System and method for estimating damage to a shaker table screen using computer vision

A system comprising:

• a shale shaker;
• a shale shaker screen installed on the shale shaker;
• a processor;
• and
• a single camera positioned to capture one or more images of the shale shaker screen installed on the shale shaker and arranged at a camera angle relative to the shale shaker, wherein the camera is operably connected to the processor and the processor capable of receiving the one or more images of the shale shaker screen from the single camera during operation of the shale shaker screen installed on the shale shaker;
• wherein the processor is configured to:
• analyze the one or more images and is trained to detect clogged sections of the shale shaker screen using training images, and determine whether a percentage of the shale shaker screen that is clogged exceeds a pre-defined threshold during operation of the shale shaker screen installed on the shale shaker;
• generate a simulated view of the shale shaker screen from the one or more images at the camera angle from the single camera, wherein the simulated view is at a simulated angle different from the camera angle;
• detect damaged regions of the shale shaker screen using the simulated view;
• and
• provide an alert to an operator in response to determining that the percentage of the shale shaker screen that is clogged exceeds the pre-defined threshold or responsive to the detected damaged regions.

A method comprising:

• capturing visual images of a shale shaker screen installed in a shale shaker using a single camera and at a camera angle relative to the shale shaker screen;
• transferring the captured images to a processor operably connected to the single camera;
• analyzing, using the processor, the captured images during operation of the shale shaker screen installed on the shale shaker;
• detecting, using the processor, damaged regions or clogged regions of the shale shaker screen based on analysis of the captured images;
• determining, using the processor, whether a percentage of the shale shaker screen that is damaged or clogged exceeds a pre-defined threshold, wherein the pre-defined threshold ranges from 3% to 20%;
• and
• providing an alert to an operator in response to determining that the percentage of the shale shaker screen that is damaged or clogged exceeds the pre-defined threshold,
• wherein the method further comprises:
• generating, using the processor, a simulated view of the shale shaker screen from the at least one image at the camera angle from the single camera, wherein the simulated view is at a simulated angle different from the camera angle;
• and
• detecting, using the processor, damaged regions of the shale shaker screen using the simulated view.

A system for detecting damaged shaker screens comprising:

• a shale shaker screen installed on a shale shaker;
• a processor;
• and
• at least one camera operably connected to the processor and arranged at a camera angle relative to the shale shaker screen, wherein the camera is positioned to capture at least one image of at least a portion of the shale shaker screen installed on the shale shaker and wherein the processor is configured to receive the image from the camera and analyze the image in order to detect damaged area of the shale shaker screen during operation of the shale shaker screen installed on the shale shaker;
• wherein the processor is trained to detect damaged regions of the shale shaker screen using the image and training images, and is configured to determine whether a percentage of the shale shaker screen that is damaged exceeds a pre-defined threshold, wherein the pre-defined threshold ranges from 3% to 20%;
• and
• wherein the processor is configured to provide an alert to an operator in response to determining that the percentage of the shale shaker screen that is damaged exceeds the pre-defined threshold, wherein the processor is further configured to generate a simulated view of the shale shaker screen at a simulated angle different from the camera angle by:
• receiving input images of the portion of the at least portion of the shale shaker screen from the at least one camera;
• and
• generating the simulated view of the shale shaker screen at the simulated angle by warping the received input images, the simulated view with the simulated angle being different from the camera angle of the received input images;
• and
• wherein the processor is further configured to detect damaged regions of the shale shaker screen using the simulated view.