Scraper conveyor chain breakage monitoring device and system based on machine vision

Abstract

The utility model relates to the technical field of mining scraper conveyor equipment, in particular to a scraper conveyor chain breakage monitoring device and system based on machine vision. The device comprises a mounting bracket 1, a camera mounting frame 2 and an image acquisition and processing module 3, the mounting bracket 1 is detachably and fixedly mounted above a machine head of the scraper conveyor; the mounting bracket 1 is provided with a sliding chute 11, and the camera mounting frame 2 is provided with a mounting plate 21 matched with the sliding chute 11; the camera mounting frame 2 is mounted on the mounting bracket 1 in a sliding manner through the mounting plate 21; and the image acquisition and processing module 3 is detachably mounted in the camera mounting frame 2. The mounting bracket, the camera mounting frame and the image acquisition and processing module are detachable, so that the equipment is more flexible to mount and easier to adjust, the mounting difficulty is reduced, and the working efficiency is improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of mining scraper conveyor equipment, and in particular to a scraper conveyor chain breakage monitoring device and system based on machine vision. BACKGROUND

[0002] The scraper conveyor is the main transportation equipment of the fully mechanized coal mining face in the underground coal mine. During the operation of the scraper conveyor, various factors such as excessive coal loading, uneven working face, and foreign matter jamming cause the chain to be repeatedly subjected to impact load, resulting in phenomena such as severe chain wear and tear and fatigue damage, and chain breakage faults often occur. The chain breakage fault not only affects production, but also damages the scraper conveyor and causes the entire fully mechanized working face to stop in serious cases, greatly reducing the production efficiency of the enterprise and causing huge economic losses. Therefore, the chain breakage monitoring of the scraper chain of the scraper conveyor is particularly important under the requirements of the smart mine at present.

[0003] At present, the chain tension is calculated by monitoring parameters such as power, sag, and cylinder pressure on the scraper conveyor to realize the prediction of the scraper chain breakage. Before the scraper conveyor is transported to the underground working site, the equipment needs to be fixed and installed on the scraper conveyor, and it is difficult to adjust the equipment after it reaches the site.

[0004] Therefore, the existing scraper conveyor chain breakage monitoring device has the problems of inconvenient fixing or adjustment, which greatly inconveniences the installation, maintenance, and transportation. CONTENT OF THE INVENTION

[0005] Therefore, it is necessary to provide a scraper conveyor chain breakage monitoring device and system based on machine vision to solve the problems of inconvenient adjustment, installation, maintenance, and transportation of the equipment in the prior art.

[0006] A scraper conveyor chain breakage monitoring device based on machine vision, comprising a mounting bracket 1, a camera mounting frame 2, and an image acquisition and processing module 3.

[0007] The mounting bracket 1 is detachably fixed and installed above the head of the scraper conveyor. The mounting bracket 1 is provided with a sliding groove 11, and the camera mounting frame 2 is provided with a mounting plate 21 matched with the sliding groove 11. The camera mounting frame 2 is slidably installed on the mounting bracket 1 through the mounting plate 21. The image acquisition and processing module 3 is detachably installed in the camera mounting frame 2.

[0008] Preferably, the mounting bracket 1 comprises a bracket leg 12, and the mounting bracket 1 is detachably fixed and installed above the head of the scraper conveyor through the bracket leg 12.

[0009] The support leg 12 is telescopic, and the telescopic length of the support leg 12 can be fixed through the height positioning hole 13 and the pin.

[0010] Preferably, the upper end of the support leg 12 is fixedly installed with one end of the reinforcing rib 13, and the other end of the reinforcing rib 13 is fixedly installed with the mounting support 1.

[0011] Preferably, the two ends of the sliding groove 11 are provided with limit blocks.

[0012] Preferably, the camera mounting frame 2 is provided with a protective cover 22, and the image acquisition and processing module 3 is detachably installed in the protective cover 22.

[0013] Preferably, the protective cover 22 is provided with a shooting window 23, and the image acquisition and processing module 3 acquires the image information of the scraper conveyor chain through the shooting window 23.

[0014] Preferably, the mounting plate 21 is provided with a fixing hole 24, and the relative position of the mounting plate 21 and the sliding groove 11 is fixed through the fixing hole 24.

