JP6920067B2 - Belt damage detection system - Google Patents

Description

The present invention relates to a belt damage detection system.

Conventionally, when excavating a tunnel, a belt conveyor is often used as a means for carrying out excavation scraps (excavation debris). Then, in the transport method using this belt conveyor, the traffic of transportation means such as a dump truck can be omitted by continuously arranging the belt conveyor from the excavation point in the mine to the temporary excavation site outside the mine. , Long-distance transport of excavation scraps can be performed efficiently in a large amount and in a short time.

If the belt meanders on the belt conveyor, the belt may rub against the surrounding frame or the like and be damaged. The belt may also be damaged due to excavation slippage on the belt. Therefore, Patent Document 1 discloses a belt damage detection system that detects a damaged portion from an image of an captured belt and displays an image of the damaged portion on a display.

Japanese Unexamined Patent Publication No. 2012-30952

However, in the belt damage detection system described in Patent Document 1, only the damaged portion is displayed on the display. Therefore, the user cannot know what kind of measures are required for the damaged part only by checking the image of the damaged part displayed on the display. Therefore, the user has to visually check the damaged part of the belt in order to determine what kind of measures are necessary.

The present invention has been made in view of such circumstances, and an object of the present invention is to provide a belt damage detection system capable of appropriately dealing with a damaged part of a belt without visually observing the damaged part of the belt. be.

One aspect of the present invention is a belt damage detection system that detects a damaged portion of a belt of a belt conveyor, based on an image pickup unit that images the belt surface of the belt and an image of the belt surface that has been imaged. The damaged part detection part that detects the damaged part, the damaged shape acquisition part that acquires the shape of the damaged part based on the image of the damaged part, and the damage level of the damaged part are determined based on the shape of the damaged part. includes a damage level determining section, wherein the damage shape obtaining unit, before SL obtains the length of the longitudinal length and the transverse direction of the injury site, based on the shading of the injury site of the image, the acquired injury site Of the four damaged area ranks indicating the size of the damaged area based on the vertical length and the horizontal length of the above, the area rank determining unit for determining the damaged area rank and the damaged depth. Among the three damage depth ranks indicating the above, the damage level determination unit includes a depth rank determination unit that determines the damage depth rank according to the shade of the image of the damage portion, and the damage level determination unit is the area rank. It is a belt damage detection system that determines a damage level based on a combination of the damage area rank determined by the determination unit and the damage depth rank determined by the depth rank determination unit.

Further, one aspect of the present invention is the belt damage detection system described above, wherein the position calculation unit for calculating the position of the damaged portion on the belt and the damaged portion whose damage level is determined by the damage level determining unit. Further includes a storage unit that stores the image of the above and the position of the damaged part in association with each other.

Further, one aspect of the present invention is the above-mentioned belt damage detection system, in which the position calculation unit uses the origin position where a marker provided on the belt is detected and a roller that supports the belt from below. The position of the damaged portion is calculated based on the pulse signal output from the encoder according to the rotation.

Further, one aspect of the present invention is the above-mentioned belt damage detection system, and when the damage level determined by the damage level determination unit is equal to or higher than a predetermined level, an alarm corresponding to the damage level is output. It is further provided with an alarm unit.
Further, one aspect of the present invention is the above-mentioned belt damage detection system, in which the three damage depth ranks are set according to the shade level of the image, and the depth rank determination unit is the imaging unit. The damage depth rank of the damaged part is determined from the three damage depth ranks according to the shade level of the image of the damaged part captured in.
Further, one aspect of the present invention is the above-mentioned belt damage detection system, in which a plurality of damage levels indicating the damage state of the damaged part are set in advance, and each of the plurality of damage levels has the said damage part. At least one of the treatment and the urgency is set, and the damage level determination unit determines the damage area rank and the depth of the plurality of damage levels determined by the area rank determination unit. The damage level is determined according to the combination of the damage depth rank determined by the rank determination unit.

As described above, according to the present invention, it is possible to provide a belt damage detection system capable of appropriately dealing with a damaged part of the belt without visually observing the damaged part of the belt.

