Grate cooler abnormal material detection system and implementation method

Abstract

The invention provides a grate cooler abnormal material detection system and an implementation method, the grate cooler abnormal material detection system is characterized by comprising a Doppler ultrasonic detection module, an infrared and image recognition module, a cooling system module and a data analysis and report module, the Doppler ultrasonic detection module is used for detecting the position and size of large cement clinker and the thickness of a material bed; the infrared and image recognition module is used for recognizing edge column red materials; according to the infrared and image recognition system, through the vanadium oxide non-refrigeration type detector, a specific algorithm and high-temperature adaptability design, the infrared and image recognition system can stably work in the grate cooler environment with the high temperature of 200-1000 DEG C and much dust, and the problems that common infrared rays are reduced in precision at the high temperature and prone to being interfered are solved; according to the method, the position and the size of the large cement clinker are detected in combination with the Doppler ultrasonic technology, accurate detection and treatment of abnormal materials of the grate cooler are achieved, the problems that traditional manual detection is low in efficiency and poor in precision are solved, and the stability and the intelligent level of cement production are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of cement production detection, and particularly relates to a grate cooler abnormal material detection system and an implementation method. BACKGROUND

[0002] Cement is an essential building material in the construction industry. With the acceleration of urbanization, the demand for cement is increasing, and it is crucial to ensure the quality of cement production. Cement production is a thermal process, and the grate cooler is a key equipment for cooling clinker. Its operating efficiency directly affects the output and energy consumption of the cement production line. However, the grate cooler is easily disturbed by abnormal materials (such as oversized clinker, edge column red material, etc.) during operation, leading to equipment failure, reduced efficiency, and even shutdown.

[0003] At present, most domestic cement enterprises still use manual control to handle abnormal materials, which is greatly affected by human factors and is difficult to ensure cement quality and production efficiency. Therefore, there is an urgent need to develop an intelligent grate cooler abnormal material detection system.

[0004] Although existing infrared detection technology on the market can be used for material detection, it has obvious defects in the harsh environment of high temperature (200-1000 ℃) and high dust of the grate cooler: first, the high-temperature resistance is insufficient, and long-term work can cause equipment damage or a significant decrease in detection accuracy (usually more than 80 ℃ environment causes error increase); second, the anti-interference ability is weak, dust and water vapor can cause infrared signal scattering, causing misjudgment; third, the imaging resolution is low (usually below 320x240), making it difficult to accurately locate the edge column red material; fourth, when used alone, it can only detect temperature and cannot combine with material morphology information for comprehensive judgment.

[0005] Therefore, there is a lack of efficient abnormal material detection system for the environment of the grate cooler, and traditional detection methods and ordinary infrared technology have low visualization, poor real-time performance, insufficient accuracy, and other problems, which cannot meet the needs of modern cement production.

[0006] Therefore, a new grate cooler abnormal material detection system and implementation method are provided to solve the above problems. SUMMARY

[0007] According to the above technical problems, the present application provides a grate cooler abnormal material detection system and implementation method that realizes accurate detection and real-time processing of abnormal materials of the grate cooler, and improves the stability and intelligent level of cement production.

[0008] The application provides a grate cooler abnormal material detection system and an implementation method, characterized by comprising a Doppler ultrasonic detection module, an infrared and image recognition module, a cooling system module, a data analysis and report module, and a communication and feedback module, the Doppler ultrasonic detection module is used for detecting the position and size of large cement clinker and the thickness of the material bed; the infrared and image recognition module is used for identifying the edge column red material, the cooling system module is used for ensuring that the detection system works normally in a high-temperature environment; and the data analysis and report module is used for realizing data acquisition, processing and alarm.

[0009] A plurality of 1P20 ultrasonic probes are arranged in the Doppler ultrasonic detection module, the number of the ultrasonic probes is 6, the 6 ultrasonic probes are arranged in the device in the form of a ring array, the signal acquisition line in the Doppler ultrasonic detection module is separated from each probe and fixed to the outside of the grate cooler through a support, the position and size of the large cement clinker are determined according to the different reflectivity of the ultrasonic wave of a specific range of frequencies reflected by the large cement clinker and other parts of the semi-fluid in the high-temperature semi-fluid, and the thickness and conveying speed of the material on the external conveying belt are detected.

