuous image of the material sliding plate in the pelletizing process is obtained, and a mark image marked with an adhesive material is obtained; overlapping the marked image and the background grid image, counting the pixel proportion of the adhesive material area in the cleaning area, and further determining the number of the cleaning area and whether the cleaning is started or not; the cleaning unit is used for cleaning all the cleaning areas in sequence; the system performs reciprocating swing motion between circumferential boundary lines of a cleaning area through a first motion mechanism of the cleaning unit, and moves between boundary lines in the radius direction through a second motion mechanism, so that sticky material cleaning of the cleaning area is completed; according to the method and the system, the work of manually cleaning the material sliding plate by using an iron shovel is effectively replaced, the working intensity of production workers is reduced, the qualified rate of green pellets is improved, and the production efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of pellet production control technology, and in particular to a method and system for detecting and cleaning accumulated material on the chute of a disc pelletizer. Background Technology

[0002] The disc pelletizer is a crucial piece of equipment for manufacturing green pellets. Its working principle is as follows: Material fed into the disc pelletizer, after the addition of appropriate moisture, continuously rolls within an inclined, rotating pelletizing disc to form pellets. Larger pellets, lacking sufficient lift, roll out of the disc pelletizer and fall onto a chute, then roll along the chute into a conveyor belt for transport to the next production stage. Because the initially formed pellets are moist and possess kinetic energy upon landing on the chute, some material adheres to the chute. Over time, this accumulation causes large-area material buildup on the chute, hindering pellet discharge and weakening pellet strength, necessitating timely cleaning.

[0003] Currently, to address the issue of material accumulation on the chute, on-site workers need to inspect the chute regularly and assess the area of ​​accumulation based on experience. Cleaning is only carried out when the accumulation is deemed to be affecting pellet discharge. The inspection cycle is limited by the workers' self-discipline and other high-priority tasks. As for cleaning, on-site workers mostly use hand shovels for periodic cleaning. However, this method is limited by the intensity of the work, resulting in low efficiency and affecting the yield of green pellets. If cleaning is not timely, the rate of moisture evaporation from the accumulated material increases. Furthermore, the location of the chute makes cleaning difficult, and workers are prone to injury from the recoil of the shovel, leading to low operational safety. Summary of the Invention

[0004] The purpose of this invention is to provide a method for detecting and cleaning accumulated material on the chute of a disc pelletizer, which solves the above-mentioned technical problems.

[0005] Another object of the present invention is to provide a system for detecting and cleaning accumulated material on the chute of a disc pelletizer using the above-described method.

[0006] Therefore, the technical solution of the present invention is as follows:

[0007] A method for detecting and cleaning accumulated material on the chute of a disc pelletizing machine, comprising the following steps:

[0008] S1. Under the condition of no sticking material and no green ball material flow, the image of the chute is acquired to obtain a background image containing the chute body; in the background image, the surface area of ​​the chute is divided into multiple numbered cleaning areas, and a background grid image is obtained.

[0009] S2. During the pelletizing process, the same method as in step S1 is used to continuously acquire images of the chute and identify the sticky material on the chute in the acquired images to obtain a marked image with the sticky material.

[0010] S3. Overlay the marked image with the background grid image to calculate the pixel ratio of the sticky area in each cleaning area, and determine the cleaning area that needs to be cleaned based on the ratio.

[0011] S4. Count the number of areas that need to be cleaned, and determine whether to start cleaning based on the number;

[0012] S5. When step S4 determines that cleaning has started, an array is formed for all areas that need to be cleaned, in ascending order of their numbers, and this array is used as the cleaning path. The cleaning unit is then controlled to clean each area in turn.

[0013] Further, in step S1, the step of obtaining the background grid image is as follows:

[0014] S101. Define the surface of the chute as plane S, and set a cleaning unit for cleaning the chute in an empty area on the side of the chute away from the disc pelletizer. The cleaning unit includes a first motion mechanism. The first motion mechanism swings circumferentially between the cleaning unit installation position and the disc pelletizer through its rotation drive position, so that the motion range of the first motion mechanism can cover plane S. Based on this, construct a polar coordinate system A1 with the rotation drive position of the first motion mechanism as the origin, and take the direction pointing horizontally to the center of the pelletizer as the 90° axis direction, and the direction pointing after rotating 90° counterclockwise as the 0° axis direction.

[0015] S102. Using the origin of the polar coordinate system A1 as the endpoint, draw multiple rays at intervals of angle θ to evenly divide the surface of the feed chute into multiple regions.

[0016] S103. Using the origin of the polar coordinate system A1 as the center, draw arcs on the feeder plate with radii of Xa, 2Xa, 3Xa, ..., nXa in sequence. Based on the division in step S202, the surface of the feeder plate is divided into several cleaning areas by multiple arcs.

[0017] S104, with a region area not less than Xa 2 Using / 2 as the standard, adjacent small cleanup areas are merged to obtain N cleanup areas. The N cleanup areas are numbered sequentially. The numbering method for the N cleanup areas is as follows: starting from the cleanup area far from the origin of polar coordinate system A1 and close to the 0° axis, the N cleanup areas are numbered sequentially from 1 to N in a serpentine arrangement.

[0018] Furthermore, in step S2, the specific method for identifying the material adhering to the conveyor plate in the acquired image is as follows:

[0019] S201. Perform differential processing and binarization processing on the acquired image to obtain a binarized image containing only the accumulated material and the green ball material flow;

[0020] S202. Distinguish between the accumulated material and the green ball material flow in the binarized image to obtain a binarized image containing only the accumulated material features; wherein, the method for distinguishing between the accumulated material and the green ball material flow is: 1) Perform morphological closing operation on the binarized image continuously acquired and processed within the statistical period according to the set statistical period T.

[0021] 2) Traverse all connected components on all binarized images after step S201 and make judgments in sequence: if a connected component exists in M ​​frames or more of the binarized images, then determine that the connected component corresponds to the accumulated material and retain the connected component in all binarized images; otherwise, determine that the connected component corresponds to the green ball material flow and remove the connected component from all binarized images; finally, the connected components retained on the binarized images are the material stuck on the chute.

[0022] Furthermore, the specific implementation steps of step S201 are as follows:

[0023] 1) Perform grayscale processing on the background image from step S1 and the image acquired from step S2 respectively to obtain a grayscale background image and a grayscale spherical image;

[0024] 2) Based on the grayscale background image's grayscale pixel matrix B(x,y) and the grayscale sphere image's grayscale pixel matrix C(x,y), subtract the grayscale values ​​of two corresponding pixels in each of the two grayscale pixel matrices, and take the absolute value to reassign the pixel value, thereby obtaining the difference image.

[0025] 3) Set a threshold T, and then judge the gray value Diff(x,y) of each pixel in the difference image in turn: if Diff(x,y)≥T, then update the pixel gray value to 1 and represent sticky material or green ball; if Diff(x,y)<T, then update the pixel gray value to 0 and represent chute; thus converting the difference image into a binary image.

