A truck scale sensor rotation detection robot and method

Abstract

The application relates to a truck scale sensor rotation detection robot and method, and relates to the technical field of truck scale sensor detection. The robot comprises a tracked mobile chassis; a detection unit is arranged on the tracked mobile chassis; the detection unit comprises a mounting seat and an image acquisition module arranged in the mounting seat; the mounting seat is fixedly arranged on the tracked mobile chassis at a fixed elevation angle; a processing unit is further arranged on the tracked mobile chassis; the processing unit is electrically connected with the image acquisition module; the processing unit is used for acquiring a current image of a positioning mark arranged on a sensor and shot upward by the image acquisition module, and comparing the current image with a pre-stored reference mark to determine whether the sensor rotates. The application has the effect of realizing automatic detection of a small space at the bottom of a truck scale.

Description

Technical Field

[0001] This application relates to the field of truck scale sensor detection technology, and in particular to a truck scale sensor rotation detection robot and method. Background Technology

[0002] Truck scales, also known as weighbridges, are the main equipment used for weighing bulk goods. Their core components are multiple weighing sensors installed at the bottom of the weighing platform. In the industry, cheating on truck scales is common. One common cheating method is to manually rotate the sensor body to change the direction of force, causing the weighing result to be inaccurate.

[0003] Currently, the inspection of sensor rotation mainly relies on manual methods. Inspectors need to crawl into the narrow space under the weighbridge and visually observe whether the alignment marks drawn on the side of the sensor are aligned. This method has the following problems: First, it is labor-intensive and inefficient; second, the space under the weighbridge is narrow and dirty, and there are safety hazards for manual crawling in; third, the inspection results depend on the conscientiousness of the personnel and are prone to missed or mis-inspection.

[0004] Existing general-purpose inspection robots are too large to fit into the gap of less than 10cm between the weighing platform and the ground. Some solutions involve lifting the weighing platform before entering, but the lifting process is complex and poses safety risks. Therefore, there is an urgent need for an automatic inspection solution that can directly enter the narrow space under the weighing platform, has a simple structure, and is easy to operate. Summary of the Invention

[0005] To achieve simple, convenient, and easy-to-operate automatic detection of the narrow space at the bottom of a truck scale, this application provides a truck scale sensor rotation detection robot and method.

[0006] Firstly, the technical solution adopted in this application for a truck scale sensor rotation detection robot is as follows: A robot for detecting the rotation of a truck scale sensor includes a tracked mobile chassis. A detection unit is mounted on the tracked mobile chassis, the detection unit including a mounting base and an image acquisition module disposed within the mounting base. The mounting base is fixedly mounted on the tracked mobile chassis at a fixed elevation angle. A processing unit is also mounted on the tracked mobile chassis, the processing unit being electrically connected to the image acquisition module. The processing unit acquires a current image of an alignment mark set on the sensor, taken upwards by the image acquisition module, and compares this current image with a pre-stored reference mark to determine whether the sensor has rotated.

[0007] Preferably, the alignment mark is drawn manually and consists of a first marking line located on the side wall of the sensor housing and a second marking line located on the side wall of the sensor base connected end to end.

[0008] Preferably, the first marking line and the second marking line have different colors.

[0009] Preferably, the detection unit further includes at least one light source, the illumination direction of which is consistent with the shooting direction of the image acquisition module.

[0010] Preferably, the maximum height of the tracked mobile chassis is ≤80mm.

[0011] Preferably, the tracked mobile chassis adopts a flat design, and the tracked mobile chassis integrates a drive motor, a battery, and a wireless remote control receiver module.

[0012] Preferably, the elevation angle of the mounting base is preset to be between 45° and 60°.

[0013] Secondly, the detection method for a truck scale sensor rotation detection robot provided in this application adopts the following technical solution: A detection method for a truck scale sensor rotation detection robot includes the following steps: S1: The operator remotely controls the robot to enter the bottom of the weighing platform through the inspection port on the side of the truck scale; S2: Remotely move the robot so that the top of the robot is roughly directly below the sensor to be tested; S3: The image acquisition module takes a picture at a fixed upward angle to obtain the current image of the alignment mark on the sensor; S4: The processing unit identifies the first and second marker lines in the current image and calculates their relative offset at the seam. S5: If the offset exceeds the preset threshold, it is determined that the sensor has moved and an alarm signal is issued.