[0010] An infrared high-temperature camera is arranged in the center of the 6 ultrasonic probes in the infrared and image recognition module, the infrared and image recognition module combines machine vision and edge detection algorithm, identifies the edge column continuous red material in the high-temperature semi-fluid cement clinker in real time, and feeds back to the material conveying control system in real time, the infrared and image recognition module adopts a vanadium oxide uncooled detector, is assembled in the center of the Doppler ultrasonic array, identifies the edge column red material, realizes 10-point temperature measurement through intelligent information superposition, identifies the edge column red material at a resolution of 640512 and a pixel of 17 microns, the temperature measurement distance is 0.5-15 m, and the temperature range is 0-800 DEG C.

[0011] The cooling system module adopts a high-pressure gas cooling strategy, is configured with a 15-0.8 MPa fixed screw air compressor, a JS-10HP gas storage tank with a design pressure of 0.84 MPa and a SIZE-015Q dryer with a design pressure of 1 MPa, is cooled through a vacuum layer and double-layer thermal insulation cotton, and adopts a split air blowing flow to cool the probe and the circuit board respectively, so that the infrared module can stably work in an environment of 200-1000 DEG C.

[0012] The data analysis and report module supports real-time display of thickness data, large block data and red river temperature, has large block supercritical alarm and red river positioning high-temperature alarm functions, records data in real time and generates video reports in different time periods, The communication and feedback module adopts an efficient data processing mechanism, and the recognition result is quickly transmitted to the grate cooler control system through Profibus / Profinet / Modbus TCP protocol.

[0013] The specific implementation method of applying the system to the grate cooler material detection comprises the following steps: S1: System design and module development: determine the technical route of Doppler ultrasonic wave, infrared and image recognition, develop a Doppler ultrasonic detection module with a 6-probe ring array, select an infrared and image recognition module with a vanadium oxide non-refrigeration detector, design a cooling system module containing high-pressure gas cooling, build a data analysis and reporting module supporting real-time data acquisition and alarm, and formulate detailed technical specifications and acceptance standards, including but not limited to detection accuracy, response time, working temperature range, anti-interference capability and other indicators; S2: Integrate the Doppler ultrasonic probe, infrared detection and cooling system, verify the ultrasonic detection accuracy using 1 ton of cement products with different block sizes, verify the infrared recognition effect by simulating the red material in a high-temperature furnace, test the cooling system performance in a 0-1000℃ adjustable temperature environment, conduct at least 72 hours of continuous operation test, record the system stability, data accuracy and failure rate, and form a detailed test report; S3: Open a 30cm diameter through-hole in the top of the grate cooler kiln, install the probe box and circuit box respectively, and use the kiln blower to interface the cooling system; conduct 15 days of continuous testing in a real production environment to verify the detection accuracy and stability of the system under 200-1000℃ working conditions, record ≥100 abnormal material events, and require the system detection accuracy to be ≥95% and the alarm response time to be ≤1 second.

[0014] In the S1 stage, the Doppler ultrasonic detection module needs to meet the detection accuracy of the large cement clinker size ≤20cm, the position accuracy ≤10cm, and the material bed thickness detection accuracy ≤10cm; the infrared and image recognition module needs to meet the position accuracy of the edge column red material ≤20cm, the detection distance ≥15m, and the detection angle ≥30%; all modules need to pass the CE certification and ISO9001 quality system certification.

[0015] In the S2 stage, the cooling system needs to ensure that the detection equipment works stably under 200-1000℃ working conditions, the system communication delay is ≤2 seconds; the data acquisition accuracy needs to reach 99.9% or above, and the false alarm rate is ≤0.1%.

[0016] The present application provides a grate cooler abnormal material detection system and implementation method, the infrared module has the following advantages compared with ordinary infrared: using a vanadium oxide non-refrigeration detector and a 640x512 high resolution, combined with an edge detection algorithm, solving the problems of ordinary infrared in high temperature, such as accuracy decline and weak anti-interference, realizing the positioning accuracy of ±20cm for the edge column red material, which is more than 30% better than ordinary infrared.

[0017] (2) High temperature adaptability design: The cooling system is customized for the infrared module, ensuring its stable operation under the condition of 200-1000 ℃, overcoming the defects of ordinary infrared high temperature resistance, communication delay ≤ 2 seconds, meeting the real-time detection requirements of the grate cooler high temperature.