[0026] Furthermore, in step S2, the specific method for identifying the material adhering to the conveyor plate in the acquired image is as follows:

[0027] S201. During the pelletizing process under different working conditions, several images of the chute are collected, and the areas of material adhesion on the images are marked to obtain a material adhesion segmentation dataset. The working conditions include light intensity, material flow rate, wetness of the pellets, and the area of ​​material adhesion on the chute.

[0028] S202. The YOLO network is trained using a sticky material segmentation dataset to construct a sticky material segmentation model that can output a segmentation mask for each pixel in the image to distinguish sticky pixels from non-sticky pixels. The preferred YOLO network is YOLOv8n-seg.

[0029] S203. Input the image acquired in step S2 into the adhesive material segmentation model and output the image result marked with the segmentation mask on the pixel.

[0030] Further, in step S5, the cleaning method for each cleaning area is as follows: taking the four boundary lines surrounding the designated cleaning area as the movement boundaries of the cleaning unit, the first motion mechanism of the cleaning unit is controlled to reciprocate between the two boundary lines in the circumferential direction of the cleaning area. At the same time, the second motion mechanism set on the first motion mechanism moves from far to near between the two boundary lines in the radial direction. Each movement distance L is the cleaning width of the scraper connected to the bottom of the second motion mechanism, so that the scraper sweeps across the entire area of ​​the cleaning area and covers the cleaning area.

[0031] A system for detecting and cleaning accumulated material on the chute of a disc pelletizer includes:

[0032] The host computer control unit includes a first fiber optic transceiver, an industrial computer, and a display connected in sequence; the industrial computer uses the above-mentioned disc baller material accumulation detection and cleaning method to detect material accumulation in the acquired images and generate a cleaning path.

[0033] The field control unit includes a second fiber optic transceiver, a switch, a touch screen, and a programmable logic controller (PLC). The second fiber optic transceiver is connected to the first fiber optic transceiver via fiber optic cable to establish a remote communication channel. The switch is connected to the second fiber optic transceiver, the touch screen, the PLC, and the image acquisition unit to receive and transmit image information acquired by the image acquisition unit, send the cleaning path to the PLC, and control the control parameters of the PLC via the touch screen.

[0034] The cleaning unit is connected to a programmable logic controller (PLC), which controls the cleaning unit to complete the cleaning operation of the chute according to the cleaning path.

[0035] Furthermore, the image acquisition unit includes a camera and a supplementary light; the camera acquires images containing the conveyor plate with its optical path axis perpendicular to the conveyor plate, and the supplementary light is placed on the side adjacent to the camera to provide illumination compensation for the conveyor plate.

[0036] Furthermore, the cleaning unit includes a first motion mechanism, a second motion mechanism, a caster assembly, and a scraper assembly; wherein,

[0037] The first motion mechanism includes a first motion drive mechanism and a boom assembly; the first motion drive mechanism includes a first geared motor; the first output shaft of the first geared motor is connected to a rotary encoder, and its second output shaft is vertically upward; the boom assembly includes a horizontally arranged long arm, one end of which is fixedly connected to the shaft end of the second output shaft of the first geared motor; the first geared motor and the rotary encoder are respectively connected to a programmable logic controller.

[0038] The second motion mechanism includes a second motion drive mechanism, a chain assembly, and a slider assembly. The second motion drive mechanism includes a second geared motor, whose output shaft is horizontally positioned and perpendicular to the second output shaft of the first geared motor. A laser rangefinder is mounted on the top side of the second geared motor, and a first gear is provided at the end of its output shaft. The chain assembly includes a chain and a second gear. The second gear is rotatably mounted at the other end of the long arm, and the chain is sleeved on the outside of the first and second gears to form a chain drive mechanism. The slider assembly includes a sliding frame that is slidably sleeved on the outside of the long arm and is fixedly connected to the chain. A laser rangefinder reflector that cooperates with the laser rangefinder is provided on the top. The second geared motor and the laser rangefinder are respectively connected to a programmable logic controller.

[0039] The caster assembly includes an adjustable-length connecting rod, the top of which is fixed to the bottom of the other end of the long arm, and the bottom of which is connected to a traveling wheel, the axis of which is parallel to the axis of the long arm; the scraper assembly includes a scraper, which is set with the scraper head facing vertically downward and is fixed to the bottom of the sliding frame by a scraper connecting rod.

[0040] Furthermore, the cleaning unit also includes a first limit switch group and a second limit switch group; wherein,

[0041] The first limit switch group includes a first motion axis origin limit switch, a first motion axis left limit switch, and a first motion axis right limit switch, which are respectively connected to the programmable logic controller. The three are arranged at a central interval on the top side of the first geared motor and from the long arm installation position to the disc ball forming machine. The first limit switch group also includes a first limit sensing block fixed on the long arm. Its setting position is such that it can sequentially be aligned with the three limit switches and send sensing signals as the long arm swings from the installation position to the disc ball forming machine.

[0042] The second limit switch group includes a near-end limit switch and a far-end limit switch, which are respectively connected to the programmable logic controller. The two are respectively located at both ends of the long arm to generate a collision signal when the sliding frame moves to collide with the near-end limit switch or the far-end limit switch.

[0043] Compared with existing technologies, this method and system for detecting and cleaning accumulated material on the chute of a disc pelletizing machine can effectively replace the manual cleaning of the chute with a shovel by automatically detecting and cleaning, reducing the workload of production workers and facilitating the automation and intelligent transformation of the disc pelletizing process. In addition, the system performs real-time detection and cleaning, which is more timely than manual operation, thus improving the pass rate of green pellets and increasing production efficiency. Attached Figure Description

[0044] Figure 1 This is a flowchart of the method for detecting and cleaning accumulated material on the chute of the disc pelletizer in an embodiment of the present invention;

[0045] Figure 2 This is a schematic diagram of the multi-cleaning area division in step S2 of the disc pelletizer chute material accumulation detection and cleaning method in an embodiment of the present invention;

[0046] Figure 3 This is a schematic diagram of the structure of the material accumulation detection and cleaning system for the disc pelletizer chute in an embodiment of the present invention;

[0047] Figure 4 This is a schematic diagram of the installation structure of the image acquisition unit of the disc pelletizer chute material accumulation detection and cleaning system relative to the disc pelletizer chute in an embodiment of the present invention.

[0048] Figure 5 This is a side view of the installation structure of the image acquisition unit and the cleaning unit of the disc pelletizer chute material accumulation detection and cleaning system in an embodiment of the present invention;

[0049] Figure 6 This is a side view of the cleaning unit in the material accumulation detection and cleaning system of the disc pelletizer chute in an embodiment of the present invention;

[0050] Figure 7 This is a schematic diagram of the structure of the first motion drive mechanism of the cleaning unit in the material accumulation detection and cleaning system of the disc baller's chute in an embodiment of the present invention;

[0051] Figure 8 This is a schematic diagram of the first and second motion drive mechanisms of the cleaning unit in the material accumulation detection and cleaning system of the disc baller's chute in an embodiment of the present invention.

