Coal Flow Identification Using Background Subtraction on Scraper Conveyors
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Solution Overview
Problem
Existing coal flow detection methods on scraper conveyors are inadequate for the complex operating conditions and high vibration shocks, making accurate measurement challenging.
Innovation Solution
A coal flow identification method using a background subtraction algorithm, involving image preprocessing, region-of-interest delimiting, and image calibration to calculate coal flow volume, utilizing multiple cameras and filters to enhance accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If contact measurement mode (electronic belt scale) is used on belt conveyor, then measurement precision is improved, but adaptability to scraper conveyor operating conditions deteriorates
Solution Approach 1:
The patent replaces contact mechanical measurement (electronic belt scale) with non-contact optical measurement (camera-based background subtraction algorithm). This substitution enables the system to adapt to scraper conveyor conditions where contact measurement fails due to high vibration and complex operating environments, while maintaining measurement precision through image processing and pixel-area calculation methods.
2Adaptability or versatility
If non-contact measurement method is used, then adaptability to scraper conveyor conditions is improved, but measurement precision deteriorates due to dust and vibration interference
Solution Approach 1:
The patent applies preliminary action by performing background subtraction to create a reference background image before measuring coal flow. This pre-processing step establishes a baseline that separates the stationary background from moving coal particles, enabling accurate motion region extraction even in dusty and vibrating environments. The background model is updated dynamically to adapt to changing conditions while maintaining measurement precision.
Solution Approach 2:
The patent introduces an intermediary processing layer between the camera and measurement result: the background subtraction algorithm acts as a mediator that filters out dust and vibration interference by separating static background elements from dynamic coal flow. This intermediary processing step converts raw images into motion region masks, eliminating the direct impact of environmental disturbances on measurement precision.
3Measurement precision
If multiple cameras are used to capture images, then measurement precision is improved through multiple viewpoints, but device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the measurement task across multiple cameras positioned at different angles. Each camera captures a specific viewpoint of the coal flow, and the system processes each image independently through background subtraction. This segmentation allows the system to reconstruct a comprehensive 3D understanding of coal flow volume by combining measurements from multiple perspectives, improving precision while keeping each individual camera simple.
Data Source
AI summary
A coal flow identification method based on a background subtraction algorithm, including: S1: simultaneously capturing images of a coal layer at a coal unloading end of a scraper conveyor using a plurality of cameras mounted on a reversed loader in parallel; S2: determining an optimal sequence image of simultaneously captured three sequence images, and delimiting a region of interest; S3: extracting a motion region outline in the image; S4: performing line adding repair on the motion region outline, and padding the repaired motion region outline; S5: calculating a number of pixels in a motion region, and calculating an area of the motion region according to a scale; and S6: calculating a coal flow volume.