A belt deviation detection device based on image acquisition

Abstract

The utility model discloses a kind of belt deviation detection device based on image acquisition, including mounting bracket, conveying belt, runner, connecting frame, image detector and cleaning device, the runner is rotatably connected inside the mounting bracket, the conveying belt is connected with runner surface cover, the connecting frame is installed on the surface of mounting bracket, the image detector is fixedly connected inside the connecting frame. The utility model cleaning device, gear is rotated by air cylinder driving gear plate, gear drives moving plate and cleaning cotton to image detector cleaning, realizes the dust adsorbed by fast cleaning image detector detection end, improve the practicability of equipment, solve the problem that simply relying on visual detection in prior art is easy to fail in harsh working conditions, realize double protection mechanism, greatly improve the adaptability and stability of equipment, effectively improve the reliability of equipment in extreme environment.

Description

Technical Field

[0001] This utility model relates to the field of belt misalignment detection technology, and in particular to a belt misalignment detection device based on image acquisition. Background Technology

[0002] In industrial production, belt conveyors are widely used in the material transport process. However, belt misalignment is one of the common problems in the operation of belt conveyors. If it is not detected and dealt with in time, it will lead to material spillage, accelerated belt wear, and even safety accidents. Traditional belt misalignment detection methods, such as mechanical contact detection, are easily affected by environmental factors and have low detection accuracy. Manual monitoring has problems such as low efficiency and poor timeliness. Therefore, using an image acquisition-based belt misalignment detection device can perform real-time visual inspection of the belt and can detect belt misalignment in real time and accurately.

[0003] However, the existing equipment has the following shortcomings: when the existing equipment is in use, the detection end of the image detector is prone to dust accumulation, making it difficult for the equipment to take clear pictures between the conveyor belt and the roller, which affects the normal use of the equipment.

[0004] Therefore, we propose an image acquisition-based belt misalignment detection device to address the problems mentioned above. Utility Model Content

[0005] The purpose of this invention is to address the shortcomings of existing technologies where the detection end of image detectors easily attracts dust, affecting the normal operation of the equipment. Therefore, this invention proposes a belt misalignment detection device based on image acquisition.

[0006] To achieve the above objectives, this utility model adopts the following technical solution: a belt misalignment detection device based on image acquisition, comprising a mounting frame, a transmission belt, a rotating wheel, a connecting frame, an image detector, and a cleaning device. The rotating wheel is rotatably connected inside the mounting frame, the transmission belt is sleeved and connected to the surface of the rotating wheel, the connecting frame is mounted on the surface of the mounting frame, the image detector is fixedly connected inside the connecting frame, and the cleaning device is fixedly disposed on the lower surface of the image detector. The cleaning device includes a connecting column and a gear. The connecting column is fixedly connected to the lower surface of the image detector, the gear is rotatably connected to the lower surface of the connecting column, a movable plate is fixedly connected to the side of the gear, and cleaning cotton is fixedly connected to the upper surface of the movable plate by screws. The cleaning cotton is attached to the detection end of the image detector.

[0007] Furthermore, a toothed plate is meshed with the side of the gear, and a cylinder is fixedly connected to the end surface of the toothed plate away from the gear. By setting the toothed plate, the gear can be rotated, reducing the situation where the gear is difficult to rotate during use.

[0008] Furthermore, a support frame is fixedly connected to the surface of the cylinder.

[0009] Furthermore, a connecting block is fixedly connected to the surface of the support frame. The connecting block is fixedly connected to the surface of the image detector. The connecting block is provided to facilitate the limiting of the support frame.