It is a figure which shows an example of the schematic structure of the belt damage detection system 1 in this embodiment. It is a figure which shows an example of the schematic structure of the belt damage detection device 30 in this embodiment. It is a figure explaining the method of determining the damage area rank in this embodiment. It is a figure which shows the method of determining the damage level of the damage level determination part 303 in this embodiment. It is a figure explaining the damage level A to E in this embodiment. It is a figure which shows an example of the data stored in the storage part 53 in this embodiment. It is a figure which shows the flow of operation of the belt damage detection apparatus 30 in this embodiment.

Hereinafter, the present invention will be described through embodiments of the invention, but the following embodiments do not limit the inventions that fall within the scope of the claims. Also, not all combinations of features described in the embodiments are essential to the means of solving the invention. In the drawings, the same or similar parts may be designated by the same reference numerals to omit duplicate explanations.

The belt damage detection system according to the embodiment is a system for detecting a damaged portion of a belt of a belt conveyor, and determines the damage level of the damaged portion based on the shape of the damaged portion of the belt. That is, the belt damage detection system in the embodiment calculates the degree of influence of the damaged portion on the belt 3 according to the size and depth of the damaged portion of the belt.
Hereinafter, the belt damage detection system of the embodiment will be described with reference to the drawings.

FIG. 1 is a diagram showing an example of a schematic configuration of the belt damage detection system 1 according to the present embodiment. As shown in FIG. 1, the belt damage detection system 1 includes a belt conveyor 2, a marker detection unit 6, a position detection unit 7, lighting units 10, 11, imaging units 20, 21, a control device 25, and a belt damage detection device 30. It includes an operation unit 40 and a display device 50.

The belt conveyor 2 transports excavation scraps excavated by tunnel excavation or the like. The belt conveyor 2 includes a belt 3, a roller 4, a marker 5, and a motor (not shown) for rotating the rollers.
The belt 3 is wound around the roller 4. The excavation scraps excavated by tunnel excavation or the like are placed on the upper surface of the belt 3 and transported. For example, a black rubber belt is used as the belt 3 used for tunnel excavation and the like.

The marker 5 is provided at a predetermined position on the belt 3. For example, the marker 5 may be provided at the edge of the belt 3 or may be embedded in the belt 3. The marker 5 indicates the position of the base point of the belt 3, and is, for example, a magnetized body.

The marker detection unit 6 detects the marker 5 provided on the belt 3. For example, when the marker 5 is a magnetized body, the marker detection unit 6 is a magnetic detector. When the marker detection unit 6 detects the marker 5 provided on the belt 3, it outputs a marker detection signal indicating that the marker 5 has been detected to the control device 25.

The position detection unit 7 detects an arbitrary position of the belt 3 running in circulation. For example, the position detection unit 7 detects an arbitrary position of the traveling belt 3 by detecting the rotation position of the roller 4. For example, the position detection unit 7 is an encoder provided on the roller 4. The position detection unit 7 outputs a pulse signal corresponding to the rotation of the roller 4 to the control device 25.

The illumination unit 10 is a light that irradiates the upper surface (surface) of the belt 3 with light. The illumination unit 11 is a light that irradiates the lower surface (back surface) of the belt 3 with light. For example, the lighting units 10 and 11 are LED (Light Emitting Diode) lighting.

The imaging units 20 and 21 image the belt surface of the belt 3. The image pickup unit 20 photographs the upper surface of the belt 3 irradiated with light by the illumination unit 10. The image pickup unit 20 outputs the captured image to the belt damage detection device 30. The image pickup unit 21 photographs the lower surface of the belt 3 irradiated with light by the illumination unit 11. The image pickup unit 21 outputs the captured image to the belt damage detection device 30. For example, the imaging units 20 and 21 are line scanner cameras that continuously image the belt surface.

The control device 25 includes a belt conveyor drive unit 26, a lighting drive unit 27, and a state calculation unit 28.
When the belt conveyor drive unit 26 acquires an operation signal indicating that the belt conveyor 2 is to be operated from the operation unit 40, the belt conveyor drive unit 26 drives the motor of the belt conveyor 2 to circulate the belt 3. For example, the operation unit 40 outputs an operation signal to the control device 25 by being operated by the user.

The illumination drive unit 27 supplies electric power to each of the illumination units 10 and 11 to irradiate the upper surface and the lower surface, which are belt surfaces, with light from the illumination units 10 and 11.