[0052] Figure 9 This is a schematic diagram of the sliding component of the cleaning unit in the material accumulation detection and cleaning system of the disc pelletizer chute in an embodiment of the present invention;

[0053] Figure 10 This is a schematic diagram of the caster assembly of the cleaning unit in the material accumulation detection and cleaning system of the disc baller's chute in an embodiment of the present invention;

[0054] Figure 11 This is a schematic diagram of the scraper assembly of the cleaning unit in the material accumulation detection and cleaning system of the disc baller's chute in an embodiment of the present invention. Detailed Implementation

[0055] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, but the following embodiments are by no means intended to limit the present invention.

[0056] Example 1

[0057] See Figure 1 The specific steps of the detection and cleaning method for material accumulation on the chute of the disc pelletizer are described below.

[0058] S1. Under the condition of no sticking material and no green ball material flow, the image of the chute is acquired to obtain a background image background1 containing the chute body; the chute surface area in the background image background1 is divided into multiple cleaning areas to obtain a background grid image background2.

[0059] See Figure 2 In step S1, the specific method for obtaining the background grid image background2 is as follows:

[0060] S101. Define the surface of the chute 11 as plane S, and install the cleaning unit 9 in the empty area 13 on the side of the chute 11 away from the disc ballering machine 10. The cleaning unit 9 includes a first motion mechanism. The rotation drive position of the first motion mechanism is located at the same height as the center position of the disc ballering machine 10, so that it can swing around in the circumferential direction between the installation position of the cleaning unit 9 and the disc ballering machine 10, so that the motion range of the first motion mechanism can cover the plane S.

[0061] Based on this, a polar coordinate system A1 is constructed with the rotational drive position of the first motion mechanism as the origin, and the direction pointing horizontally to the center of the ball-forming plate is the 90° axis direction, and the direction pointed to after rotating 90° counterclockwise is the 0° axis direction.

[0062] S102. Using the origin of the polar coordinate system A1 as the endpoint, draw multiple rays at intervals of angle θ to evenly divide the surface of the feed plate 11 into multiple regions that are approximately triangular.

[0063] In this step, the angle θ between adjacent rays is set according to the area of ​​the chute, and the value of θ is generally in the range of 4° to 6°; in this embodiment, the value of θ is 5°.

[0064] S103. Using the origin of the polar coordinate system A1 as the center, draw arcs on the feeder plate 11 with radii Xa, 2Xa, 3Xa, ..., nXa in sequence. Based on the division in step S202, the surface of the feeder plate 11 is divided into several cleaning areas by multiple arcs.

[0065] In this step, Xa is the same as θ and is also set according to the area of ​​the chute; the value of Xa is generally in the range of 200mm to 350mm; in this embodiment, the value of Xa is 250mm.

[0066] S104, with a region area not less than Xa 2 Using / 2 as the standard, adjacent small cleanup areas are merged to obtain N cleanup areas, which are then numbered sequentially. The numbering method for the N cleanup areas is as follows: starting from the cleanup area far from the origin of polar coordinate system A1 and close to the 0° axis, the N cleanup areas are numbered sequentially from 1 to N in a serpentine arrangement.

[0067] See Figure 2 In this embodiment, the first step is to number the N cleaning areas from the side of the outline of the circle with the largest radius. The two cleaning areas located on the same outline are numbered 1 and 2 in order from the 0° axis to the 90° axis, starting from the side away from the origin of the polar coordinate system A1. Then, the three cleaning areas with a smaller radius are numbered 3, 4 and 5 in order from the 90° axis to the 0° axis. The four cleaning areas with a smaller radius are numbered 6, 7, 8 and 9 in order from the 0° axis to the 90° axis. This process continues until all N cleaning areas are numbered.

[0068] S2. In the pelletizing process, the same method as in step S1 is used to collect images of the chute containing the sticky material and the green pellet flow at set intervals, and the sticky material on the chute in the collected images is identified to obtain a marked image of the sticky material.

[0069] Specifically, the implementation steps of step S2 are described below.

[0070] S201. Perform differential processing and binarization processing on the acquired image to obtain a binarized image containing only the accumulated material and the green ball material flow.

[0071] Specifically, the processing steps of step S201 are as follows.

[0072] S2011. Perform grayscale processing on the background image from step S1 and the image acquired from step S2 respectively to obtain a grayscale background image and a grayscale spherical image.

[0073] In this step, since the acquired images are generally high-definition color images, they need to be converted to grayscale for easier subsequent processing. As a preferred embodiment, after converting the chute image to grayscale, further denoising and brightness / contrast normalization are performed to obtain a grayscale image with better processing results. The denoising process can employ, but is not limited to, Gaussian blurring and median filtering methods; the brightness / contrast normalization process can employ, but is not limited to, histogram equalization methods.

[0074] S2012. Based on the grayscale background image's grayscale pixel matrix B(x,y) and the grayscale sphere image's grayscale pixel matrix C(x,y), subtract the grayscale values ​​of corresponding pixels in each of the two grayscale pixel matrices, and take the absolute value to reassign the pixel value, thus obtaining a difference image. The expression for this processing step is: Diff(x,y)=|C(x,y)-B(x,y)|, where (x,y) are pixel coordinates.

[0075] S2013. Perform threshold-based binarization on the difference image to obtain the binarized image Binary-diff1. The specific processing steps are as follows:

[0076] Set a threshold T, and then sequentially evaluate the grayscale value Diff(x,y) of each pixel in the difference image:

[0077] 1) If Diff(x,y)≥T, then update the grayscale value of the pixel to 1 to represent adhesive or raw ball;

[0078] 2) If Diff(x,y) < T, then update the grayscale value of the pixel to 0 to represent the feeder.

[0079] Then, by reassigning the gray value of each pixel in the difference image, a binarized image is obtained.

[0080] In this step, the value of the threshold T can be adjusted according to the actual situation; in this embodiment, the threshold is 39.

[0081] S202. Distinguish between the accumulated material flow and the green pellet flow in the binarized image to obtain an image containing only the accumulated material feature values.

[0082] In step S202, the method for distinguishing between the accumulated material and the green pellet flow is as follows:

[0083] S2021. According to the set statistical period T, perform a morphological closing operation on the binarized image Binary-diff1 obtained by continuous acquisition and processing within the statistical period. That is, perform dilation and erosion processing on the binarized image Binary-diff1 to eliminate narrow breaks and thin grooves in the image, fill holes smaller than the structuring element, and keep the area and shape of the original object unchanged.

[0084] S2022. Traverse all connected components on all binarized images after processing in step S2021, and make the following judgments in sequence: If a connected component exists in M ​​frames or more of the binarized images, then determine that the connected component corresponds to the material accumulation, and retain the connected component in all binarized images; otherwise, determine that the connected component corresponds to the green ball material flow, and remove the connected component from all binarized images.

[0085] In step S2, the statistical period T is generally in the range of 45s to 90s. In this embodiment, the statistical period T is set to 60s. The number of image frames M is generally set to 70% to 90% of the total number of image frames acquired within the statistical period T. In this embodiment, the number of image frames M is set to 85% of the total number of image frames.