[0010] Furthermore, an auxiliary component is fixedly provided on the surface of the mounting bracket. The auxiliary component includes a mounting block and a pressing hole. The mounting block is fixedly connected to the outer surface of the mounting bracket, and the pressing hole is opened on the side of the connecting bracket. The connecting bracket is inserted into the interior of the mounting block. A limit hole is opened on the side of the mounting block, and a limit block is slidably connected inside the pressing hole. The limit block is inserted into the interior of the limit hole. By setting the limit block, the connecting bracket can be limited, reducing the possibility that the connecting bracket may easily detach from the interior of the mounting block during use, making it difficult to fix the image detector.

[0011] Furthermore, a first spring is fixedly connected to the end of the limiting block away from the limiting hole, and the end of the first spring away from the limiting block is fixedly connected inside the pressure hole. The first spring is provided to facilitate the application of a reset spring force to the limiting block.

[0012] Furthermore, a pressure rod is fixedly connected to the upper surface of the limiting block near the first spring. The pressure rod is slidably connected inside the pressure hole. The pressure rod facilitates the movement of the limiting block.

[0013] The mounting bracket is symmetrically provided with redundant detection modules on both sides. The redundant detection modules include a mounting base, a contact sensor, and a flexible swing arm.

[0014] The mounting base is fixedly connected to the side wall of the mounting frame near the edge of the conveyor belt. One end of the elastic swing arm is hinged to the mounting base, and the other end extends to the upper side of the conveyor belt. The contact sensor is fixedly installed on the surface of the mounting base and located on the swing path of the elastic swing arm. The distance between the elastic swing arm and the conveyor belt is 5-10mm. When the conveyor belt deviates and contacts the elastic swing arm, the elastic swing arm swings and triggers the contact sensor.

[0015] Furthermore, the end of the elastic rocker arm is provided with a wear-resistant roller, which makes rolling contact with the surface of the conveyor belt.

[0016] Furthermore, the redundant detection module is connected in parallel with the image detector signal, and the detection mode switching is achieved through the control unit;

[0017] When the image detector's sharpness threshold is ≥90%, the image detection mode is used;

[0018] When the clarity threshold is less than 90%, it automatically switches to the contact detection mode of the redundant detection module.

[0019] Compared with the prior art, the advantages and positive effects of this utility model are as follows:

[0020] 1. This utility model effectively cleans the detection end of the image detector by setting up a cleaning device, which can quickly remove dust adhering to the detection end of the image detector. This reduces the situation where the detection end of the image detector easily attracts dust during the use of existing equipment, making it difficult for the equipment to clearly capture images between the conveyor belt and the rotating wheel, thus affecting the normal use of the equipment. This cleaning device uses a cylinder to drive a gear plate to rotate a gear, which in turn drives a moving plate and cleaning cotton to clean the image detector, achieving rapid cleaning of dust adhering to the detection end of the image detector and improving the practicality of the equipment.

[0021] 2. This utility model effectively installs the image detector by setting an auxiliary component, which enables rapid installation of the image detector. It reduces the need for tools to install and remove the bolts, which are usually used to fix the image detector's connecting frame to the mounting frame surface. The use of tools is too cumbersome and results in low user efficiency. This auxiliary component enables rapid installation of the image detector, making it convenient for users and improving their installation efficiency.

[0022] 3. This utility model welds mounting seats on both sides of the mounting frame. The mounting seat positions must ensure an 8mm gap between the elastic swing arm and the edge of the conveyor belt. The elastic swing arm is made of spring steel, and a polyurethane wear-resistant roller is installed at its end to reduce belt wear. The contact sensor uses a waterproof micro switch, and the signal is connected to the control unit. Normal mode: The image detector analyzes the edge position of the conveyor belt in real time. Switching condition: When the system detects that the blur of 3 consecutive frames of images is >10%, the redundant detection module is automatically activated. Contact detection: Belt deviation pushes the elastic swing arm to swing until it triggers the micro switch, generating an emergency stop signal. When the image detector's recognition clarity decreases due to dust, fog, or lens contamination, the system automatically switches to contact detection mode. The elastic swing arm senses belt deviation through physical contact, triggering the contact sensor to generate an alarm signal. This design solves the problem of easy failure under harsh conditions when relying solely on visual detection in existing technologies, realizing a dual protection mechanism, greatly improving the adaptability and stability of the equipment, and effectively enhancing the reliability of the equipment in extreme environments. Attached Figure Description

[0023] Figure 1 This is a three-dimensional structural diagram of a belt misalignment detection device based on image acquisition according to this utility model;

[0024] Figure 2This is a bottom view of the belt misalignment detection device based on image acquisition according to this utility model.