[0014] In summary, this application includes at least one of the following beneficial technical effects: 1. The robot in this application has excellent maneuverability, with the overall height controlled within 8cm. It can directly enter the bottom of the scale through the standard maintenance port without lifting the scale platform, making it safe and convenient. 2. The robot in this application has a very simple structure and high reliability. It adopts a fixed elevation angle mounting base and has no moving parts such as lifting or rotating parts. The structure is simple, the cost is low, the failure rate is low, and it is suitable for use in harsh environments. 3. The robot in this application is easy to modify and deploy. The markings are drawn manually with paint, without any disassembly or modification of the existing sensors. The cost is extremely low and it can be quickly and massively promoted. 4. The robot detection in this application is accurate and intuitive. It adopts a design with two-color marking lines connected end to end. The image recognition algorithm can quickly locate the mark based on color segmentation. It has strong anti-fouling and interference resistance and the detection results are accurate and reliable. Attached Figure Description

[0015] Figure 1 This is a three-dimensional schematic diagram of the overall structure of the robot according to an embodiment of this application.

[0016] Figure 2 This is a structural schematic diagram of the working state of the bottom of the weighing platform according to an embodiment of this application.

[0017] Figure 3 These are schematic diagrams of the sensor in normal state (a) and misaligned state after the sensor has been rotated (b).

[0018] Figure 4 This is a flowchart of the detection method of this application.

[0019] Explanation of reference numerals in the attached diagram: 1. Ring-shaped LED light source; 2. Fixed elevation angle mounting base; 3. Image acquisition module; 4. Tracked mobile chassis; 51. First marking line; 52. Second marking line; 8. Seam. Detailed Implementation

[0020] The following is in conjunction with the appendix Figure 1-4 This application will be described in further detail.

[0021] This application discloses a robot for detecting the rotation of a truck scale sensor. (Refer to...) Figure 1 and Figure 2 The system includes a tracked mobile chassis 4, with a maximum height of ≤80mm. The tracked mobile chassis 4 adopts a flat design and integrates a drive motor, battery, and wireless remote control receiver module. Operators can remotely control the robot's forward, backward, and turning movements via a wireless remote control. In addition, the tracked mobile chassis 4 is equipped with an alarm module (not shown in the figure), which includes a buzzer and an LED warning light.

[0022] Reference Figure 1 and Figure 2 A detection unit is installed on the tracked mobile chassis 4 and fixed to the top of the tracked mobile chassis 4. The detection unit includes a mounting base and an image acquisition module 3 installed in the mounting base. The mounting base is fixed on the tracked mobile chassis 4 at a fixed elevation angle. The elevation angle of the mounting base is preset to be between 45° and 60°. In this embodiment, the elevation angle of the mounting base is preset to be 50°. The optical axis of the image acquisition module 3 points obliquely upward to the side of the sensor. The detection unit also includes at least one light source. The illumination direction of the light source is consistent with the shooting direction of the image acquisition module 3. Specifically, the light source is a ring LED light source 1. The ring LED light source 1 is arranged around the lens of the image acquisition module 3, and its illumination direction is consistent with the shooting direction, providing sufficient illumination for the dark environment of the scale bottom.

[0023] Reference Figure 1 and Figure 2The image acquisition module 3 uses a high-resolution miniature industrial camera, and a processing unit is also set on the tracked mobile chassis 4. The processing unit is electrically connected to the image acquisition module 3 and runs an image recognition and comparison algorithm.

[0024] Reference Figure 3 The processing unit is used to acquire the current image of the alignment mark set on the sensor by the image acquisition module 3 shooting upwards, and compare the current image with the pre-stored reference mark to determine whether the sensor has rotated; the alignment mark is manually drawn and is composed of a first marking line 51 located on the side wall of the sensor housing and a second marking line 52 located on the side wall of the sensor base connected end to end; the first marking line 51 and the second marking line 52 have different colors, specifically, the first marking line 51 is red and the second marking line 52 is white.

[0025] During implementation, using two different colored paint pens (e.g., red and white), two vertical line segments, approximately 10mm long and 2mm wide, are drawn close to the seam 8 between the sensor housing and the immovable sensor base. The two lines must be aligned end-to-end at the seam 8. The line on the sensor housing is designated as the first marking line 51, and the line on the sensor base as the second marking line 52. After marking, the robot takes a photograph in a standard state. The processing unit extracts the feature information of the markings (including the color, position, and relative relationship of the two lines) and stores it in memory as a reference marking template.

