AU2015372216B2

AU2015372216B2 - Disorder rope monitoring system and judging method for winding reel of mine hoist

Info

Publication number: AU2015372216B2
Application number: AU2015372216A
Authority: AU
Inventors: Guohua Cao; Shanzeng LIU; Yanjun NIU; Weihong Peng; Yuxing PENG; Gang Shen; Jinjie WANG; Naige WANG; Yandong Wang; Zhencai Zhu
Original assignee: China University of Mining and Technology CUMT; China University of Mining and Technology Beijing CUMTB
Current assignee: China University of Mining and Technology Beijing CUMTB
Priority date: 2014-12-25
Filing date: 2015-05-13
Publication date: 2017-07-06
Anticipated expiration: 2035-05-13
Also published as: CN104477723B; AU2015372216A1; WO2016101500A1; CN104477723A

Abstract

Disclosed are a disorder rope monitoring system and a judging method for a winding reel of a mine hoist. The disorder rope monitoring system comprises an industrial camera (2), a shaft encoder (3), a data acquisition card (4) and an industrial control computer (5), wherein the industrial camera is arranged at the upper rear part or lower front part of a middle outlet rope of a reel (1), the shaft encoder is arranged at a shaft end of the reel (1) and is connected to a shaft, and the data acquisition card and the industrial control computer are sequentially connected to the shaft encoder (3); and the industrial camera (2) is connected to the industrial control computer (5) through a communication cable (7). The disorder rope judging method comprises the steps of measuring the rotation angle of a reel via a shaft encoder, measuring a rope outlet position of a steel wire rope via an industrial camera, and determining whether the rope is in disorder or not by analysing the change characteristics of angles and rope outlet positions in a certain period. The monitoring system is convenient to mount, there is no need to retrofit the reel, and meanwhile the safety of operation of a mine hoisting system is increased.