[0025] Figure 3 This is a partial structural schematic diagram of a belt misalignment detection device based on image acquisition according to this utility model;

[0026] Figure 4 This invention relates to a belt misalignment detection device based on image acquisition. Figure 3 Enlarged structural diagram at point A in the middle;

[0027] Figure 5 This invention relates to a belt misalignment detection device based on image acquisition. Figure 3 Enlarged structural diagram at point B;

[0028] Figure 6 This is a schematic diagram of the redundant detection module of a belt misalignment detection device based on image acquisition according to this utility model.

[0029] Explanation of reference numerals in the attached drawings: 1. Mounting frame; 2. Conveyor belt; 3. Rotary wheel; 4. Connecting frame; 5. Image detector; 6. Cleaning device; 61. Moving plate; 62. Cleaning cotton; 63. Connecting column; 64. Gear; 65. Toothed plate; 66. Cylinder; 67. Support frame; 68. Connecting block; 7. Auxiliary component; 71. Mounting block; 72. Pressing hole; 73. Limiting hole; 74. Limiting block; 75. Pressing rod; 76. First spring; 8. Redundant detection module; 81. Mounting base; 82. Contact sensor; 83. Elastic swing arm; 84. Wear-resistant roller. Detailed Implementation

[0030] like Figures 1-6 As shown, this utility model provides a technical solution: a belt misalignment detection device based on image acquisition, including a mounting frame 1, a transmission belt 2, a rotating wheel 3, a connecting frame 4, an image detector 5, and a cleaning device 6. The rotating wheel 3 is rotatably connected inside the mounting frame 1, the transmission belt 2 is sleeved and connected to the surface of the rotating wheel 3, the connecting frame 4 is installed on the surface of the mounting frame 1, and the image detector 5 is fixedly connected inside the connecting frame 4.

[0031] Mounting frame 1 is welded from high-strength steel, and its frame structure has been mechanically optimized to withstand the tension and vibration generated by the conveyor belt 2 during operation. The conveyor belt 2 is made of wear-resistant and tear-resistant rubber material with anti-slip texture to ensure stable material conveying. The roller 3 is forged from high-quality alloy steel, and its surface has been quenched, resulting in high hardness and wear resistance. It is equipped with high-precision bearings, allowing for flexible rotation and low noise. The connecting frame 4 is made of aluminum alloy, which is lightweight yet strong. Its hollow design reduces weight while ensuring structural stability. The image detector 5 is equipped with a high-resolution industrial camera and a wide-angle lens, with a built-in image processing chip, which can quickly and accurately capture image information of the contact area between the conveyor belt 2 and the roller 3.

[0032] The following section will describe in detail the specific settings and functions of its cleaning device 6 and auxiliary components 7.

[0033] In this embodiment: the cleaning device 6 is fixedly installed on the lower surface of the image detector 5. The cleaning device 6 includes a connecting column 63 and a gear 64. The connecting column 63 is fixedly connected to the lower surface of the image detector 5. The gear 64 is rotatably connected to the lower surface of the connecting column 63. A movable plate 61 is fixedly connected to the side of the gear 64. A cleaning cotton 62 is fixedly connected to the upper surface of the movable plate 61 by screws. The cleaning cotton 62 is attached to the detection end of the image detector 5. The cleaning cotton 62 is made of soft, highly absorbent fiber material with a moderate thickness. It can effectively clean dust without causing wear to the detection end of the image detector 5. At the same time, the cleaning cotton 62 can be replaced by screw installation.