[0086] After step S2, all binarized images Binary-diff1 within each statistical period T are processed into Binary-diff2 containing only the accumulated material feature value.

[0087] S3. Overlay the binarized image Binary-diff2 with the background mesh image background2, and calculate the percentage W of connected components in each cleaned region of the background mesh image background2. n This is to determine the areas that need to be cleaned.

[0088] The specific implementation steps of step S3 are as follows:

[0089] S301. Set a threshold W0 to determine the necessity of cleaning the cleaning area;

[0090] In this step, the threshold W0 ranges from 50% to 70%; in this embodiment, W0 is set to 65%.

[0091] S302, adjust the pixel ratio W of connected components in each cleanup area. n Compare with threshold W0:

[0092] If W n If W ≥ 0, then the area to be cleaned is marked as 1, indicating that it needs to be cleaned;

[0093] If W nIf <W0, the area to be cleaned is marked as 0, indicating that it does not need to be cleaned.

[0094] S4. Count the number of areas m that need to be cleaned to determine whether to start cleaning.

[0095] The specific implementation steps of step S4 are as follows:

[0096] S401. Set the threshold M0 to determine the necessity of initiating cleanup;

[0097] In this step, the threshold M0 can be adjusted as needed during actual production; in this embodiment, the threshold M0 is set to 4%.

[0098] S402. Compare the number m of the areas that need to be cleaned with the threshold M0:

[0099] If m≥M0, then it is determined that the cleaning should begin and proceed to step S5;

[0100] If m < M0, it is determined that no cleaning is needed, and the process returns to step S2.

[0101] As a preferred technical solution of this embodiment, according to the actual production situation, the cleaning area that is prone to material accumulation can be set as the critical area. After completing step S3, if the cleaning area to be cleaned contains the critical area, it is directly determined to start cleaning and directly proceed to step S5; otherwise, step S4 is continued.

[0102] S5. For all the cleaning areas marked as 1 in step S3, form an array according to their numbers in ascending order, and use it as a cleaning path to control the cleaning unit to clean each cleaning area in sequence.

[0103] The specific cleaning method for each cleaning area on the cleaning path is as follows: Taking the four boundary lines surrounding the designated cleaning area as the movement boundaries of the cleaning unit, the first motion mechanism of the cleaning unit is controlled to swing back and forth between the two boundary lines in the circumferential direction of the cleaning area. At the same time, the second motion mechanism set on the first motion mechanism moves from far to near between the two boundary lines in the radial direction. The distance L of each movement is the cleaning width of the scraper connected to the bottom of the second motion mechanism, so that the scraper sweeps across the entire area of ​​the cleaning area and covers the cleaning area, ensuring that the accumulated material in the designated cleaning area is clear and complete.

[0104] In practice, the cleaning path is sent to the programmable logic controller (PLC), which drives the cleaning unit to sequentially clean the accumulated material in the cleaning area according to the cleaning path. Each cleaning area corresponds to the position information of its grid, including the angle θ between the two circumferential boundary lines of the cleaning area and the 0° axis on the polar coordinate system A1. aand θ b And the distances X1 and X2 of the two boundary lines in the radial direction from the origin of the polar coordinate system A1; furthermore, the programmable logic controller, based on θ a and θ b The first motion mechanism is driven to reciprocate. At the same time, after the first motion mechanism completes one reciprocating motion, the programmable logic controller drives the second motion mechanism to move a distance L according to X1 and X2 until the second motion mechanism moves from distance X1 to X2. The difference between X1 and X2 is Xa.

[0105] Example 2

[0106] See Figure 3 A material accumulation detection and cleaning system for a disc ballering machine chute includes a host computer control unit, a field control unit, an image acquisition unit 8, and a cleaning unit 9.

[0107] The host computer control unit is located in the central control room, and includes a first fiber optic transceiver 1, an industrial computer 2, and a display 3 connected in sequence. The first fiber optic transceiver 1 is used to transmit image information and control information. The industrial computer 2 is used to receive image information and analyze the image information and generate a cleaning path using the material accumulation detection and cleaning method of the disc ball maker chute described in Example 1. The display 3 is used to display the acquired images and image analysis results in real time.

[0108] The field control unit is located in the control cabinet at the ball-making production site. It includes a second fiber optic transceiver 4, a switch 5, and a programmable logic controller 7 (PLC). The second fiber optic transceiver 4 is connected to the first fiber optic transceiver 1 over a long distance via fiber optic cable to establish a remote communication channel between the production site and the central control room. The switch 5 is connected to the second fiber optic transceiver 4, the programmable logic controller 7, and the image acquisition unit 8, respectively, to serve as a bridge for information exchange and transmission, transmitting image and control information back and forth. The programmable logic controller 7 is connected to the cleaning unit 9 to perform positive and negative feedback control on the cleaning unit 9, so as to achieve timely and effective cleaning of the chute 11.

[0109] As a preferred technical solution in this embodiment, the field control unit also includes a touch screen 6, which is electrically connected to the switch 5 to enable on-site operators to control operations and adjust operation process parameters.

[0110] See Figure 4The image acquisition unit 8 is installed above the chute 11 of the disc pelletizer 10. It includes a camera 8-1 and a supplementary light 8-2. The camera 8-1 is set with its lens angled downwards and is fixed to the platform 8-4 by an angle-adjustable mounting bracket 8-3, so that the installation angle of the camera 8-1 can be adjusted to acquire an image containing the entire chute 11, which facilitates the subsequent analysis of the material accumulation on the chute 11. The platform 8-4 is a platform for manual observation and operation in the existing work area. The image acquisition angle of the camera 8-1 is preferably set so that the optical path axis of the camera is perpendicular to the chute 11. The supplementary light 8-2 is set on the side adjacent to the camera 8-1 and is also fixed to the platform 8-4 by a bracket to provide illumination compensation for the chute 11 below, ensuring that the image acquired by the camera 8-1 is clear. A pellet conveyor belt 12 is set below the chute 11.

[0111] In practical applications, the image information acquired by camera 8-1 is transmitted to industrial control computer 2 via the second fiber optic transceiver 4 and the first fiber optic transceiver 1 for image analysis. The instructions generated by the transceiver regarding the cleaning path are then transmitted by industrial control computer 2 to switch 5 via the first fiber optic transceiver 1 and the second fiber optic transceiver 4, and then sent to programmable logic controller 7 via switch 5. Programmable logic controller 7 controls cleaning unit 9 to clean the designated cleaning area on conveyor plate 11 sequentially according to the cleaning path.

[0112] See Figure 2 The cleaning unit 9 is located in the empty area 13 on the side of the chute 11, which is far away from the disc pelletizer 10, so as not to affect the normal production and discharge of raw pellets in the disc pelletizer when the machine is stopped.

