阅读说明：本技术 一种皮带输送机跑偏检测装置及自动调整方法 (Deviation detection device for belt conveyor and automatic adjustment method ) 是由 刘银奎 刘新华 华德正 郭潇墙 张晓光 郝敬宾 刘晓帆 周皓 路和 刘浩 王勇 于 2021-09-18 设计创作，主要内容包括：本发明公开了一种皮带输送机跑偏检测及自动调整方法,包括视觉检测模块和托辊控制模块。首先通过安装在皮带输送机中部的视觉检测模块,分别获取皮带输送机工作时的中部皮带运行图像、中部前后方运行图像及中部煤流信息,使用伽马和分数阶进行图像增强处理,对处理后的图像进行Canny边缘检测以获取托辊与皮带边缘信息,通过皮带中部前后的托辊和皮带边缘直线计算出跑偏角度,再根据中部边缘检测得出的信息检测出横向跑偏量；视觉检测模块的线激光相机获得的皮带中部煤流信息来计算皮带的受力情况,最后通过托辊控制模块根据皮带受力情况及偏移量对皮带跑偏进行实时修正,及时有效的检测出皮带的跑偏量并及时进行调整,实现煤炭输送安全生产的目的。(The invention discloses a method for detecting and automatically adjusting deviation of a belt conveyor. Firstly, respectively acquiring a middle belt running image, a middle front and rear running image and middle coal flow information when a belt conveyor works through a visual detection module arranged in the middle of the belt conveyor, performing image enhancement processing by using gamma and fractional orders, performing Canny edge detection on the processed image to acquire carrier roller and belt edge information, calculating a deviation angle through carrier rollers in front and rear of the middle of the belt and the belt edge straight line, and then detecting a transverse deviation amount according to the information obtained by the middle edge detection; the stress condition of the belt is calculated according to the coal flow information in the middle of the belt, which is obtained by a line laser camera of the visual detection module, and finally the deviation of the belt is corrected in real time through the carrier roller control module according to the stress condition and the offset of the belt, so that the deviation of the belt is timely and effectively detected and timely adjusted, and the purpose of safe production of coal conveying is realized.)

1. The utility model provides a belt conveyor off tracking detection device which characterized in that: comprises that

The visual detection module is erected right above a middle belt (4) of the belt conveyor and consists of a bearing frame (6), a high-definition camera (1) and a line laser camera (2) which are arranged on the bearing frame (6);

and the carrier roller adjusting modules (5) are positioned on the inner side of the bearing frame (6), are respectively arranged on two sides of the bottom of the belt (4), and are composed of bearing bearings (8) and moving hydraulic cylinders (7) connected to two ends of the bearing bearings (8).

2. The belt conveyor deviation detecting device of claim 1, wherein: high-definition cameras (1) arranged at two ends of the vision acquisition module acquire images of the left side edge and the right side edge of the belt (4); the line laser range finder (2) in the middle of the coal material collecting device is used for measuring the height h (u) from the top end of the coal material (3) to the collecting module frame; the front camera and the rear camera in the middle of the vision acquisition module are used for acquiring front and rear images of the middle belt (4); the carrier roller adjusting module (5) further pushes a bearing (8) installed at a carrier roller shaft end (9) by adjusting the propelling quantity delta L of the movable hydraulic cylinder (7) up and down, and the change of an included angle theta between the carrier roller and the conveyor belt frame can be realized by hydraulic up and down pushing.

3. An automatic adjustment method of the belt conveyor deviation detection device based on claim 1 is characterized in that: the automatic adjustment method comprises the following steps

Step S1: acquiring image data, wherein four high-definition cameras (1) on a vision acquisition module acquire a video image I when a belt works; the middle line laser distance meter (2) measures the distance from the coal material (3) to the top beam of the bearing frame (6);

step S2: preprocessing image data, namely extracting key frames of a video image I acquired from a high-definition camera (1), and enhancing the frame image by using gamma and a fractional order image to obtain an image G; carrying out data denoising processing on the height information obtained by the middle line laser range finder (2);

step S3: image data analysis, Canny edge detection of the image G, and identification of coordinate points B [ B ] on the belt and conveyor belt frame lines₁,b₂,b₃......b_n]And D [ D ]₁,d₂,d₃......d_n]；