[0026] The implementation principle of the truck scale sensor rotation detection robot in this embodiment is as follows: An operator carries the robot to the truck scale site, opens the inspection port cover on the side of the scale platform, and remotely controls the robot to enter the space under the scale platform through the inspection port. Since the robot's overall height is only 80mm, it can easily enter the narrow gap between the scale platform and the ground. The operator, using an auxiliary camera mounted on the robot (not shown in the figure, not mandatory) or based on experience, remotely controls the robot to move sequentially under the eight sensors. When the robot reaches approximately directly under the sensor to be inspected, the operator can fine-tune its position so that the mounting base is roughly aligned with the side of the sensor. At this time, the image acquisition module 3 shoots upwards at a fixed 50-degree angle, and the field of view completely covers the alignment marks on the side of the sensor. The ring LED light source 1 automatically turns on to provide supplementary lighting.

[0027] After the processing unit acquires the current image, it executes the following algorithm steps: First, the image is segmented based on the color space, and the red region and the white region are extracted respectively, namely the first marker line 51 and the second marker line 52.

[0028] Then, identify the endpoints of the two line segments that are closest to the seam 8, and calculate the pixel distance between the two endpoints in the image coordinate system.

[0029] If the distance between the pixels is less than a preset threshold (e.g., 2 pixels, corresponding to an actual physical offset of about 0.5mm), then it is determined that the two marker lines are aligned and the sensor has not rotated.

[0030] If the pixel distance is greater than or equal to the threshold, it is determined that the two marker lines are misaligned and the sensor has rotated.

[0031] At this time, the processing unit triggers the buzzer to sound an alarm, the LED warning light flashes, and at the same time sends the alarm information (including sensor number and misalignment image) to the operator's remote control screen or the background monitoring center via the wireless module.

[0032] After one sensor is checked, the operator remotely moves the robot to the next sensor location and repeats the above shooting and judgment process until all eight sensors have been checked.

[0033] Reference Figure 4 This application also provides a detection method for a truck scale sensor rotation detection robot, including the following steps: S1: The operator remotely controls the robot to enter the bottom of the weighing platform through the inspection port on the side of the truck scale; S2: Remotely move the robot so that the top of the robot is roughly directly below the sensor to be tested; S3: Image acquisition module 3 takes an upward shot at a fixed elevation angle to acquire the current image of the alignment mark on the sensor; S4: The processing unit identifies the first marker line 51 and the second marker line 52 in the current image and calculates their relative offset at the seam 8. S5: If the offset exceeds the preset threshold, it is determined that the sensor has moved and an alarm signal is issued.

[0034] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A robot for detecting the rotation of a truck scale sensor, characterized in that: The system includes a tracked mobile chassis; a detection unit is mounted on the tracked mobile chassis, the detection unit including a mounting base and an image acquisition module disposed within the mounting base, the mounting base being fixedly mounted on the tracked mobile chassis at a fixed elevation angle; a processing unit is also mounted on the tracked mobile chassis, the processing unit being electrically connected to the image acquisition module, the processing unit being used to acquire the current image of the alignment mark disposed on the sensor taken upward by the image acquisition module, and comparing the current image with a pre-stored reference mark to determine whether the sensor has rotated.

2. The truck scale sensor rotation detection robot according to claim 1, characterized in that: The alignment mark is drawn manually and consists of a first marking line located on the side wall of the sensor housing and a second marking line located on the side wall of the sensor base, connected end to end.

3. The truck scale sensor rotation detection robot according to claim 2, characterized in that: The first marking line and the second marking line have different colors.

4. The truck scale sensor rotation detection robot according to claim 1, characterized in that: The detection unit also includes at least one light source, the illumination direction of which is consistent with the shooting direction of the image acquisition module.

5. The truck scale sensor rotation detection robot according to claim 1, characterized in that: The maximum height of the tracked mobile chassis is ≤80mm.

6. The truck scale sensor rotation detection robot according to claim 1, characterized in that: The tracked mobile chassis adopts a flat design and integrates a drive motor, battery, and wireless remote control receiver module.

7. The truck scale sensor rotation detection robot according to claim 1, characterized in that: The elevation angle of the mounting base is preset to be between 45° and 60°.

8. A detection method applied to a robot as described in any one of claims 1-5, characterized in that, Includes the following steps: S1: The operator remotely controls the robot to enter the bottom of the weighing platform through the inspection port on the side of the truck scale; S2: Remotely move the robot so that the top of the robot is roughly directly below the sensor to be tested; S3: The image acquisition module takes a picture at a fixed upward angle to obtain the current image of the alignment mark on the sensor; S4: The processing unit identifies the first and second marker lines in the current image and calculates their relative offset at the seam. S5: If the offset exceeds the preset threshold, it is determined that the sensor has moved and an alarm signal is issued.

Images