[0015] Preferably, the fan 4 is detachably installed with the mounting support 1, and the wind direction of the fan 4 at least blows toward the scraper conveyor chain.

[0016] Compared with the prior art, the beneficial effects of the present application are that each part such as the mounting support, the camera mounting frame and the image acquisition and processing module can be detached, so that the equipment installation is more flexible and easier to adjust, thereby reducing the installation difficulty; and the position of the image acquisition and processing module can be finely adjusted as needed to obtain images that meet the requirements, thereby effectively improving the work efficiency. The real-time three-dimensional image of the chain movement is obtained through the image acquisition and processing module to monitor the chain breakage, which can monitor the chain state in real time and accurately. BRIEF DESCRIPTION OF DRAWINGS

[0017] Figure 1 The structure diagram of the scraper conveyor chain breakage monitoring device based on machine vision provided by the embodiment of the present application is shown.

[0018] Figure 2 The structure diagram of the mounting support 1 provided by the embodiment of the present application is shown.

[0019] Figure 3 The structure diagram of the support leg 12 provided by the embodiment of the present application is shown.

[0020] Figure 4 The structure diagram of the camera mounting frame 2 provided by the embodiment of the present application is shown.

[0021] Figure 5A schematic diagram of the structure of the machine vision-based scraper conveyor chain breakage monitoring system 200 provided in the embodiments of this application. Detailed Implementation

[0022] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Please see Figures 1 to 4 , Figure 1 This is a schematic diagram of the machine vision-based scraper conveyor chain breakage monitoring device provided in this application embodiment. The machine vision-based scraper conveyor chain breakage monitoring device includes a mounting bracket 1, a camera mounting frame 2, and an image acquisition and processing module 3.

[0024] Mounting bracket 1 can be detachably and fixedly installed above the head of scraper conveyor 100. The scraper and chain at the head of the scraper conveyor are relatively clean, without excessive coal sludge affecting them; it can also be flexibly installed according to different usage environments.

[0025] The mounting bracket 1 is provided with a sliding groove 11, and the camera mounting frame 2 is provided with a mounting plate 21 that mates with the sliding groove 11. The camera mounting frame 2 is slidably mounted on the mounting bracket 1 via the mounting plate 21. The image acquisition and processing module 3 is detachably mounted inside the camera mounting frame 2. Through the sliding groove 11 and the mounting plate 21 that mates with the sliding groove 11, the camera mounting frame 2 can be moved horizontally, so that the image acquisition and processing module 3 can be adjusted to a suitable position to acquire image data that meets the requirements.

[0026] Furthermore, limit blocks are provided at both ends of the slide groove 11 to prevent the mounting plate 21 from falling off the slide groove 11. The limit blocks can be fixed to both ends of the slide groove with bolts. At the same time, after removing the fixing blocks, the mounting plate can be slid out from both ends of the slide groove and removed, which facilitates the disassembly and installation of the mounting plate.

[0027] Furthermore, such as Figure 2 The diagram shows the structure of the mounting bracket 1. The mounting bracket 1 includes bracket legs 12, which are detachably and fixedly mounted on the head of the scraper conveyor. In addition, a mounting plate can be provided at the bottom of the bracket legs 12, which is then detachably and fixedly mounted to the head of the scraper conveyor by bolts or other means.

[0028] like Figure 3The structure diagram of the shown support leg 12. The support leg 12 is a telescopic structure, and the telescopic length of the support leg 12 can be fixed through the height positioning hole 13 and the latch. Through the telescopic structure of the support leg, on the one hand, it can be adjusted according to the different height of the scraper conveyor, and on the other hand, it can adjust the height between the image acquisition processing module 3 and the scraper conveyor 100 as needed to obtain the image data that meets the needs.

[0029] Further, as shown in the structural schematic diagram of the camera mounting frame 2. The camera mounting frame 2 is provided with a protective cover 22, and the image acquisition processing module 3 can be detachably installed in the protective cover 22, which can avoid the image acquisition processing module 3 from being bumped and the like. The protective cover 22 is provided with a shooting window 23, which is usually arranged below the protective cover 22, and the image acquisition processing module 3 obtains the scraper conveyor chain image information through the shooting window 23. The shooting window ensures that the image acquisition processing module can normally obtain the chain image information and realize the monitoring function. Figure 4

[0030] Further, the mounting plate 21 is provided with a fixing hole 24, and the relative positions of the mounting plate 21 and the sliding groove 11 are fixed through the fixing hole 24. After adjusting the horizontal position of the camera mounting frame 2, the relative positions of the mounting plate 21 and the sliding groove 11 are fixed through the fixing hole 24, so as to avoid the change of the field of view of the image acquisition processing module 3.