The state calculation unit 28 includes a speed calculation unit 281 and a position calculation unit 282.
The speed calculation unit 281 calculates the speed of the belt 3 circulating and traveling based on the pulse signal output from the position detection unit 7. For example, the speed calculation unit 281 calculates the speed of the belt 3 circulating in circulation based on the interval at which the pulse signal is acquired and the number of counts of the pulse signal per unit time.

The position calculation unit 282 calculates an arbitrary position on the belt 3. For example, the position calculation unit 282 calculates the position of the damaged portion on the belt 3 (hereinafter, referred to as “damaged position”).
The position calculation unit 282 determines the origin position where the marker 5 provided on the belt 3 is detected and the pulse signal output from the position calculation unit 282 according to the rotation of the roller 4 that supports the belt 3 from below. Based on this, the damaged position of the belt 3 is calculated. For example, the position calculation unit 282 calculates an arbitrary position on the belt 3 according to the count number of pulse signals acquired from the position detection unit 7 with reference to the position where the marker 5 provided on the belt 3 is detected. .. Therefore, when the damaged portion of the belt 3 is detected by the belt damage detecting device 30, the position calculating unit 282 calculates the position of the belt 3 imaged by the imaging unit 20 or the imaging unit 21 at that time. Therefore, the damaged position of the belt 3 can be calculated. For example, the damaged position of the belt 3 is the distance from the origin position.

The belt damage detection device 30 detects the damaged portion of the belt 3 and determines the damage level indicating the degree of damage of the damaged portion.
FIG. 2 is a diagram showing an example of a schematic configuration of the belt damage detection device 30 according to the present embodiment. As shown in FIG. 2, the belt damage detection device 30 includes a damage site detection unit 301, a damage shape acquisition unit 302, a damage level determination unit 303, and an output unit 304.

The damaged part detection unit 301 detects the damaged part based on the image captured on the belt surface captured by the imaging units 20 and 21. For example, the damaged part detection unit 301 detects the damaged part based on the shading of the captured image.

The damage shape acquisition unit 302 acquires the shape of the damaged part detected by the damage part detection unit 301. For example, the damaged shape acquisition unit 302 acquires the area and depth of the damaged portion as the shape of the damaged portion based on the shading of the image of the damaged portion.
The damage shape acquisition unit 302 includes an area rank determination unit 302a and a depth rank determination unit 302b.

The area rank determination unit 302a acquires the vertical length and the horizontal length of the damaged part based on the shading of the image of the damaged part. The vertical direction is the traveling direction of the belt 3. The lateral direction is a direction perpendicular to the traveling direction of the belt 3. The area rank determining unit 302a determines the damaged area rank of the damaged part based on the acquired vertical length and horizontal length of the damaged part. FIG. 3 is a diagram illustrating a method for determining a damaged area rank in the present embodiment.

As shown in FIG. 3, a plurality of damaged area ranks are set according to the combination of the vertical length and the horizontal length. In this embodiment, four damaged area ranks ([1], [2], [3], [4]) are preset. However, the damaged area rank of the present embodiment is not limited to this, and two or more ranks may be set. In the present embodiment, the degree of the damaged area is higher in the order of the damaged area rank [1], the damaged area rank [2], the damaged area rank [3], and the damaged area rank [4].

For example, as shown in FIG. 3, the area rank determining unit 302a has a length of 20 mm in the vertical direction and a length of 10 mm in the horizontal direction of the damaged part detected by the damaged part detecting unit 301. Determines the damaged area rank of the damaged part to the damaged area rank [1]. For example, when the area rank determination unit 302a has a vertical length of 90 mm and a horizontal length of 20 mm of the damaged part detected by the damaged part detecting unit 301, the damaged part is damaged. The area rank is determined to be the damaged area rank [2]. For example, when the area rank determination unit 302a has a vertical length of 180 mm and a horizontal length of 30 mm of the damaged part detected by the damaged part detecting unit 301, the damaged part is damaged. The area rank is determined to be the damaged area rank [3]. For example, when the area rank determination unit 302a has a vertical length of 270 mm and a horizontal length of 90 mm of the damaged part detected by the damaged part detecting unit 301, the damaged part is damaged. The area rank is determined to be the damaged area rank [4].