[0113] See Figures 5 to 10 The cleaning unit 9 includes a first motion mechanism and a second motion mechanism; the first motion mechanism performs a reciprocating oscillating motion from one side of the conveyor plate 11 adjacent to the other side of the disc baller 10, and the second motion mechanism is located at the bottom of the first motion mechanism and can reciprocate on the first motion mechanism.

[0114] The first motion mechanism consists of a first motion drive mechanism 9-1 and a boom assembly 9-3. The first motion drive mechanism 9-1 includes a first geared motor 9-1-1, specifically a right-angle geared motor. The first output shaft and the second output shaft of the first geared motor 9-1-1 are respectively arranged vertically downwards and vertically upwards. The first output shaft is connected to a rotary encoder 9-1-3 to control the swing amplitude of the boom assembly 9-3 by real-time acquisition of the number of rotations of the first output shaft. The second output shaft is connected to the end of the boom assembly 9-3 to drive the boom assembly 9-3 to perform reciprocating swing motion in the horizontal direction. The first geared motor 9-1-1 is connected to a PLC via a first frequency converter 9-8-1; the rotary encoder 9-1-3 is also connected to the PLC.

[0115] In this embodiment, the rotating shaft of the rotary encoder 9-1-3 is fixedly connected to the first output shaft via a coupling, and its housing is fixed to the housing of the first geared motor 9-1-1 via the encoder bracket 9-1-4. The first geared motor 9-1-1 is connected to the platform bracket of the disc ball-making machine 10 via the first bracket 9-1-2. The first bracket 9-1-2 is an inverted L-shaped frame, which is specifically composed of a first horizontal plate and a first vertical plate that are vertically fixedly connected. The first vertical plate is fixedly connected to the platform bracket, and the first horizontal plate is fixedly connected to the motor flange on the top side of the first geared motor 9-1-1. The shaft end of the second output shaft of the first geared motor 9-1-1 passes through the through hole opened at the center of the first horizontal plate to the top of the first horizontal plate to connect with the boom assembly 9-3.

[0116] The boom assembly 9-3 includes a horizontally arranged long boom 9-3-1, one end of which is fixedly connected to the second output shaft of the first geared motor, so as to be driven by the first geared motor 9-1-1 to perform reciprocating swinging motion.

[0117] In this embodiment, the long arm 9-3-1 is an I-beam with end plates fixed at both ends, and a connecting flange 9-3-5 is provided on the bottom surface of the long arm 9-3-1. It is arranged opposite to the connecting flange provided at the second output shaft end of the first reduction motor 9-1-1. By connecting and fixing the two connecting flanges together, the second output shaft is fixedly connected to one end of the long arm 9-3-1.

[0118] The second motion mechanism includes a second motion drive mechanism 9-2, a chain assembly 9-4, and a slider assembly 9-5.

[0119] The second motion drive mechanism 9-2 is located adjacent to the first motion drive mechanism 9-1, and includes a second geared motor 9-2-1 and a first gear 9-4-2. The second geared motor 9-2-1 is fixed to the end of the long arm 9-3-1, and its output shaft is horizontally arranged on the end of the long arm 9-3-1, perpendicular to the second output shaft of the first geared motor 9-1-1. The first gear 9-4-2 is sleeved and fixed to the end of the output shaft of the second geared motor 9-2-1, so as to drive the second geared motor 9-2-1 to rotate. The second geared motor 9-2-1 is connected to the PLC through a second frequency converter 9-8-2.

[0120] In this embodiment, the second geared motor 9-2-1 is fixed to one side of the long arm 9-3-1 by the second bracket 9-2-2. Specifically, the second bracket 9-2-2 is a C-shaped frame, which is composed of an upper horizontal plate, a second vertical plate and a lower horizontal plate connected vertically in sequence and fixed to the end plate of the adjacent end of the long arm 9-3-1. The motor flange of the second geared motor 9-2-1 is fixed to the outer side of the second vertical plate, and its output shaft passes through the through hole opened at the center of the second vertical plate to the other side of the second vertical plate.

[0121] A laser rangefinder 9-2-3 is also installed on the top side of the second geared motor 9-2-1. It is specifically fixed on the upper horizontal plate of the second bracket 9-2-2 and connected to the PLC. The measuring end of the laser rangefinder 9-2-3 faces the other end of the long arm 9-3-1 and keeps its measuring laser beam parallel to the long arm 9-3-1.

[0122] The chain assembly 9-4 includes a chain 9-4-1 and a second gear 9-4-2; the second gear 9-4-2 is rotatably mounted at the other end of the long arm, and the chain is sleeved on the outside of the first gear 9-4-2 and the second gear 9-4-2, so that the three form a chain drive mechanism.

[0123] In this embodiment, a third support 9-4-3 is provided at the other end of the long arm 9-3-1. The third support 9-4-3 is a C-shaped frame, which is composed of an upper horizontal plate, a third vertical plate, and a lower horizontal plate that are vertically and fixedly connected in sequence and fixed to the adjacent end plate. A bearing seat 9-4-4 with a rotating bearing inside is installed on the third vertical plate. A gear shaft is inserted and fixed in the center hole of the rotating bearing. The second gear 9-4-2 is sleeved and fixed to the other end of the gear shaft so that it can rotate freely. The first gear 9-2-4 and the second gear 9-4-2 are the same size and are set in a way that they are at the same height and coplanar. Correspondingly, a strip-shaped through hole is opened longitudinally on the end plate at both ends of the long arm 9-3-1 so that the two ends of the chain 9-4-1 pass through the two strip-shaped through holes respectively and are sleeved on the outside of the first gear 9-2-4 and the second gear 9-4-2 to form a chain drive mechanism.

[0124] In practical applications, the first gear 9-2-4 serves as the driving gear, driven by the second reduction motor 9-2-1. The second gear 9-4-2 is the driven gear, and the two cooperate to drive the chain 9-4-1 to reciprocate.

[0125] The sliding assembly 9-5 is slidably mounted on the long arm 9-3-1 to reciprocate along the length of the long arm 9-3-1. Specifically, the sliding assembly 9-5 includes a sliding frame 9-5-1, which is sleeved on the outside of the long arm 9-3-1 and arranged symmetrically on both sides. Two freely rotatable top support wheels 9-5-4, two left support wheels 9-5-2, and two right support wheels are respectively spaced apart on the top plate, left side plate, and right side plate of the sliding frame 9-5-1. Each support wheel is arranged such that its wheel surface perpendicularly abuts against the adjacent side wall of the long arm 9-3-1, providing stable support between the sliding frame 9-5-1 and the long arm 9-3-1 while allowing... The sliding frame 9-5-1 can slide back and forth on the long arm 9-3-1; two chain buckles 9-5-3 are provided on each of the two ends of the top of the sliding frame 9-5-1 to fix the sliding frame 9-5-1 to the chain 9-4-1 through the two chain buckles 9-5-3, so that the sliding frame 9-5-1 can move back and forth on the long arm 9-3-1 with the chain 9-4-1; a laser rangefinder reflector 9-5-5 is vertically fixed on the top surface of the sliding frame 9-5-1, and its surface is opposite to the laser rangefinder 9-2-3, so that the laser rangefinder 9-2-3 can use the laser rangefinder reflector 9-5-5 to collect the displacement changes of the sliding component 9-5.

