机器视觉论文：基于机器视觉的轧钢厂自动分钢系统的研究及应用_

1、机器视觉论文：基于机器视觉的轧钢厂自动分钢系统的研究及应用【中文摘要】钢铁厂中的轧钢厂主要是生产螺纹钢和圆钢,也称棒材厂。棒材厂一般采用实重或定支的成捆出售方式。无论采用哪种出售方式,两个必不可少的工作是统计一捆棒材中棒材个数和分离不同捆棒材。大多数棒材厂都是采用机械式人工计数和人工分离方式完成的,这种方式很容易出现统计错误和分钢错误问题。一方面直接影响棒材厂经济效益,另一方面如果出现少支情况会降低棒材厂的信誉。本文提出了一种高效、易操作的棒材自动分钢方式,称作自动分钢系统。该系统采用先进的图像处理技术,识别链床上的棒材并统计棒材个数。当统计的棒材个数到达额定支数后,由上位机通过串口通讯给伺服

2、驱动器发送相关的分钢命令,伺服驱动器再控制高精度的伺服电机带动端分机到达分钢位置进行棒材端头分离。然后,上位机控制若干中分机将端头分开的棒材之间的距离拉大,直到完全分离。这样就实现了棒材的自动完全分离,称作完全分钢。基于机器视觉的自动分钢系统是在自动计数系统的基础上设计实现的。自动计数系统通过采集棒材端面图像来识别棒材信息。本文采用的是在图像处理识别目标物体中应用比较广泛的一种算法来确认棒材中心,这种算法称作干杯算法。干杯算法是近期提出的一种类圆形目标识别方法,该算法首先获取目标图像的类圆形模块边缘检测信息,以及提取目标图像边缘时得到的边缘梯度信息,然后增强图像中类圆形模块中心信息,采用中心聚

3、合算法获得类圆形模块中心位置,再根据一定参数确定类圆形模块中心。本课题研究的基于机器视觉的自动分钢系统在山东莱芜钢铁厂轧钢一车间调试运行成功后,进过一个月的使用已经能到达现场的使用要求并被厂家认可,现已在该车间正式投入使用。本文研究的自动分钢系统有两大创新点：1采用高精度、快速的伺服电机实现精确分钢和快速分钢。伺服电机的精度可达到微米级,电机转速最高可达到3000r/min。利用该伺服电机实现的系统性能,即能保证分离成捆棒材的正确性,又不耽误棒材厂生产车间正常的生产节奏。2针对棒材出现复杂的叠层情况,本文提出了分钢校正的设计方法。该方法先将叠层的棒材捅开或打散,变成容易分离的部分,然后再进行分

4、钢。这种情况无疑是自动分钢系统重点需要解决的问题,解决了这个问题相当于将系统的精度提到一个很高的水平。【英文摘要】The main production of the rolling mills, or the bar mills, is steel and round steel. The rolling mills generally use the sale of the actual weight of a bundle of steel bars. Either way of the sale styles, there are two essential works. One is

5、 to count the number of a bundle of steel bars; the other is to split the steel bars between two bundles of steel bars. Most of rolling mills use artificially manual counting and separation manner, this approach is prone to statistical errors and separation errors. On the one hand it will bring a di

6、rect impact on economic to rolling mills, on the other hand it will reduce the credibility of rolling mills if the situation appears.This paper presents an efficient and easy way for separating steel bars automatically, which is called the system of separating steel bars automatically. It adopts adv

7、anced image recognition technology to identify the end face of bars and count the number of the bars. When the statistics of the number of bars reaches the rating number, the chain bed is stopped by IPCs command and the IPC sends separation of steel bars signals to servo driver through serial port c

8、ommunication. The servo driver controls the servo motor driving separation machine to the appointed separation position and separates steel bars. After that, the IPC controls the middle separation machine to widen the distance between the steel bars until the separation is completed. When the bars a

9、re totally separated, the separation machine send a signal to IPC, which will start the next automatic count and separation process. This is the whole separation process.Automatic separating steel bars system is implemented on the basis of the automatic counting system. The automatic separating stee

10、l bars system has been debugged successfully in NO.1 workshop of Laiwu rolling mill in Shandong province and has been used formerly. The automatic counting system adopts collecting images of bar end to identify the bar information. In this paper, the cheer algorithm, which is widely used in image pr

11、ocessing, is used to recognition the bar center. The cheer algorithm is circular-like target recognition algorithm, which uses edge detection to obtain the edge information of the end face of steel bars and direction information. Then it enhances the central message of the end face of steel bars and

12、 uses central aggregation algorithm to get and confirm the center of the end face of steel bars next. At last, it establishes circular-like center according to certain parameters.The research of the automatic separating steel bars system has two main innovations:1 This paper uses a high-precision an

13、d fast servo motor to achieve the precise and rapid separation of steel bars, which guarantees the correctness of the number of bundles of bar and do not delay the normal production rhythm of the factory workshop in rolling mills. The accuracy of the servo motor can achieve micron-level, and its spe

14、ed can reach 3000r/min.2 This paper proposes a design method of separation emendation to resolve the complex situation of the multiple stacked steel bars. Separation emendation is adopted firstly to make the distance of the bars become large in order to separate them simply. Separation emendation ta

15、kes the measure of controlling the end separation wedge raise a distance aiming at pulling the bars away. This is undoubtedly the bottleneck of the automatic separating steel barssystem. If this problem is resolved, the separation system will achieve a very high level.【关键词】机器视觉 图像处理 伺服电机 串口通讯【英文关键词】

16、Machine vision Image processing Servo motor Serial communication【目录】基于机器视觉的轧钢厂自动分钢系统的研究及应用摘要10-12ABSTRACT12-13第一章 绪论14-201.1 研究背景141.2 研究现状及意义棒材计数分钢系统研究现状棒材计数分钢系统研究意义16-171.3 课题的研究内容17-20第二章 棒材自动分钢系统介绍20-282.1 棒材自动分钢系统设计方案20-212.2 自动分钢系统的硬件架构21-242.3 自动分钢系统的软件组成24-28第三章 棒材自动计数系统原理28-463.1 机器视觉与图像处理机器视觉图像处理技术28-313.2 棒材识别算法模板匹配算法环匹配棒材识别算法干杯算法35-363.3 棒材识别过程采集棒材端面图像图像滤波算法棒材端面图像预处理图像中的棒材识别过程41-46第四章 自动分钢系统设计46-544.1 自动分钢系统分钢流程46-474.2 计算分钢位置值47-494.3 完全分钢棒材端头分钢棒材中分50-514.4 自动分钢系统操作模式选择51-54第五章 棒材分离的实现方法54-685.1 伺服电机和伺服驱动器伺服系统伺服电机伺服驱动器实现上位