Step S4: calculating the deviation of the belt, and calculating the horizontal offset delta L of the belt aiming at the coordinate points acquired by the left high-definition camera and the right high-definition camera of the acquisition module; the angle offset delta theta of the belt can be calculated according to the middle high-definition camera of the acquisition module; calculating the coal flow loaded on the belt, and calculating the load Q of the belt according to the height information acquired by the laser range finder in the middle of the acquisition module and the belt speed v;

step S5: adjusting the deviation of the belt, and calculating the adjustment quantity delta of the belt carrier roller bracket according to the deviation quantity delta L, delta theta and the load Q of the belt_Lθ。

4. The automatic adjusting method for deviation detection of the belt conveyor according to claim 3, characterized in that: in the step S2, the image enhancement utilizes gamma transformation and fractional order image enhancement, the gamma transformation is used for enhancing the illumination of the image, and the transformation parameter γ is 0.5; the fractional order image enhancement fractional order coefficient is 2/3; and the height information obtained by the laser range finder adopts a wavelet transformation denoising mode.

5. The automatic adjusting method for deviation detection of the belt conveyor according to claim 3, characterized in that: in step S3, after the image is subjected to edge detection, 50 coordinate points on the belt and carriage edge lines in the areas of I to VI are extracted.

6. The automatic adjusting method for deviation detection of the belt conveyor according to claim 1, characterized in that: in the step S3, the step of calculating the belt deviation amount includes the steps of calculating regression lines of 50 corresponding points of each zone,regression coefficient The regression line equation isRespectively calculating the distance [ d ] between the regression lines of the 6 regions₁,d₂,d₃,d₄,d₅,d₆]。

7. The automatic adjusting method for deviation detection of the belt conveyor according to claim 6, characterized in that: if the condition is satisfiedThe belt has no angle deviation, thenIf the deviation does not meet the requirement, the belt has the angle deviation,(b_iregression coefficient of edge line of endothelial zone in I-VI region), horizontal deviation is DeltaL ═ d₃-d₄|。

8. The automatic adjusting method of the belt conveyor deviation detecting device according to claim 3, characterized in that: in the step S4, the method for calculating the coal flow rate comprises

Wherein rho is the density of the coal material; v is the belt speed of the belt; m₁、M₂The coal flow rates of the left side and the right side of the belt are respectively; l is a coal material starting coordinate point on the left side of the belt, m is a coordinate point in the middle of the conveying frame, and n is a coal material ending coordinate point on the right side of the belt; h (u), G (u) are respectively the height coordinate functions of the coal material and the roller frame.

9. The automatic adjusting method for deviation detection of the belt conveyor according to claim 3, characterized in that: the device comprises a specific step of calculating the floating adjustment angle of the carrier roller according to the deviation quantity delta L and delta thetaThen according to the coal flow M of the left side and the right side of the conveying belt₁、M₂Judging the adjusting position of the carrier roller if M₁≥M₂The rising delta of the left carrier roller needs to be adjusted_LθOr right idler drop delta_Lθ(ii) a If M is₁≤M₂The left idler roller descending delta needs to be adjusted_LθOr right idler rising delta_Lθ。

10. The belt conveyor deviation detecting and automatic adjusting method according to claim 9, characterized in that: the device utilizes the telescopic hydraulic cylinder to adjust the carrier roller up and down so as to realize the adjustment of the angle between the carrier roller and the conveyor belt frame.

Technical Field

The invention relates to a belt conveyor deviation detection device, in particular to a belt conveyor deviation detection and automatic adjustment method, and belongs to the technical field of belt transportation monitoring control.

Background

The belt conveyor is the important equipment of coal mine transportation coal material, because the coal material piles up the influence of inhomogeneous belt atress that leads to, coal material impact belt etc. factor on the belt, the belt is after long-time operation, and the belt off tracking condition takes place often, and when the belt off tracking reaches the certain degree, the belt can trigger and be used for preventing inclined scram device, causes the operating system to shut down, influences the production process. The belt deviation also increases the axial force borne by the roller and the carrier roller, and causes the damage of the roller shaft and the carrier roller bearing. If the belt is in the off tracking state for a long time, the belt can be turned over, the stress on the single side of the belt exceeds the longitudinal tensile force of the belt, and therefore potential safety hazards such as transverse tearing of the belt are caused, and the problems of timely finding of the belt off tracking and off tracking correction of the belt off tracking need to be solved urgently.