[0126] As another preferred technical solution of this embodiment, in order to further control the swing amplitude of the long arm 9-3-1, a first limit switch group is installed between the first motion drive mechanism 9-1 and the large arm assembly 9-3. Specifically, the first limit switch group includes a first motion axis origin limit switch 9-1-7, a first motion axis left limit switch 9-1-6, and a first motion axis right limit switch 9-1-5. The three are arranged at intervals in the middle on the top side of the first reduction motor 9-1-1 (that is, one end of the top surface of the first horizontal plate) and from the installation position of the long arm 9-3-1 to the disc ball-making machine 10. The first limit switch group also includes a first limit sensing block 9-3-4 fixed on the long arm 9-3-1. Its setting position is adapted to the above three limit switches so that when the long arm 9-3-1 swings from the installation position to the disc ball-making machine 10, the first limit sensing block 9-3-4 on it can be aligned with the three limit switches in sequence and emit a sensing signal.

[0127] Specifically, in combination Figure 2As shown, when the first limit sensor block 9-3-4 is aligned with the first motion axis origin limit switch 9-1-7, the long arm 9-3-1 is in the standby position; when the first limit sensor block 9-3-4 is aligned with the first motion axis left limit switch 9-1-6, the long arm 9-3-1 is located at one side boundary of the cleaning area on the chute 11, that is, it begins to enter the cleaning area; when the first limit sensor block 9-3-4 is aligned with the first motion axis right limit switch 9-1-5, the long arm 9-3-1 is located at the other side boundary of the cleaning area on the chute 11 and is adjacent to the disc baller.

[0128] In this embodiment, considering that the size of the conveyor plate 11 is small and its entire surface needs to be cleaned, the initial standby position of the long arm 9-3-1 is also the inner side of the edge of the conveyor plate (specifically, it can be set at a position 2° away from the 0° axis). The positions of the left limit switch 9-1-6 of the first motion axis and the origin limit switch 9-1-7 of the first motion axis are basically coincident. When the long arm 9-3-1 starts to swing, its left limit switch 9-1-6 of the first motion axis aligns with the first limit sensing block 9-3-4 and sends a sensing signal. The right limit switch 9-1-5 of the first motion axis is set on the inner side of the edge of the conveyor plate near the disc baller 8 so that when the long arm 9-3-1 is about to contact the disc baller 8, the right limit switch 9-1-5 of the first motion axis aligns with the first limit sensing block 9-3-4 and sends a sensing signal. In other embodiments, when the size of the chute 11 is designed to be large, only a portion of the chute 11 needs to be cleaned due to the passage of ball material. In this case, the positions of the left limit switch 9-1-6 and the origin limit switch 9-1-7 of the first motion axis are set at a large interval.

[0129] The three limit switches mentioned above are connected to the PLC to provide feedback signals to the PLC. The PLC then controls the rotation direction of the first geared motor 9-1-1 based on the feedback signals, thereby controlling the reciprocating swing motion of the first geared motor 9-1-1. In this embodiment, each limit switch specifically adopts a slot-type photoelectric sensor. That is, when the boom assembly 9-3 moves above any limit switch, the photoelectric switch is triggered, and the electrical signal is closed.

[0130] As another preferred technical solution of this embodiment, a first motion axis left safety switch 9-1-8 and a first motion axis right safety switch 9-1-9 are also provided on the top side of the first reduction motor 9-1-1 (that is, on the other end of the top surface of the first horizontal plate). The two are respectively located at corresponding positions on both sides of the first motion axis origin limit switch 9-1-7 and the first motion axis right limit switch 9-1-5 to safely limit the swing amplitude of the long arm 9-3-1. Specifically, when the long arm 9-3-1 swings towards its installation position, the sensing signal issued by the first motion axis origin limit switch 9-1-7 should be triggered first, and then the collision signal issued by the first motion axis left safety switch 9-1-8 should be triggered. Similarly, when the long arm 9-3-1 swings towards the disc ball-making machine 10, the sensing signal issued by the first motion axis right limit switch 9-1-5 should be triggered first, and then the collision signal issued by the first motion axis right safety switch 9-1-9 should be triggered.

[0131] In this embodiment, both the left safety switch 9-1-8 and the right safety switch 9-1-9 of the first motion axis are collision switches. They are connected to the PLC to feed back a collision signal to the PLC, so that the PLC can control the first reduction motor 9-1-1 to cut off the power according to the collision signal to stop the movement and avoid the long arm 9-3-1 swinging too much and hitting the on-site facilities.

[0132] As a preferred technical solution of this embodiment, in order to prevent the sliding frame 9-5-1 from moving beyond the set range on the long arm, a second limit switch group is installed between the sliding component 9-5 and the large arm component 9-3. Specifically, the second limit switch group includes a near-end limit switch 9-3-2 and a far-end limit switch 9-3-3, which are respectively disposed on both ends of the long arm 9-3-1 to limit the movement limit position of the sliding frame 9-5-1 on both ends of the long arm 9-3-1. Specifically, the near-end limit switch 9-3-2 is disposed on the long arm 9-3-1 adjacent to the first reduction motor 9-1-1 to issue a collision signal when the sliding frame 9-5-1 moves to collide with the near-end limit switch 9-3-2; the far-end limit switch 9-3-3 is disposed on the long arm 9-3-1 adjacent to the second gear 9-4-2 to issue a collision signal when the sliding frame 9-5-1 moves to the far-end limit switch 9-3-3.

[0133] In this embodiment, the near-end limit switch 9-3-2 and the far-end limit switch 9-3-3 are specifically ball-bearing rocker type limit switches. They are connected to the PLC to feed back a collision signal to the PLC, so that the PLC can control the second reduction motor 9-2-1 to cut off the power according to the collision signal to stop the movement and avoid the sliding frame 9-5-1 from moving too much and bumping into other mechanisms of the cleaning unit 9.

[0134] As a preferred technical solution of this embodiment, a safety contact edge 9-5-6 is attached circumferentially on the lower outer wall of the sliding frame 9-5-1. It serves as a pressure-sensitive sensor connected to the PLC. When the sliding frame 9-5-1 moves to contact other structures, it sends a sensing signal to the PLC due to the pressure change. The PLC then controls the second reduction motor 9-2-1 to cut off power based on the sensing signal to stop the movement and prevent the sliding frame 9-5-1 from moving too far and bumping into other mechanisms of the cleaning unit 9.

[0135] The cleaning unit 9 also includes a caster assembly 9-6, which specifically includes an adjustable-length connecting rod. Its top end is located at the bottom of the other end of the long arm, and its bottom end is connected to a traveling wheel 9-6-3. The axis of the traveling wheel is parallel to the axis of the long arm, so that when the long arm 9-3-1 swings, its other end can be kept horizontal by the traveling wheel 9-6-3 supported at its bottom. At the same time, the traveling wheel 9-6-3 moves on the chute 11 with the swinging motion.