Description

2015372216 11 Jul2016

Description

DISORDER ROPE MONITORING SYSTEM AND JUDGING METHOD FOR WINDING REEL OF MINE HOIST 5 0 5 .0 ,5 30 35 40

Field of the Invention The present invention relates to a rope disorder monitoring system and a rope disorder judging method for a steel wire rope reel, in particular to a rope disorder monitoring system and a rope disorder judging method for the rope winding reel of a mine hoist, which are applicable to single-rope or multi-rope winding reels, and especially suitable for use for the winding reel of a mine hoist in a new or built construction shaft. Background Art A hoisting system is an important part of a transport system, and the steel wire rope takes an important role in such a hoisting system. For a single-rope or multi-rope winding reel, the hoisted object is moved up and down by the steel wire rope(s) wound on the reel. The steel wire rope may not be aligned along the existing track during rope winding on the reel, i.e., a rope disorder phenomenon may occur, owing to a variety of factors. Such a rope disorder phenomenon has severe damages to the steel wire rope. For example, the rope disorder phenomenon may aggravate the abrasion of the steel wire rope or even destroy the winding structure of the steel wire rope; especially, in a multi-rope winding process, the rope disorder phenomenon may cause uneven stress on the steel wire ropes or even a rope breaking accident. The rope disorder phenomenon has a strong impact on the safety of hoisting. Therefore, it is of great significance to monitor the running state of the steel wire rope during rope winding/releasing on a reel and accurately judge any rope disorder of steel wire rope, to avoid the occurrence of any severe hoisting accident. Contents of the Invention A rope disorder monitoring system for the winding reel of a mine hoist in the present invention comprises: an industrial camera arranged at the upper rear part or lower front part of a middle rope outlet of the reel; a shaft encoder arranged at a shaft end of the reel and connected with a shaft; and a data acquisition card and an industrial PC connected with the shaft encoder sequentially; the industrial camera is connected with the industrial PC through a communication cable. A rope disorder judging method for the winding reel of a mine hoist in the present invention comprises: 1) setting a judging period T and a sampling number n for an industrial camera and an shaft encoder in the judging period T, i.e., a sampling interval At=T/n, and setting analyzing periods Τι, T2, T3, ..., Tz in the same judging period T in different time periods in a sampling process at a time interval m*At, and setting lengths SI and S2 as thresholds for judging whether a rope disorder has occurred, wherein, m<n, and S2>S 1; 2) acquiring the images of the steel wire rope continuously in the rope winding/releasing process of the reel via the industrial camera, and transmitting the images to an industrial PC; 3) processing the images on the industrial PC by graying processing and threshold processing, to separate the steel wire rope from the background; 4) setting a horizontal line near the surface of the reel on the images processed by threshold processing, setting a color A for the steel wire rope region above the horizontal line, setting a different color B for the other region, and selecting the pixels in the region of the color A above the horizontal line where the average value of the horizontal coordinate values is equal 1 to a steel wire rope outlet position; 2015372216 11 Jul2016 5) setting limit positions Ai, Bi for the rope outlet position on the reel at the two ends of the reel in the width direction under different winding layers of the steel wire rope, wherein, i=l, 2, ..., j, i.e., the ith winding layer counted from the inner side to the outer side on the reel; 5 6) analyzing the rotation angle of the reel measured by the shaft encoder and the rope outlet position on the reel measured by the industrial camera in a period T among the periods Τι, T2, T3, ..., Tz sequentially on the industrial PC: a) if the rope outlet position in a period T doesn't reach to Ai or Bi: judging a rope disorder has occurred in the rope winding process of the reel and giving off an 0 alarm, if the rotation angle of the reel measured by the shaft encoder 5 changes continuously and the absolute value of the difference between the final rope outlet position of the steel wire rope and the initial rope outlet position is within the threshold SI or greater than or equal to the threshold S2; judging there is no rope disorder in the rope winding process of the reel, if the rotation angle of the 5 reel measured by the shaft encoder changes continuously and the absolute value of the difference between the final rope outlet position of the steel wire rope and the initial rope outlet position is beyond the threshold SI and smaller than the threshold S2; judging that the reel has stopped winding, if the rotation angle values of the reel measured by the shaft encoder are the same. 0 b) if the rope outlet position in a period T reaches to the limit position Ai or Bi: judging a rope disorder has occurred in the rope winding process of the reel and giving off an alarm, if the rotation angle of the reel measured by the shaft encoder changes continuously and the sum of the absolute value of the difference between the final rope outlet position of the steel wire rope and the position coordinate of Ai or Bi and the absolute value of the difference between the 5 initial rope outlet position of the steel wire rope and the position coordinate of Ai or Bi is within the threshold SI or greater than or equal to the threshold S2; judging there is no rope disorder in the rope winding process of the reel, if the rotation angle of the reel measured by the shaft encoder changes continuously and the sum of the absolute value of the difference between the final rope outlet position of the steel wire rope and the position coordinate 0 of Ai or Bi and the absolute value of the difference between the initial rope outlet position of the steel wire rope and the position coordinate of Ai or Bi is beyond the threshold SI and smaller than the threshold S2; judging that the reel has stopped winding, if the rotation angle values of the reel measured by the shaft encoder are the same. 35 Beneficial effects: With the above-mentioned technical solution, the present invention has the following advantages: 1) 2)

The monitoring system is composed of less components, doesn't require any modification to the structure of the reel, is convenient to install and low in cost;

The monitoring system employs machine vision technology to monitor the running state of the steel wire rope of the reel winding/releasing in a contactless manner, and incorporates a shaft encoder to measure the rotation angle of the reel so as to judge any rope disorder and give off an alarm in case of any rope disorder; thus, the monitoring system realizes real-time, intuitive, automatic and intelligent rope disorder monitoring for the rope winding reel of a mine hoist, and ensures safe operation of the reel of the mine hoist. 45 2 2015372216 11 Jul2016 ο 5 0 ,5 30 35 40