[0031] Further, one end of the reinforcing rib 13 is fixedly installed on the upper end of the support leg 12, and the other end of the reinforcing rib 13 is fixedly installed on the mounting support 1. The design of the reinforcing rib enhances the overall structural strength of the support and improves the durability of the equipment.

[0032] Further, the scraper conveyor chain breakage monitoring device based on machine vision further comprises a fan 4, which is detachably installed on the mounting support 1, and the direction of the fan 4 blows at least the scraper conveyor chain. Dust on the surface of the chain is blown away by the fan 4 to improve the information quality of the obtained chain image.

[0033] In addition, the image acquisition processing module 3 can include a stereo camera, a line laser, and a processor, etc. The stereo camera is used to obtain real-time three-dimensional images when the chain moves, the line laser can assist in positioning and enhance the contrast of the image to ensure that the features on the surface of the chain are clearly visible. Therefore, a laser binocular stereo camera with higher integration can be used. The processor can process the image information collected by the stereo camera to monitor the breakage of the scraper conveyor chain.

[0034] When the image acquisition processing module 3 monitors the breakage of the scraper conveyor chain, the following steps can be taken for breakage monitoring:​

[0035] S101: Obtain real-time three-dimensional images of the chain in motion through a stereo camera.

[0036] The stereo camera is composed of a pair of lenses installed at a certain distance to capture images of the chain from different angles. The stereo camera can use a binocular stereo camera, which can be placed above the chain. When the chain is in motion, the stereo camera continuously captures a sequence of images of the chain. To ensure image quality, the stereo camera needs to be configured with appropriate lighting conditions. A line laser can be used to assist positioning to enhance the contrast of the images and ensure that the surface features of the chain are clearly visible. In addition, the distance between the stereo camera and the scraper chain should be kept within a reasonable range to ensure the resolution and coverage of the images.

[0037] S102: Obtain real-time state data of the chain according to the real-time three-dimensional images.

[0038] After obtaining the real-time three-dimensional images of the chain, the processor extracts the key feature information of the chain through image processing algorithms. These information includes but not limited to the position, size, shape and other geometric properties of the chain link. First, the algorithm will preprocess the three-dimensional images, including filtering and denoising, enhancing contrast, etc., to improve the accuracy of subsequent feature extraction. Then, the calibration algorithm is used to determine the position coordinates of the chain link in three-dimensional space, and the straight line and circular arc fitting algorithm is used to calculate the actual distance and relative position between chain links. In addition, the pitch data between adjacent chain links and the circular angle between chain links need to be calculated, which are part of the real-time state data of the chain.

[0039] S103: Compare the real-time state data with the standard data, and determine that the chain has a risk of chain breakage if it does not meet the preset threshold.

[0040] After obtaining the real-time state data of the chain, the processor compares these data with the preset standard data. The standard data usually comes from the statistical data of the chain in normal working state, or the ideal state parameters provided by the manufacturer. If the real-time state data deviates from the standard data beyond the preset threshold, it indicates that the chain may be worn or damaged, and there is a risk of chain breakage. At this time, the system will generate a warning information, and notify the operator through the alarm or display screen to check or maintain, to prevent chain breakage failure from causing production interruption or other more serious consequences.

[0041] Further, according to the real-time three-dimensional image, real-time surface texture data of the chain is obtained. By analyzing the surface texture data in the real-time three-dimensional image, the state information of the chain is obtained. The surface texture data can help identify defects such as wear and tear and cracks on the surface of the chain, thereby more comprehensively evaluating the health of the chain. This method can effectively supplement the state evaluation based on geometric features, improving the comprehensiveness and accuracy of monitoring.