[0034] A toothed plate 65 is meshed with the side of the gear 64. A cylinder 66 is fixedly connected to the end surface of the toothed plate 65 away from the gear 64. The cylinder 66 is a small pneumatic actuator with fast response speed and stable thrust, which can accurately control the moving distance of the toothed plate 65.

[0035] In this embodiment: by setting the toothed plate 65, the gear 64 can be rotated, reducing the situation where the gear 64 is difficult to rotate during use.

[0036] A support frame 67 is fixedly connected to the surface of cylinder 66.

[0037] A connecting block 68 is fixedly connected to the surface of the support frame 67. The connecting block 68 is fixedly connected to the surface of the image detector 5. The connecting block 68 is provided to facilitate the limiting of the support frame 67.

[0038] In this embodiment: An auxiliary component 7 is fixedly provided on the surface of the mounting bracket 1. The auxiliary component 7 includes a mounting block 71 and a pressing hole 72. The mounting block 71 is fixedly connected to the outer surface of the mounting bracket 1. The pressing hole 72 is opened on the side of the connecting bracket 4. The connecting bracket 4 is inserted into the interior of the mounting block 71. A limiting hole 73 is opened on the side of the mounting block 71. A limiting block 74 is slidably connected inside the pressing hole 72. The limiting block 74 is inserted into the interior of the limiting hole 73.

[0039] In this embodiment: by setting the limiting block 74, the connecting frame 4 can be limited, which reduces the possibility that the connecting frame 4 may easily detach from the interior of the mounting block 71 during use, making it difficult to fix the image detector 5.

[0040] A first spring 76 is fixedly connected to one end of the limiting block 74 away from the limiting hole 73. The other end of the first spring 76 away from the limiting block 74 is fixedly connected inside the pressure hole 72. The first spring 76 is provided to facilitate the application of a reset spring force to the limiting block 74.

[0041] A pressure rod 75 is fixedly connected to the upper surface of the limiting block 74 near the first spring 76. The pressure rod 75 is slidably connected inside the pressure hole 72. The pressure rod 75 is provided to facilitate the movement of the limiting block 74.

[0042] The mounting bracket 1 is symmetrically provided with redundant detection modules 8 on both sides. The redundant detection module 8 includes a mounting base 81, a contact sensor 82 and an elastic swing rod 83.

[0043] The mounting base 81 is fixedly connected to the side wall of the mounting frame 1 near the edge of the conveyor belt 2. One end of the elastic swing rod 83 is hinged to the mounting base 81, and the other end extends to the upper side of the conveyor belt 2. The contact sensor 82 is fixedly disposed on the surface of the mounting base 81 and is located on the swing path of the elastic swing rod 83. The distance between the elastic swing rod 83 and the conveyor belt 2 is 5-10mm. When the conveyor belt 2 deviates and contacts the elastic swing rod 83, the elastic swing rod 83 swings and triggers the contact sensor 82.

[0044] The end of the elastic swing arm 83 is provided with a wear-resistant roller 84, which makes rolling contact with the surface of the conveyor belt 2.

[0045] The redundant detection module 8 is connected in parallel with the image detector 5, and the detection mode is switched through the control unit;

[0046] When the sharpness threshold of image detector 5 is ≥90%, image detection mode is adopted;

[0047] When the clarity threshold is less than 90%, it automatically switches to the contact detection mode of the redundant detection module 8.