It should be noted that the scratches in the horizontal direction tend to have a higher influence on the proof stress of the belt 3 than the scratches in the vertical direction. Therefore, in the present embodiment, the damage area rank is determined so that the damage in the lateral length is severely determined with respect to the lateral length of the damaged portion.

The depth rank determination unit 302b acquires the depth of the damaged part based on the shading of the image of the damaged part. Then, the depth rank determination unit 302b determines the damage depth rank of the damaged part based on the acquired depth of the damaged part. The damage depth rank is determined according to the depth of the damage site.

The depth of the damaged part is deeper as the shade of the image of the damaged part becomes darker. Therefore, in the present embodiment, a plurality of damage depth ranks are set according to the shade level of the image. Therefore, the depth rank determination unit 302b determines the damage depth rank according to the shade level of the image of the damaged portion. In this embodiment, three damage depth ranks [1], [2], and [3] are preset. However, the damage depth rank of the present embodiment is not limited to this, and two or more ranks may be set. In the present embodiment, the degree of damage depth is higher in the order of damage depth rank [1], damage depth rank [2], and damage depth rank [3]. For example, when the shading of the image of the damaged part is less than the first shading threshold value, the damage depth rank [1] is set. For example, when the shading of the image of the damaged portion is equal to or more than the first shading threshold value and less than the second shading threshold value (> first shading threshold value), the damage depth rank [2] is set. For example, when the shading of the image of the damaged portion is equal to or higher than the third shading threshold value (> second shading threshold value), the damage depth rank [3] is set.

The damage level determination unit 303 determines the damage level of the damaged part based on the shape of the damaged part acquired by the damage shape acquisition unit 302. FIG. 4 is a diagram showing a method of determining the damage level of the damage level determination unit 303 in the present embodiment.

More specifically, as shown in FIG. 4, the damage level determination unit 303 includes the damage area rank determined by the area rank determination unit 302a, the damage depth rank determined by the depth rank determination unit 302b, and the damage depth rank. The damage level of the damaged part is determined based on the combination of. In the present embodiment, the damage level determination unit 303 determines the damage level of the damaged portion based on the combination of the damage area rank determined by the area rank determination unit 302a and the depth rank determined by the depth rank determination unit 302b. Determines which of the damage levels A to E corresponds to.

This damage level indicates the damage state of the damaged part. Therefore, the user can appropriately perform the treatment on the damaged portion by setting the treatment according to the damage level in advance. FIG. 5 is a diagram illustrating damage levels A to E in the present embodiment.

As shown in FIG. 5, the damage state of the damaged part is worse in the order of the damage level A, the damage level B, the damage level C, the damage level D, and the damage level E, and the urgency of the treatment for the damaged part is high. For example, the damage level A indicates that the damaged state of the damaged part is only the damage of the upper cover rubber of the belt 3. Therefore, the damaged site of damage level A does not need to be repaired because the urgency of treatment is the lowest.

The damage level B indicates that the damaged state of the damaged part does not affect the strength of the belt 3. Therefore, as a treatment for the damaged part of the damage level B, for example, at the time of regular maintenance, the damaged part is repaired by applying a patch.

The damage level C indicates that the damaged state of the damaged part is such that the strength of the belt 3 is reduced. Therefore, as a treatment for the damaged part of the damage level C, for example, at the time of regular maintenance, the damaged part is patched and repaired with priority.

The damage level D indicates that the damaged state of the damaged part is such that the canvas of the belt 3 is damaged by 50% or more. Therefore, as the treatment of the damaged portion of the damage level D, for example, the repair treatment is determined by visually observing the damaged state of the damaged portion, and the repair treatment is performed after the excavation is completed.

Damage level E indicates that the damaged state of the damaged site is fatal. Therefore, as a treatment for the damaged portion of the damage level E, for example, the belt conveyor 2 is stopped and the belt 3 at the damaged portion is cut off for repair.

The output unit 304 acquires the damage position of the damaged part where the damage level is determined from the position calculation unit 282. Then, the output unit 304 links the captured image of the damaged portion whose damage level is determined, the damaged level, and the damaged position of the damaged portion, and transmits the image to the display device 50 by wire or wirelessly. The communication network between the belt damage detection device 30 and the display device 50 may be a transmission line for wireless communication, or may be a combination of a transmission line for wireless communication and a transmission line for wired communication. The communication network may be a mobile communication network such as a mobile phone line network, a wireless packet communication network, the Internet and a dedicated line, or a combination thereof.