The existing coal mine belt deviation monitoring mode mainly determines deviation amount and processes deviation through a deviation switch sensor, however, the actual coal mine production environment is complex, more deviation switch sensors need to be installed on two sides of the running belt, and in the detection mode, magnetic interference of adjacent sensors mainly exists in the running process of the belt, the output is in an unstable state, and data interpretation is influenced; the belt deviation switch and the protection device also need to be stopped regularly for calibration and testing, the underground conveying belt is long, manpower and time need to be input for detection, and the underground production efficiency of the coal mine can be affected.

Disclosure of Invention

The invention aims to provide a method for detecting and automatically adjusting deviation of a belt conveyor in order to solve the problem.

The invention realizes the purpose through the following technical scheme: a deviation detection and automatic adjustment method for a belt conveyor comprises

The visual detection module is erected right above a belt in the middle of the belt conveyor and consists of a bearing frame, a high-definition camera and a line laser camera, wherein the high-definition camera and the line laser camera are arranged on the bearing frame;

and the carrier roller adjusting modules are positioned on the inner side of the bearing frame, are respectively arranged on two sides of the bottom of the belt and are composed of bearing bearings and movable hydraulic cylinders connected to two ends of the bearing bearings.

As a still further scheme of the invention: high-definition cameras arranged at two ends of the vision acquisition module acquire images of the left side edge and the right side edge of the belt; the line laser range finder in the middle of the coal bunker is used for measuring the height h (u) from the top end of the coal bunker to the acquisition module frame; the front camera and the rear camera in the middle of the vision acquisition module are used for acquiring images of the front part and the rear part of the middle belt; the carrier roller adjusting module pushes a bearing installed at the end of the carrier roller shaft by adjusting the propelling quantity delta L of the movable hydraulic cylinder up and down, and the change of an included angle theta between the carrier roller and the conveyor belt frame can be realized by hydraulic up and down pushing.

An automatic adjusting method of a deviation detecting device of a belt conveyor comprises the following steps

Step S1: acquiring image data, wherein four high-definition cameras on a visual acquisition module acquire a video image I when a belt works; the middle line laser distance measuring instrument measures the distance from the coal material to the top beam of the bearing frame;

step S2: preprocessing image data, extracting key frames of a video image I acquired from a high-definition camera, and enhancing the frame image by using gamma and fractional order images to obtain an image G; carrying out data denoising processing on the height information obtained by the middle line laser range finder;

step S3: image data analysis, Canny edge detection of the image G, and identification of coordinate points B [ B ] on the belt and conveyor belt frame lines₁,b₂,b₃......b_n]And D [ D ]₁,d₂,d₃......d_n]；

Step S4: calculating the deviation of the belt, and calculating the horizontal offset delta L of the belt aiming at the coordinate points acquired by the left high-definition camera and the right high-definition camera of the acquisition module; the angle offset delta theta of the belt can be calculated according to the middle high-definition camera of the acquisition module; calculating the coal flow loaded on the belt, and calculating the load Q of the belt according to the height information acquired by the laser range finder in the middle of the acquisition module and the belt speed v;

step S5: adjusting the deviation of the belt, and calculating the adjustment quantity delta of the belt carrier roller bracket according to the deviation quantity delta L, delta theta and the load Q of the belt_Lθ。

As a still further scheme of the invention: in the step S2, the image enhancement utilizes gamma transformation and fractional order image enhancement, the gamma transformation is used for enhancing the illumination of the image, and the transformation parameter γ is 0.5; the fractional order image enhancement fractional order coefficient is 2/3; and the height information obtained by the laser range finder adopts a wavelet transformation denoising mode.

As a still further scheme of the invention: in step S3, after the image is subjected to edge detection, 50 coordinate points on the belt and carriage edge lines in the areas of I to VI are extracted.

