煤矿输送带纵向撕裂视觉检测间歇式除尘系统设计

Design of an intermittent dust removal system for visual detection of longitudinal tearing of coal mine conveyor belts

  • 摘要: 基于机器视觉的煤矿输送带纵向撕裂检测在应用时,视觉系统易出现粉尘遮挡、污损等问题,影响图像采集的清晰度和正确率。目前采用的玻璃罩刮雨器式的连续除尘方式虽能维持图像的可用率,但因采集的图像质量不高而影响数据分析的准确性。针对上述问题,提出一种基于间歇式旋转玻璃组件与毛刷的间歇式除尘系统设计方案。采用36BL57−1242直流无刷电动机驱动齿轮系带动旋转玻璃组件与旋转毛刷分别清除激光发射器短玻璃罩和工业摄像仪长玻璃罩的煤尘。基于STM32F030F4P6单片机实现直流无刷电动机的精准运动控制,包括启停、转向、脉冲宽度调制调速及过流保护等,当检测到电动机过流或堵转时立即触发停机报警。在除尘过程中,针对连续运行会导致刷毛与粉尘持续接触,削弱刷体回弹清灰能力的问题,采用间歇运行方式,通过中间齿轮嵌入磁铁与霍尔开关形成周期性感应,结合双电压比较器构建位置反馈闭环,实现电动机带动玻璃组件旋转1周−停歇3 s的周期性动作,以利于回弹去尘。实验室及井下测试结果表明:在2 000 h间歇旋转除尘运行期间,电动机运行稳定;激光照射在输送带上的图像对比度高,没有出现因污物遮挡引起的激光线暗淡、图像模糊和无法识别的情况;间歇式除尘设计能够有效清洁玻璃罩煤尘,确保图像识别精准,从而获得可靠的撕裂检测结果。

     

    Abstract: In the application of visual detection of longitudinal tearing of coal mine conveyor belts, the visual system is prone to problems such as dust blockage and contamination, which affect the clarity and accuracy of image acquisition. At present, the continuous cleaning method using a glass housing with a wiper can maintain image availability, but the accuracy of data analysis is affected due to the low quality of collected images. To address the above problems, a design scheme of a dust removal system based on an intermittent rotary glass component and brush was proposed. A 36BL57-1242 Direct Current (DC) brushless motor was used to drive a gear system to rotate the glass component and the brush separately to remove coal dust from the short glass cover of the laser emitter and the long glass cover of the industrial camera. Based on the STM32F030F4P6 Microcontroller Unit (MCU) chip, precise motion control of the DC brushless motor was realized, including start-stop, steering, Pulse Width Modulation (PWM) speed regulation, and overcurrent protection. When overcurrent or stalling of the motor was detected, a shutdown alarm was immediately triggered. During the dust removal process, considering that continuous operation would lead to continuous contact of the bristles with dust and weaken the rebound cleaning ability of the brush body, an intermittent operation mode was adopted. A magnet was embedded into the intermediate gear and combined with a Hall switch to form periodic induction, and a dual-voltage comparator was used to construct a position-feedback closed loop, thereby realizing the periodic action of the motor driving the glass component to perform a full rotation and then stop for 3 seconds, which facilitated rebound dust removal. Laboratory and underground test results showed that during 2 000 hours of intermittent rotary dust removal operation, the motor operated stably. The images obtained with laser irradiation on the conveyor belt had high contrast, with no occurrences of dim laser lines, blurred images, or unrecognizable conditions caused by contamination. The intermittent dust removal design effectively cleaned the coal dust on the glass cover, ensured accurate image recognition, and thus obtained reliable tearing detection results.

     

/

返回文章
返回