The display device 50 includes a display monitor 51, an alarm unit 52, and a storage unit 53. The display device 50 links the captured image of the damaged portion whose damage level is determined, the damaged level, and the damaged position of the damaged portion, which are received from the output unit 304, to the storage unit 53. save. As a result, the user can display the data stored in the storage unit 53 on the display monitor 51, and can view the captured image of the damaged portion. FIG. 6 is a diagram showing an example of data stored in the storage unit 53. As shown in FIG. 6, if necessary, the date on which the captured image of the damaged portion was acquired may be associated with the captured image and stored in the storage unit 53. As a result, the user can check the history of the captured image of the damaged part. Therefore, the user can grasp the progress process of the damage at the damaged site and formulate an appropriate repair plan.

The display device 50 displays as display data the captured image of the damaged portion whose damage level has been determined, and the data in which the damage level and the damaged position of the damaged portion are associated with each other, which is received from the output unit 304. Display on.
When the damage level determined by the damage level determination unit is equal to or higher than a predetermined level, the alarm unit 52 outputs an alarm according to the damage level. For example, the alarm unit 52 may display an alarm on the display monitor 51, or may give an alarm by sound. The display device 50 may be configured to be included in the belt damage detection device 30. In this way, when an alarm is output, the user confirms the damage level of the damaged part displayed on the display monitor 51 to determine whether such a countermeasure is necessary for the damaged part. , The damaged part can be easily grasped without visually observing.

The operation flow of the belt damage detection device 30 in the present embodiment will be described below. FIG. 7 is a diagram showing an operation flow of the belt damage detection device 30 in the present embodiment.

The damaged part detection unit 301 acquires an image of the belt surface imaged by the image pickup units 20 and 21 while the belt conveyor 2 is operating. The damaged part detection unit 301 determines whether or not there is a damaged part in the captured image based on the acquired image (step S101). For example, the damaged part detection unit 301 detects a portion having a shade level equal to or higher than a predetermined level as a damaged part in the acquired image. If the acquired image does not have a shade level portion equal to or higher than a predetermined level, the damaged part detection unit 301 discards the image and acquires the next captured image from the imaging units 20 and 21 (step S102). ).

The area rank determination unit 302a acquires the vertical length and the horizontal length of the damaged part based on the shading of the image of the damaged part. Then, the area rank determining unit 302a determines the damaged area rank of the damaged part from the plurality of damaged area ranks based on the combination of the acquired vertical length and the horizontal length of the damaged part (step S103). ).

The depth rank determination unit 302b acquires the depth of the damaged part based on the shading of the image of the damaged part. Then, the depth rank determination unit 302b determines the damage depth rank of the damaged part from the plurality of damage depth ranks based on the acquired depth of the damaged part (step S104).

The damage level determination unit 303 determines the damage level of the damaged part based on the combination of the damage area rank determined by the area rank determination unit 302a and the damage depth rank determined by the depth rank determination unit 302b. (Step S105).

The output unit 304 acquires the damage position of the damaged part where the damage level is determined from the position calculation unit 282. Then, the output unit 304 links the captured image of the damaged portion whose damage level is determined, the damaged level, and the damaged position of the damaged portion, and transmits the image to the display device 50 by wire or wirelessly.

As described above, the belt damage detection system 1 in the present embodiment detects the damaged part based on the image pickup units 20 and 21 that image the belt surface of the belt 3 and the image of the imaged belt surface. A unit 301, a damage shape acquisition unit 302 that acquires the shape of the damaged part based on an image of the damaged part, and a damage level determination unit 303 that determines the damage level of the damaged part based on the shape of the damaged part are provided. As a result, the user can appropriately deal with the damaged part by checking the damage level. That is, the user can appropriately deal with the damaged part of the belt without visually observing the damaged part.

The image pickup unit 20 may take an image in a state where the upper surface of the belt 3 is washed, or may take an image in a state where the upper surface of the belt 3 is not washed.

Each part of the belt damage detection device 30 may be realized by hardware, may be realized by software, or may be realized by a combination of hardware and software.