Description of the Drawings Fig. 1 is a layout diagram of the rope disorder monitoring system for the rope winding reel of a mine hoist according to the present invention; Fig. 2 is a schematic diagram of the steel wire rope image after graying processing and threshold processing; Fig. 3 is a schematic diagram of the limit positions at the two ends of the reel in width direction. In the figures: 1- reel; 2 - industrial camera; 3 - shaft encoder; 4 - data acquisition card; 5 - upper computer; 6 - steel wire rope; 7 - communication cable; 8 - horizontal line. Detailed Description of the Embodiments Hereunder the rope disorder monitoring system and rope disorder judging method for the rope winding reel of a mine hoist in the present invention will be further detailed in an embodiment with reference to the accompanying drawings. Embodiment: The present invention includes a monitoring system and a monitoring method. Fig. 1 is a layout diagram of the rope disorder monitoring system for the steel wire rope winding reel of a mine hoist according to the present invention. The monitoring system comprises: an industrial camera 2 arranged at the upper rear part or lower front part of a middle rope outlet of the reel 1; a shaft encoder 3 arranged at a shaft end of the reel 1 and connected with a shaft; and a data acquisition card 4 and an industrial PC 5 connected with the shaft encoder 3 sequentially, the industrial camera 2 is connected with the industrial PC 5 through a communication cable 7. A rope disorder judging method for the steel wire rope winding reel of a mine hoist, comprising: 1) setting a judging period T and a sampling number n for an industrial camera 2 and an shaft encoder 3 in the judging period T, i.e., a sampling interval At=T/n, via an industrial PC 5, setting analyzing periods Τι, T2, T3, ..., Tz in the same judging period T in different time periods in a sampling process at a time interval ιη·Δΐ, and setting lengths SI and S2 as thresholds forjudging whether a rope disorder has occurred, wherein, m<n, and S2>S1; 2) mounting the industrial camera 2 at the upper rear part of the steel wire rope reel 1, so that the industrial camera 2 can fully shoot the rope outlet position of the steel wire rope 6 on the reel 1; connecting the industrial camera 2 with the upper computer 5 through a communication cable 7; 3) acquiring the images of the steel wire rope 6 continuously in the rope winding/releasing process of the reel 1 via the industrial camera 2, and transmitting the images to the industrial PC 5; 4) processing the images on the industrial PC 5 by graying processing and threshold processing, to separate the steel wire rope 6 from the background; 5) setting a horizontal line 8 near the surface of the reel 1 on the images processed by threshold processing, setting a color A (such as black) for the steel wire rope region above the horizontal line 8, setting a different color B (such as white) for the other region, and selecting the pixels in the region of the color A above the horizontal line 8 where the average value of the horizontal coordinate values is equal to an outlet position of the steel wire rope 6; 6) setting limit positions Ai, Bi for the rope outlet position on the reel 1 at the two ends of the reel 1 in the width direction under different winding layers of the steel wire rope 6 via the industrial PC 5, wherein, i=l, 2, ..., j, i.e., the ith winding layer counted from the inner side to the outer side on the reel 1; 3 7) analyzing the rotation angle of the reel 1 measured by the shaft encoder 5 and the rope outlet position on the reel 1 measured by the industrial camera 2 in a period T among the periods Τι, T2, T3, ..., Tz sequentially on the industrial PC 5: 2015372216 11 Μ 2016 a) if the rope outlet position in a period T doesn't reach to Ai or Bi: 5 judging a rope disorder has occurred in the rope winding process of the reel 1 and giving off an alarm, if the rotation angle of the reel 1 measured by the shaft encoder 5 changes continuously and the absolute value of the difference between the final rope outlet position of the steel wire rope 6 and the initial rope outlet position is within the threshold SI or greater than or equal to the threshold S2; 0 judging there is no rope disorder in the winding process of the reel 1, if the rotation angle of the reel 1 measured by the shaft encoder 5 changes continuously and the absolute value of the difference between the final rope outlet position of the steel wire rope 6 and the initial rope outlet position is beyond the threshold SI and smaller than the threshold S2; judging that the reel 1 has stopped winding, if the rotation angle values of the reel 1 measured by 5 the shaft encoder 5 are the same. b) if the rope outlet position in a period T reaches to the limit position Ai or Bi: judging a rope disorder has occurred in the rope winding process of the reel 1 and giving off an alarm, if the rotation angle of the reel 1 measured by the shaft encoder 5 changes continuously and the sum of the absolute value of the difference between the final rope outlet position of the 0 steel wire rope 6 and the position coordinate of Ai or Bi and the absolute value of the difference between the initial rope outlet position of the steel wire rope 6 and the position coordinate of Ai or Bi is within the threshold SI or greater than or equal to the threshold S2; judging there is no rope disorder in the rope winding process of the reel 1, if the rotation angle of the reel measured by the shaft encoder 5 changes continuously and the sum of the absolute value 5 of the difference between the final rope outlet position of the steel wire rope 6 and the position coordinate of Ai or Bi and the absolute value of the difference between the initial rope outlet position of the steel wire rope 6 and the position coordinate of Ai or Bi is beyond the threshold SI and smaller than the threshold S2; judging that the reel 1 has stopped winding, if the rotation angle values of the reel 1 measured by 0 the shaft encoder 5 are the same. 4