[0048] In this embodiment: when the image detector 5 experiences a decrease in clarity due to dust, fog, or lens contamination, the system automatically switches to contact detection mode. The elastic swing arm 83 senses belt misalignment through physical contact, triggering the contact sensor 82 to generate an alarm signal. This design solves the problem of easy failure under harsh conditions when relying solely on visual detection in existing technologies, achieving a dual protection mechanism, significantly improving the adaptability and stability of the equipment, and effectively enhancing the reliability of the equipment in extreme environments. Mounting seats 81 are welded on both sides of the mounting frame 1. The position of the mounting seats 81 must ensure that the elastic swing arm 83 maintains an 8mm gap with the edge of the conveyor belt 2. The elastic swing arm 83 is made of spring steel, and a polyurethane wear-resistant roller 84 is installed at its end to reduce belt wear. The contact sensor 82 uses a waterproof micro switch, and the signal is connected to the control unit. Normal mode: The image detector 5 analyzes the edge position of the conveyor belt 2 in real time. Switching condition: When the system detects that the blur of 3 consecutive frames of images is >10%, the redundant detection module 8 is automatically activated: Contact detection: Belt misalignment pushes the elastic swing arm 83 to swing until it triggers the micro switch, generating an emergency stop signal.

[0049] Working Principle: When using the equipment, the user installs the image detector 5 on the surface of the mounting bracket 1 and then performs visual inspection on the contact end between the conveyor belt 2 and the rotating wheel 3. During operation, the user activates the cylinder 66 to move the toothed plate 65. The toothed plate 65 moves, causing the gear 64 to rotate on the surface of the connecting column 63. The rotation of the gear 64 causes the moving plate 61 to move the cleaning cotton 62, which then cleans the lower surface of the image detector 5. By setting up the cleaning device 6, the detection end of the image detector 5 is effectively cleaned, quickly removing dust adhering to it. This reduces the problem of dust easily adhering to the detection end of the image detector 5, which makes it difficult for the equipment to clearly capture images between the conveyor belt 2 and the rotating wheel 3, affecting normal operation. This cleaning device 6, through the cylinder 66 driving the toothed plate 65 to rotate the gear 64, and the gear 64 driving the moving plate 61 and the cleaning cotton 62 to clean the image detector 5, achieves rapid cleaning of dust adhering to the detection end of the image detector 5, improving the practicality of the equipment.

[0050] When the connecting frame 4 is disassembled, the user presses the pressure rod 75 to move the limiting block 74 inside the pressure hole 72. Then, the movement of the limiting block 74 causes the first spring 76 to displace and deform, generating elastic force. Subsequently, the limiting block 74 disengages from the limiting hole 73, and the connecting frame 4 is released from its restraint and can move mechanically. By setting the auxiliary component 7, the image detector 5 can be installed effectively, achieving the function of quickly installing the image detector 5. This reduces the need for tools to install and remove the connecting frame 4 of the image detector 5 from the surface of the mounting frame 1, which is usually fixed with bolts. The use of tools is too cumbersome and results in low user efficiency. This auxiliary component 7 enables the rapid installation of the image detector 5, making it convenient for users to install and improving their installation efficiency.

[0051] When the image detector 5 experiences a decrease in clarity due to dust, fog, or lens contamination, the system automatically switches to contact detection mode. The elastic swing arm 83 senses belt misalignment through physical contact, triggering the contact sensor 82 to generate an alarm signal. This design solves the problem of easy failure under harsh conditions when relying solely on visual detection in existing technologies, achieving a dual protection mechanism, significantly improving the adaptability and stability of the equipment, and effectively enhancing the reliability of the equipment in extreme environments. Mounting seats 81 are welded to both sides of the mounting frame 1. The position of the mounting seats 81 must ensure that the elastic swing arm 83 maintains an 8mm gap with the edge of the conveyor belt 2. The elastic swing arm 83 is made of spring steel, and a polyurethane wear-resistant roller 84 is installed at its end to reduce belt wear. The contact sensor 82 uses a waterproof micro switch, and the signal is connected to the control unit. Normal mode: The image detector 5 analyzes the edge position of the conveyor belt 2 in real time. Switching condition: When the system detects that the blur of 3 consecutive frames of images is >10%, the redundant detection module 8 is automatically activated: Contact detection: Belt misalignment pushes the elastic swing arm 83 to swing until it triggers the micro switch, generating an emergency stop signal.