Further, the belt damage detection device 30 in the above-described embodiment may be realized by a computer. In that case, the program for realizing this function may be recorded on a computer-readable recording medium, and the program recorded on the recording medium may be read by the computer system and executed. The term "computer system" as used herein includes hardware such as an OS and peripheral devices. Further, the "computer-readable recording medium" refers to a portable medium such as a flexible disk, a magneto-optical disk, a ROM, or a CD-ROM, or a storage device such as a hard disk built in a computer system. Further, a "computer-readable recording medium" is a communication line for transmitting a program via a network such as the Internet or a communication line such as a telephone line, and dynamically holds the program for a short period of time. It may also include a program that holds a program for a certain period of time, such as a volatile memory inside a computer system that serves as a server or a client in that case. Further, the above program may be for realizing a part of the above-mentioned functions, and may be further realized for realizing the above-mentioned functions in combination with a program already recorded in the computer system. It may be realized by using a programmable logic device such as FPGA (Field Programmable Gate Array).

Although the embodiments of the present invention have been described in detail with reference to the drawings, the specific configuration is not limited to this embodiment, and includes designs and the like within a range that does not deviate from the gist of the present invention.

The order of execution of each process such as operation, procedure, step, and step in the device, system, program, and method shown in the claims, specification, and drawings is particularly "before" and "prior to". It should be noted that it can be realized in any order unless the output of the previous process is used in the subsequent process. Even if the scope of claims, the specification, and the operation flow in the drawings are explained using "first", "next", etc. for convenience, it means that it is essential to carry out in this order. It's not a thing.

1 Belt damage detection system 2 Belt conveyor 3 Belt 6 Marker detection unit 7 Position detection unit 10, 11 Lighting unit 20, 21 Imaging unit 25 Control device 30 Belt damage detection device 40 Operation unit 50 Display device 301 Damage site detection unit 302 Damage shape Acquisition unit 303 Damage level determination unit 304 Output unit

Claims (6)

A belt damage detection system that detects damaged parts of a belt on a conveyor belt.
An imaging unit that images the belt surface of the belt and
A damaged part detection unit that detects the damaged part based on the captured image of the belt surface, and a damaged part detecting unit.
A damaged shape acquisition unit that acquires the shape of the damaged part based on an image of the damaged part,
A damage level determination unit that determines the damage level of the damaged part based on the shape of the damaged part,
With
The damaged shape acquisition unit
Get the length of the longitudinal length and the transverse direction of the injury site, based on the shading of the front Symbol injury site of the image, based on the length of the longitudinal length and the lateral acquired the injury site From the four damaged area ranks indicating the size of the damaged area, the area rank determining unit that determines the damaged area rank, and the area rank determining unit that determines the damaged area rank.
From the three damage depth ranks indicating the damage depth, a depth rank determination unit that determines the damage depth rank according to the shade of the image of the damage site, and a depth rank determination unit.
With
The damage level determination unit determines the damage level based on a combination of the damage area rank determined by the area rank determination unit and the damage depth rank determined by the depth rank determination unit.
Belt damage detection system. A position calculation unit that calculates the position of the damaged part on the belt, and
An image of the damaged part whose damage level is determined by the damage level determining unit, a storage unit that stores the position of the damaged part in association with each other, and a storage unit.
The belt damage detection system according to claim 1. The position calculation unit is based on the origin position where the marker provided on the belt is detected and the pulse signal output from the encoder in response to the rotation of the roller supporting the belt from below. The belt damage detection system according to claim 2, wherein the position of the belt is calculated. When the damage level determined by the damage level determination unit is equal to or higher than a predetermined level, any one of claims 1 to 3 further includes an alarm unit that outputs an alarm according to the damage level. Described belt damage detection system. The three damage depth ranks are set according to the shade level of the image.
The depth rank determining unit determines the damage depth rank of the damaged part from the three damage depth ranks according to the shade level of the image of the damaged part captured by the imaging unit.
The belt damage detection system according to any one of claims 1 to 4. Multiple damage levels are preset to indicate the damage status of the damaged area.
For each of the plurality of damage levels, at least one of treatment and urgency for the damaged site is set.
The damage level determination unit corresponds to a combination of the damage area rank determined by the area rank determination unit and the damage depth rank determined by the depth rank determination unit among the plurality of damage levels. To determine the damage level,
The belt damage detection system according to any one of claims 1 to 5.

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