Claims

Claims
1. A rope disorder judging method for a rope winding reel of a mine hoist, comprising: 1) setting a judging period T and a sampling number n for an industrial camera and a shaft encoder in the judging period T, i.e., a sampling interval At=T/n, setting analyzing periods Tl, T2, T3, ..., Tz in the same judging period T in different time periods in a sampling process at a time interval m*At, and setting lengths SI and S2 as thresholds forjudging whether a rope disorder has occurred, wherein, m<n, and S2>S 1; 2) acquiring images of the steel wire rope continuously in a rope winding/releasing process of the reel via the industrial camera, and transmitting the images to an industrial PC; 3) processing the images on the industrial PC by graying processing and threshold processing, to separate the steel wire rope from the background; 4) setting a horizontal line near the surface of the reel on the images processed by threshold processing, setting a color A for the steel wire rope region above the horizontal line, setting a different color B for the other region, and selecting the pixels in the region of the color A above the horizontal line where the average value of the horizontal coordinate values is equal to a steel wire rope outlet position; 5) setting limit positions Ai, Bi for the rope outlet position on the reel at the two ends of the reel in the width direction under different winding layers of the steel wire rope, wherein, i=l, 2,..., j, i.e., the ith winding layer counted from the inner side to the outer side on the reel; 6) analyzing a rotation angle of the reel measured by the shaft encoder and a steel wire rope outlet position on the reel measured by the industrial camera in a period T among the periods Τι, T2, T3,..., Tz sequentially on the industrial PC: a) if the rope outlet position in a period T doesn't reach to the limit position Ai or Bi: judging a rope disorder has occurred in the rope winding process of the reel and giving off an alarm, if the rotation angle of the reel measured by the shaft encoder changes continuously and the absolute value of the difference between the final rope outlet position of the steel wire rope and the initial rope outlet position is within the threshold S1 or greater than or equal to the threshold S2; judging there is no rope disorder in the rope winding process of the reel, if the rotation angle of the reel measured by the shaft encoder changes continuously and the absolute value of the difference between the final rope outlet position of the steel wire rope and the initial rope outlet position is beyond the threshold S1 and smaller than the threshold S2; judging that the reel has stopped winding, if the rotation angle values of the reel measured by the shaft encoder are the same; b) if the rope outlet position in a period T reaches to the limit position Ai or Bi: judging a rope disorder has occurred in the rope winding process of the reel and giving off an alarm, if the rotation angle of the reel measured by the shaft encoder changes continuously and the sum of the absolute value of the difference between the final rope outlet position of the steel wire rope and the position coordinate of Ai or Bi and the absolute value of the difference between the initial rope outlet position of the steel wire rope and the position coordinate of Ai or Bi is within the threshold S1 or greater than or equal to the threshold S2; judging there is no rope disorder in the rope winding process of the reel, if the rotation angle of the reel measured by the shaft encoder changes continuously and the sum of the absolute value of the difference between the final rope outlet position of the steel wire rope and the position coordinate of Ai or Bi and the absolute value of the difference between the initial rope outlet position of the steel wire rope and the position coordinate of Ai or Bi is beyond the threshold S1 and smaller than the threshold S2; judging that the reel has stopped winding, if the rotation angle values of the reel measured by the shaft encoder are the same.