[0042] Further, an industrial camera can also be arranged at a suitable position of the chain to obtain a two-dimensional image of the chain. By obtaining a real-time two-dimensional image of the chain through the industrial camera, two-dimensional image data is introduced based on the three-dimensional image, and is analyzed together with the three-dimensional image, thereby obtaining more rich chain state data. The two-dimensional image can provide additional perspective information, and can also combine the two-dimensional image and the three-dimensional image to enhance the identification efficiency and quality of the chain surface texture, make up for the shortcomings of the three-dimensional image in some aspects, and improve the reliability and accuracy of the overall monitoring.

[0043] Further, the state data of the chain within a preset time period is analyzed to obtain the state change of the chain within the preset time period. By analyzing the state data of the chain within a certain time period, the trend of the state change of the chain can be observed, which helps to early detect potential chain breakage risks. By continuously monitoring and recording the state data of the chain, a state change curve can be drawn, which, in combination with real-time image analysis, can improve the accuracy of real-time image recognition and provide accurate and reliable scientific basis for predictive maintenance and early warning.

[0044] Based on an inventive concept, as Figure 5 shown, the application also provides a machine vision-based scraper conveyor chain breakage monitoring system 200, which comprises the machine vision-based scraper conveyor chain breakage monitoring device as described above, and a host computer. The host computer is used to receive data from the image acquisition and processing module. The host computer can communicate with the image acquisition and processing module through a communication interface or other wired or wireless means. Remote monitoring can be realized through the host computer. In addition, one host computer can simultaneously communicate with multiple machine vision-based scraper conveyor chain breakage monitoring devices, effectively improving the automation degree of the entire operation system.

[0045] In summary, in the scheme provided by the application, the installation bracket, the camera mounting frame, and the image acquisition and processing module can be detached, which greatly simplifies the installation and maintenance of the equipment, enhances the application range, and greatly improves the work efficiency. In addition, the real-time monitoring of the scraper conveyor chain state through the three-dimensional image can timely detect potential chain breakage risks and effectively improve the accuracy of monitoring, providing a scientific basis for preventive maintenance and improving the safety production level in coal mines.

Claims

1. A machine vision based flight conveyor chain break monitoring device, characterized in that, It comprises a mounting bracket (1), a camera mounting frame (2) and an image acquisition processing module (3). The mounting bracket (1) is detachably fixedly installed above the head of the scraper conveyor; the mounting bracket (1) is provided with a sliding groove (11), the camera mounting frame (2) is provided with a mounting plate (21) matched with the sliding groove (11); the camera mounting frame (2) is slidably installed on the mounting bracket (1) through the mounting plate (21); and the image acquisition processing module (3) is detachably installed in the camera mounting frame (2).

2. The apparatus of claim 1, wherein, The mounting bracket (1) comprises a bracket leg (12), and the mounting bracket (1) is detachably fixedly installed above the head of the scraper conveyor through the bracket leg (12). The bracket leg (12) is of a telescopic structure, and the telescopic length of the bracket leg (12) can be fixed through a height positioning hole (13) and a bolt.

3. The apparatus of claim 2, wherein, The upper end of the bracket leg (12) is fixedly installed with one end of a reinforcing rib, and the other end of the reinforcing rib is fixedly installed with the mounting bracket (1).

4. The apparatus of claim 1, wherein, Both ends of the sliding groove (11) are provided with limiting blocks.

5. The apparatus of claim 1, wherein, The camera mounting frame (2) is provided with a protective cover (22), and the image acquisition processing module (3) is detachably installed in the protective cover (22).

6. The apparatus of claim 5, wherein, The protective cover (22) is provided with a shooting window (23), and the image acquisition processing module (3) acquires the image information of the scraper conveyor chain through the shooting window (23).

7. The apparatus of claim 5, wherein, The mounting plate (21) is provided with a fixing hole (24), and the relative position of the mounting plate (21) and the sliding groove (11) is fixed through the fixing hole (24).

8. The device of any one of claims 1 to 7, wherein, It further comprises a fan (4), which is detachably installed with the mounting bracket (1), and the wind direction of the fan (4) blows at least to the scraper conveyor chain.

9. A machine vision based flighted conveyor chain breakage monitoring system, characterized by, It comprises the machine vision-based scraper conveyor chain breakage monitoring device according to any one of claims 1 to 8, and a host computer, which is used for receiving the data of the image acquisition processing module.

Images