As a still further scheme of the invention: in the step S3, the step of calculating the belt deviation amount includes the steps of calculating regression lines of 50 corresponding points of each zone,regression coefficientThe regression line equation isRespectively calculating the distance [ d ] between the regression lines of the 6 regions₁,d₂,d₃,d₄,d₅,d₆]。

As a still further scheme of the invention: if the condition is satisfied

The belt has no angle deviation, thenIf the deviation does not meet the requirement, the belt has the angle deviation,(b_iregression coefficient of edge line of endothelial zone in I-VI region), horizontal deviation is DeltaL ═ d₃-d₄|。

As a still further scheme of the invention: in the step S4, the method for calculating the coal flow rate comprises

Wherein rho is the density of the coal material; v is the belt speed of the belt; m₁、M₂The coal flow rates of the left side and the right side of the belt are respectively; l is a coal material starting coordinate point on the left side of the belt, m is a coordinate point in the middle of the conveying frame, and n is a coal material ending coordinate point on the right side of the belt; h (u), G (u) are respectively the height coordinate functions of the coal material and the roller frame.

As a still further scheme of the invention: the method specifically comprises the step of calculating the floating of the carrier roller according to the deviation quantity delta L and delta thetaAngle of adjustmentThen according to the coal flow M of the left side and the right side of the conveying belt₁、M₂Judging the adjusting position of the carrier roller if M₁≥M₂The rising delta of the left carrier roller needs to be adjusted_LθOr right idler drop delta_Lθ(ii) a If M is₁≤M₂The left idler roller descending delta needs to be adjusted_LθOr right idler rising delta_Lθ。

As a still further scheme of the invention: the device utilizes the telescopic hydraulic cylinder to adjust the carrier roller up and down so as to realize the adjustment of the angle between the carrier roller and the conveyor belt frame.

The invention has the beneficial effects that: respectively acquiring a middle belt running image, a middle front and rear running image and middle coal flow information when the belt conveyor works through a visual detection module arranged in the middle of the belt conveyor, performing image enhancement processing by using gamma and fractional orders, performing Canny edge detection on the processed image to acquire carrier roller and belt edge information, calculating a deviation angle through carrier rollers and belt edge straight lines in front and at the rear of the middle of the belt, and then detecting a transverse deviation amount according to the information obtained by the middle edge detection; the stress condition of the belt is calculated according to the coal flow information in the middle of the belt, which is obtained by a line laser camera of the visual detection module, and finally the deviation of the belt is corrected in real time through the carrier roller control module according to the stress condition and the offset of the belt, so that the deviation of the belt can be timely and effectively detected and timely adjusted, and the purpose of safe production of coal conveying is realized.

Drawings

FIG. 1 is a schematic flow chart of the method of the present invention.

FIG. 2 is a schematic view of the structure of the apparatus of the present invention.

Fig. 3 is a schematic top view of the idler cradle and belt assembly of the apparatus of the present invention.

Fig. 4 is a schematic view of the adjustment of the idler angle according to the present invention.

In the figure: 1. high definition digtal camera, 2, line laser camera, 3, coal charge, 4, belt, 5, bearing roller adjustment module, 6, bear frame, 7, removal pneumatic cylinder, 8, bearing and 9, bearing roller axle head.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

Example one

Referring to fig. 2 to 4, a method for detecting and automatically adjusting the deviation of a belt conveyor includes

The visual detection module is erected right above a belt 4 in the middle of the belt conveyor and consists of a bearing frame 6, and a high-definition camera 1 and a line laser camera 2 which are arranged on the bearing frame 6;

and the carrier roller adjusting modules 5 are positioned on the inner side of the bearing frame 6, are respectively arranged on two sides of the bottom of the belt 4, and are composed of bearing bearings 8 and moving hydraulic cylinders 7 connected to two ends of the bearing bearings 8.

In the embodiment of the invention, high-definition cameras 1 arranged at two ends of the vision acquisition module acquire images of the left side edge and the right side edge of a belt 4; the line laser range finder 2 in the middle of the coal bunker is used for measuring the height h (u) from the top end of the coal bunker 3 to the acquisition module frame; the front camera and the rear camera in the middle of the vision acquisition module are used for acquiring front and rear images of the middle belt 4; the carrier roller adjusting module 5 further pushes a bearing 8 installed at a carrier roller shaft end 9 by adjusting the pushing amount delta L of the movable hydraulic cylinder 7 up and down, and the change of an included angle theta between the carrier roller and the conveyor belt frame can be realized by hydraulic up and down pushing.