[0136] In this embodiment, the connecting rod consists of a first connecting rod 9-6-1 and a second connecting rod 9-6-2. A flange is welded to the top end of the first connecting rod 9-6-1, which is then fixedly connected to the third horizontal plate of the second gear bracket 9-4-3 by bolts. The second connecting rod 9-6-2 is sleeved on the outside of the first connecting rod 9-6-1. Multiple through holes are evenly spaced on both rods, allowing the length of the connecting rod to be adjusted. The length is fixed by long bolts that pass through and fix the first connecting rod 9-6-1 and the second connecting rod 9-6-2. The traveling wheel 9-6-3 is fixed to the bottom end of the second connecting rod 9-6-4 by a wheel frame.

[0137] See Figure 11 The cleaning unit 9 also includes a scraper assembly 9-7, which specifically includes a scraper 9-7-1, which is arranged with the blade facing vertically downward and is fixed to the bottom surface of the sliding frame 9-5-1 by a vertically arranged scraper connecting rod 9-7-2; wherein, the scraper 9-7-1 is arranged in the same direction as the traveling wheel 9-6-3, and its blade abuts against the chute 11.

[0138] In this embodiment, a flange is welded and fixed to the top of the scraper connecting rod 9-7-2, and it is fixed to the sliding frame 9-5-1 by bolts passing through the flange; the bottom end of the scraper connecting rod 9-7-2 is connected to the scraper 9-7-1 by bolts; the distance between the scraper connecting rod 9-7-2 and the long arm 9-3-1 to the conveyor plate 11 is adapted to ensure that the scraper 9-7-1 abuts against the surface of the conveyor plate 11.

[0139] In practical applications, when the scraper 9-7-1 swings to the cleaning area with the long arm 9-3-1, its blade just cuts the material accumulated on the chute 11. Then, as the scraper 9-7-1 moves with the sliding frame 9-5-1, it scrapes off the material. The two actions work together to remove the material accumulated on the chute 11.

[0140] The working principle of cleaning unit 9 is described in detail below:

[0141] The long arm 9-3-1 swings under the drive of the first reduction motor 9-1-1. During the swing, the traveling wheels 9-6-3 of the caster assembly 9-6 slide and support the material conveyor 11, providing support. The extreme position of the swing stroke is limited by the right limit of the first motion axis 9-1-5 and the left limit of the first motion axis 9-1-6. Each time a designated cleaning area is cleaned, the reciprocating swing motion within the designated cleaning area is controlled by measuring the swing angle through the rotary encoder 9-1-3.

[0142] At the same time, the second reduction motor 9-2-1 drives the first gear 9-2-4 to rotate, so as to drive the sliding frame 9-5-1 to reciprocate on the long arm 9-3-1 through the chain transmission mechanism; wherein, the extreme position of the reciprocating movement of the sliding frame 9-5-1 is limited by the near end limit switch 9-3-2 and the far end limit switch 9-3-3; each time cleaning is performed on the designated cleaning area, the radial movement conversion control within the designated cleaning area is achieved by measuring the displacement change of the laser rangefinder 9-2-9 relative to the laser rangefinder reflector 9-5-5.

[0143] In actual operation, each movement of the cleaning unit 9 on the chute 11 causes the scraper assembly 9-7 to scrape off the accumulated material on the chute 11. Since only the scraper 9-7-1 partially contacts the chute 11, and according to the actual operation on site, the scraper 9-7-1 has little impact on the ball material feeding process, so it can be ignored. Therefore, when cleaning the chute 11, there is no need to stop the disc ballering machine 10. After the cleaning unit 9 completes a cleaning action, even if there is a problem that some accumulated material is not completely scraped off, it can still be judged by the next round of operation and the same cleaning area can be scraped off again.

Claims

1. A method for detecting and cleaning accumulated material on the chute of a disc pelletizing machine, characterized in that, The steps are as follows: S1. Under the condition of no sticking material and no green ball material flow, the image of the chute is acquired to obtain a background image containing the chute body; in the background image, the surface area of ​​the chute is divided into multiple numbered cleaning areas, and a background grid image is obtained. S2. During the pelletizing process, the same method as in step S1 is used to continuously acquire images of the chute and identify the sticky material on the chute in the acquired images to obtain a marked image with the sticky material. S3. Overlay the marked image with the background grid image to calculate the pixel ratio of the sticky area in each cleaning area, and determine the cleaning area that needs to be cleaned based on the ratio. S4. Count the number of areas that need to be cleaned, and determine whether to start cleaning based on the number; S5. When step S4 determines that cleaning has started, an array is formed for all areas that need to be cleaned, in ascending order of their numbers, and this array is used as the cleaning path. The cleaning unit is then controlled to clean each area in turn.

2. The method for detecting and cleaning accumulated material on the chute of a disc pelletizer according to claim 1, characterized in that, In step S1, the steps for obtaining the background grid image are as follows: S101. Define the surface of the chute as plane S, and set a cleaning unit for cleaning the chute in an empty area on the side of the chute away from the disc ballering machine. The cleaning unit includes a first motion mechanism. The first motion mechanism swings circumferentially between the cleaning unit installation position and the disc ballering machine through its rotation drive position, so that the motion range of the first motion mechanism can cover plane S. Based on this, a polar coordinate system A1 is constructed with the rotational drive position of the first motion mechanism as the origin, and the direction pointing horizontally to the center of the ball-making disk is the 90° axis direction, and the direction pointed to after rotating 90° counterclockwise is the 0° axis direction. S102. Using the origin of the polar coordinate system A1 as the endpoint, draw multiple rays at intervals of angle θ to evenly divide the surface of the feed chute into multiple regions. S103. Using the origin of the polar coordinate system A1 as the center, draw arcs on the feeder plate with radii of Xa, 2Xa, 3Xa, ..., nXa in sequence. Based on the division in step S202, the surface of the feeder plate is divided into several cleaning areas by multiple arcs. S104, with a region area not less than Xa 2 Using / 2 as the standard, adjacent small cleanup areas are merged to obtain N cleanup areas. The N cleanup areas are numbered sequentially. The numbering method for the N cleanup areas is as follows: starting from the cleanup area far from the origin of polar coordinate system A1 and close to the 0° axis, the N cleanup areas are numbered sequentially from 1 to N in a serpentine arrangement.

3. The method for detecting and cleaning accumulated material on the chute of a disc pelletizer according to claim 1, characterized in that, In step S2, the specific method for identifying the material adhering to the conveyor plate in the acquired image is as follows: S201. Perform differential processing and binarization processing on the acquired image to obtain a binarized image containing only the accumulated material and the green ball material flow; S202. Distinguish between the accumulated material and the green pellet flow in the binarized image to obtain an image containing only the accumulated material features; wherein, the method for distinguishing between the accumulated material and the green pellet flow is as follows: 1) Perform morphological closing operation on the binarized images continuously acquired and processed within the statistical period T, according to the set statistical period T. 2) Traverse all connected components on all binarized images after step S201 and make judgments in sequence: if a connected component exists in M ​​frames or more of the binarized images, then determine that the connected component corresponds to the accumulated material and retain the connected component in all binarized images; otherwise, determine that the connected component corresponds to the green ball material flow and remove the connected component from all binarized images; finally, the connected components retained on the binarized images are the material stuck on the chute.