Claims

1. A belt misalignment detection device based on image acquisition, comprising a mounting frame (1), a conveyor belt (2), a pulley (3), a connecting frame (4), an image detector (5), and a cleaning device (6), characterized in that: The rotating wheel (3) is rotatably connected inside the mounting frame (1); The conveyor belt (2) is sleeved and connected to the surface of the wheel (3); The connecting frame (4) is mounted on the surface of the mounting frame (1); The image detector (5) is fixedly connected inside the connecting frame (4); The cleaning device (6) is fixedly installed on the lower surface of the image detector (5). The cleaning device (6) includes a connecting column (63) and a gear (64). The connecting column (63) is fixedly connected to the lower surface of the image detector (5). The gear (64) is rotatably connected to the lower surface of the connecting column (63). A moving plate (61) is fixedly connected to the side of the gear (64). A cleaning cotton (62) is fixedly connected to the upper surface of the moving plate (61) by screws. The cleaning cotton (62) is attached to the detection end of the image detector (5).

2. The belt misalignment detection device based on image acquisition according to claim 1, characterized in that: The gear (64) is meshed with a toothed plate (65) on its side, and a cylinder (66) is fixedly connected to the end surface of the toothed plate (65) away from the gear (64).

3. The belt misalignment detection device based on image acquisition according to claim 2, characterized in that: A support frame (67) is fixedly connected to the surface of the cylinder (66).

4. The belt misalignment detection device based on image acquisition according to claim 3, characterized in that: A connecting block (68) is fixedly connected to the surface of the support frame (67), and the connecting block (68) is fixedly connected to the surface of the image detector (5).

5. The belt misalignment detection device based on image acquisition according to claim 1, characterized in that: An auxiliary component (7) is fixedly provided on the surface of the mounting bracket (1). The auxiliary component (7) includes a mounting block (71) and a pressing hole (72). The mounting block (71) is fixedly connected to the outer surface of the mounting bracket (1). The pressing hole (72) is opened on the side of the connecting bracket (4). The connecting bracket (4) is inserted into the interior of the mounting block (71). A limiting hole (73) is opened on the side of the mounting block (71). A limiting block (74) is slidably connected inside the pressing hole (72). The limiting block (74) is inserted into the interior of the limiting hole (73).

6. The belt misalignment detection device based on image acquisition according to claim 5, characterized in that: The end of the limiting block (74) away from the limiting hole (73) is fixedly connected to a first spring (76), and the end of the first spring (76) away from the limiting block (74) is fixedly connected inside the pressure hole (72).

7. A belt misalignment detection device based on image acquisition according to claim 6, characterized in that: The limiting block (74) has a pressure rod (75) fixedly connected to the upper surface of one end near the first spring (76), and the pressure rod (75) is slidably connected inside the pressure hole (72).

8. The belt misalignment detection device based on image acquisition according to claim 1, characterized in that: The mounting bracket (1) is symmetrically provided with redundant detection modules (8) on both sides. The redundant detection module (8) includes a mounting base (81), a contact sensor (82), and an elastic swing arm (83). The mounting base (81) is fixedly connected to the side wall of the mounting frame (1) near the edge of the conveyor belt (2). One end of the elastic swing rod (83) is hinged to the mounting base (81), and the other end extends to the upper side of the conveyor belt (2). The contact sensor (82) is fixedly set on the surface of the mounting base (81) and located on the swing path of the elastic swing rod (83). The distance between the elastic swing rod (83) and the conveyor belt (2) is 5-10mm.

9. A belt misalignment detection device based on image acquisition according to claim 8, characterized in that: The end of the elastic swing arm (83) is provided with a wear-resistant roller (84), which makes rolling contact with the surface of the conveyor belt (2).

Images