Example two

Referring to fig. 1 to 4, an automatic adjustment method of a deviation detecting device of a belt conveyor includes the following steps

Step S1: acquiring image data, wherein four high-definition cameras 1 on a vision acquisition module acquire a video image I when a belt works; the middle line laser distance measuring instrument 2 measures the distance from the coal material 3 to the top beam of the bearing frame 6;

step S2: preprocessing image data, extracting key frames of a video image I acquired from the high-definition camera 1, and enhancing the frame image by using gamma and fractional order images to obtain an image G; carrying out data denoising processing on the height information obtained by the middle line laser range finder 2;

step S3: image data analysis, Canny edge detection of the image G, and identification of coordinate points B [ B ] on the belt and conveyor belt frame lines₁,b₂,b₃......b_n]And D [ D ]₁,d₂,d₃......d_n]；

Step S4: calculating the deviation of the belt, and calculating the horizontal offset delta L of the belt aiming at the coordinate points acquired by the left high-definition camera and the right high-definition camera of the acquisition module; the angle offset delta theta of the belt can be calculated according to the middle high-definition camera of the acquisition module; calculating the coal flow loaded on the belt, and calculating the load Q of the belt according to the height information acquired by the laser range finder in the middle of the acquisition module and the belt speed v;

step S5: adjusting the deviation of the belt, and calculating the adjustment quantity delta of the belt carrier roller bracket according to the deviation quantity delta L, delta theta and the load Q of the belt_Lθ。

In the embodiment of the present invention, in step S2, the image enhancement utilizes a gamma transformation and a fractional order image enhancement, the gamma transformation is used for enhancing the illumination of the image, and the transformation parameter γ is 0.5; the fractional order image enhancement fractional order coefficient is 2/3; and the height information obtained by the laser range finder adopts a wavelet transformation denoising mode.

In the embodiment of the present invention, in step S3, after the image is subjected to edge detection, 50 coordinate points on the edge lines of the belt and the conveyor in the areas where I to VI are located are extracted.

In the embodiment of the present invention, in the step S3, the step of calculating the belt deviation includes calculating regression lines of 50 corresponding points in each zone,regression coefficientThe regression line equation isRespectively calculating the distance [ d ] between the regression lines of the 6 regions₁,d₂,d₃,d₄,d₅,d₆]。

In the embodiment of the present invention, if the condition is satisfiedThe belt has no angle deviation, thenIf the deviation does not meet the requirement, the belt has the angle deviation,(b_iregression coefficient of edge line of endothelial zone in I-VI region), horizontal deviation is DeltaL ═ d₃-d₄|。

In the embodiment of the present invention, in the step S4, the method for calculating the coal flow rate is that

Wherein rho is the density of the coal material; v is the belt speed of the belt; m₁、M₂The coal flow rates of the left side and the right side of the belt are respectively; l is a coal material starting coordinate point on the left side of the belt, m is a coordinate point in the middle of the conveying frame, and n is a coal material ending coordinate point on the right side of the belt; h (u), G (u) are respectively the height coordinate functions of the coal material and the roller frame.

In the embodiment of the invention, the device specifically comprises the step of calculating the floating adjustment angle of the carrier roller according to the deviation quantity delta L and delta thetaThen according to the coal flow M of the left side and the right side of the conveying belt₁、M₂Judging the adjusting position of the carrier roller if M₁≥M₂The rising delta of the left carrier roller needs to be adjusted_LθOr right idler drop delta_Lθ(ii) a If M is₁≤M₂The left idler roller descending delta needs to be adjusted_LθOr right idler rising delta_Lθ。

In the embodiment of the invention, the device utilizes the telescopic hydraulic cylinder to adjust the carrier roller up and down so as to realize the adjustment of the angle between the carrier roller and the conveyor belt frame.

Firstly, respectively acquiring a middle belt running image, a middle front and rear running image and middle coal flow information when a belt conveyor works through a visual detection module arranged in the middle of the belt conveyor, performing image enhancement processing by using gamma and fractional orders, performing Canny edge detection on the processed image to acquire carrier roller and belt edge information, calculating a deviation angle through carrier rollers in front and rear of the middle of the belt and the belt edge straight line, and then detecting a transverse deviation amount according to the information obtained by the middle edge detection; and finally, correcting the belt deviation in real time through the carrier roller control module according to the belt stress condition and the offset.

It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned.

Furthermore, it should be understood that although the present description refers to embodiments, not every embodiment may contain only a single embodiment, and such description is for clarity only, and those skilled in the art should integrate the description, and the embodiments may be combined as appropriate to form other embodiments understood by those skilled in the art.