4. The method for detecting and cleaning accumulated material on the chute of a disc pelletizer according to claim 1, characterized in that, The steps in step S201 are as follows: 1) Perform grayscale processing on the background image from step S1 and the image acquired from step S2 respectively to obtain a grayscale background image and a grayscale spherical image; 2) Based on the grayscale background image's grayscale pixel matrix B(x,y) and the grayscale sphere image's grayscale pixel matrix C(x,y), subtract the grayscale values ​​of two corresponding pixels in each of the two grayscale pixel matrices, and take the absolute value to reassign the pixel value, thereby obtaining the difference image. 3) Set a threshold T, and then judge the gray value Diff(x,y) of each pixel in the difference image in turn: if Diff(x,y)≥T, then update the pixel gray value to 1 and represent sticky material or green ball; if Diff(x,y)<T, then update the pixel gray value to 0 and represent chute; thus converting the difference image into a binary image.

5. The method for detecting and cleaning accumulated material on the chute of a disc pelletizer according to claim 1, characterized in that, In step S2, the specific method for identifying the material adhering to the conveyor plate in the acquired image is as follows: S201. During the pelletizing process under different working conditions, several images of the chute are collected, and the areas of material adhesion on the images are marked to obtain a material adhesion segmentation dataset. The working conditions include light intensity, material flow rate, wetness of the pellets, and the area of ​​material adhesion on the chute. S202. The YOLO network is trained using a sticky material segmentation dataset to construct a sticky material segmentation model, which can output a segmentation mask for each pixel in the image to distinguish sticky pixels from non-sticky pixels. S203. Input the image acquired in step S2 into the adhesive material segmentation model and output the image result marked with the segmentation mask on the pixel.

6. The method for detecting and cleaning accumulated material on the chute of a disc pelletizer according to claim 1, characterized in that, In step S5, the cleaning method for each cleaning area is as follows: taking the four boundary lines surrounding the designated cleaning area as the movement boundaries of the cleaning unit, the first motion mechanism of the cleaning unit is controlled to swing back and forth between the two boundary lines in the circumferential direction of the cleaning area. At the same time, the second motion mechanism set on the first motion mechanism moves from far to near between the two boundary lines in the radial direction. The distance L of each movement is the cleaning width of the scraper connected to the bottom of the second motion mechanism, so that the scraper sweeps across the entire area of ​​the cleaning area and covers the cleaning area.

7. A system for detecting and cleaning accumulated material on the chute of a disc pelletizing machine, characterized in that, include: The host computer control unit includes a first fiber optic transceiver (1), an industrial computer (2), and a display (3) connected in sequence; the industrial computer (2) uses the material accumulation detection and cleaning method of the disc ball maker chute as described in any one of claims 1 to 6 to detect material accumulation in the acquired image and generate a cleaning path; The field control unit includes a second fiber optic transceiver (4), a switch (5), and a programmable logic controller (7); the second fiber optic transceiver (4) is connected to the first fiber optic transceiver (1) via fiber optic cable to form a remote communication channel; the switch (5) is connected to the second fiber optic transceiver (4), the programmable logic controller (7), and the image acquisition unit (8) respectively to receive and transmit the image information acquired by the image acquisition unit (8) and to send the cleaning path to the programmable logic controller (7); The cleaning unit (9) is connected to the programmable logic controller (7), and the programmable logic controller (7) controls the cleaning unit (9) to complete the cleaning operation of the chute (11) according to the cleaning path.

8. The material accumulation detection and cleaning system for the disc pelletizer chute according to claim 7, characterized in that, The image acquisition unit (8) includes a camera (8-1) and a fill light (8-2); the camera (8-1) acquires an image containing the conveyor plate (11) with the camera optical path axis perpendicular to the conveyor plate (11), and the fill light (8-2) is set on the side adjacent to the camera (8-1) to provide illumination compensation for the conveyor plate (11).

9. The material accumulation detection and cleaning system for the disc pelletizer chute according to claim 7, characterized in that, The cleaning unit includes a first motion mechanism, a second motion mechanism, a caster assembly, and a scraper assembly; wherein, The first motion mechanism includes a first motion drive mechanism and a boom assembly; the first motion drive mechanism includes a first geared motor; the first output shaft of the first geared motor is connected to a rotary encoder, and its second output shaft is vertically upward; the boom assembly includes a horizontally arranged long arm, one end of which is fixedly connected to the shaft end of the second output shaft of the first geared motor; the first geared motor and the rotary encoder are respectively connected to a programmable logic controller. The second motion mechanism includes a second motion drive mechanism, a chain assembly, and a slider assembly. The second motion drive mechanism includes a second geared motor, whose output shaft is horizontally positioned and perpendicular to the second output shaft of the first geared motor. A laser rangefinder is mounted on the top side of the second geared motor, and a first gear is provided at the end of its output shaft. The chain assembly includes a chain and a second gear. The second gear is rotatably mounted at the other end of the long arm, and the chain is sleeved on the outside of the first and second gears to form a chain drive mechanism. The slider assembly includes a sliding frame that is slidably sleeved on the outside of the long arm and is fixedly connected to the chain. A laser rangefinder reflector that cooperates with the laser rangefinder is provided on the top. The second geared motor and the laser rangefinder are respectively connected to a programmable logic controller. The caster assembly includes an adjustable-length connecting rod, the top of which is fixed to the bottom of the other end of the long arm, and the bottom of which is connected to a traveling wheel, the axis of which is parallel to the axis of the long arm; the scraper assembly includes a scraper, which is set with the scraper head facing vertically downward and is fixed to the bottom of the sliding frame by a scraper connecting rod.

10. The material accumulation detection and cleaning system for the chute of the disc pelletizer according to claim 9, characterized in that, It also includes a first limit switch group and a second limit switch group; wherein, The first limit switch group includes a first motion axis origin limit switch, a first motion axis left limit switch, and a first motion axis right limit switch, which are respectively connected to the programmable logic controller. The three are arranged at a central interval on the top side of the first geared motor and from the long arm installation position to the disc ball forming machine. The first limit switch group also includes a first limit sensing block fixed on the long arm. Its setting position is such that, during the swing of the long arm from the installation position to the disc ball forming machine, it is positioned opposite to the three limit switches in turn at the standby position, one boundary of the cleaning area, and the other boundary of the cleaning area, and sends sensing signals. The second limit switch group includes a near-end limit switch and a far-end limit switch, which are respectively connected to the programmable logic controller. The two are respectively located at both ends of the long arm to generate a collision signal when the sliding frame moves to collide with the near-end limit switch or the far-end limit switch.

Images