[0018] (3) Multi-technology fusion to realize accurate detection: Doppler ultrasonic detection module combined with 6 probe ring array, realizing the detection accuracy of ± 20 cm for large clinker size and ± 10 cm for position, working with infrared module to solve the limitations of traditional detection and ordinary infrared single technology.

[0019] (4) Intelligent data management: Data analysis module supports real-time alarm and time period report generation, providing data support for production decision-making and improving the intelligent level of cement production. BRIEF DESCRIPTION OF DRAWINGS

[0020] Figure 1 is the overall structure schematic diagram of the present application; Figure 2 is the ultrasonic detection subprogram flowchart of the present application; Figure 3 is the edge column red material detection subprogram of the present application.

[0021] Reference signs: 1. Air compressor 2. Air tank; 3. Ultrasonic probe; 4. Infrared camera; 5. Communication and feedback module line box; 6. Circuit box. DETAILED DESCRIPTION Example 1

[0022] The technical solutions of the present application will be described clearly and completely in combination with the drawings of the present application.

[0023] As shown in FIG. 1, the grate cooler abnormal material detection system provided by the present application includes a Doppler ultrasonic detection system, an infrared and image recognition system, a cooling system module, a communication and feedback module, and a data analysis and report module.

[0024] In the specific implementation process, the implementation mode of each system module is as follows: Doppler ultrasound detection system: Doppler ultrasound probes of model 1P20 are used in the form of a 6-probe ring array, which is vertically suspended from the top of the grate cooler kiln. Each probe is equipped with an independent signal acquisition line, which is fixed to the outside of the grate cooler through a support to avoid the influence of high temperature. This system detects the thickness of the material bed and the loose condition of the cement by the time difference of the ultrasonic echo and the frequency spectrum distribution of the echo, and can monitor the position and size of the large cement clinker in real time. In practical application, the detection accuracy of the system for the size of the large cement clinker can reach ±20 cm, the position accuracy can reach ±10 cm, and the detection accuracy of the material bed thickness can reach ±10 cm.

[0025] Infrared and image recognition system: Vanadium oxide uncooled detectors are selected (compared with ordinary infrared tellurium cadmium mercury detectors, the stability is improved by 40% in the environment of 100-1000°C), which are assembled in the center of the Doppler ultrasound array and are cooled by air cooling. This system realizes 10-point temperature measurement by intelligent information superposition, recognizes the edge column red material with a resolution of 640x512 and a pixel of 17 microns, the temperature measurement distance is 0.5-15 m, and the temperature range is 0-800°C (covering the common temperature of the edge column red material of the grate cooler, ordinary infrared is limited to 0-500°C). In actual operation, the system combines machine vision and edge detection algorithm (which can filter more than 90% of dust interference, and ordinary infrared can only filter 30%), and can identify the edge column continuous red material in the high-temperature semi-fluid cement clinker in real time, and can feed the related data to the material conveying control system in real time. The position accuracy of the edge column red material can reach ±20 cm.

[0026] Cooling system module: High-pressure gas cooling strategy is adopted, 15-0.8 MPa fixed permanent magnet screw air compressor, JS-10HP gas storage tank with design pressure of 0.84 MPa and SIZE-015Q dryer with design pressure of 1 MPa are configured. The cooling system is double-insulated by vacuum layer and thermal insulation cotton, and the probe and circuit board are cooled by split air flow respectively to ensure that the infrared and image recognition module 2 can operate stably at a high temperature of 200-1000°C.

[0027] Communication and feedback module: The system adopts an efficient data processing mechanism to process and analyze the data collected by the Doppler ultrasound detection system 1 and the infrared and image recognition module 2 in real time. The recognition results are quickly transmitted to the grate cooler control system through Profibus / Profinet / Modbus TCP protocol to realize automatic disposal. The delay of the whole communication process is ≤2 seconds, which ensures that the system can respond to abnormal situations in time.

[0028] The following are the preliminary test steps of the system applied to the material detection of the grate cooler: S1: System design and device development In the system design phase, the technical route centered on Doppler ultrasound, infrared, and image recognition was determined, focusing on optimizing the differences between the infrared module and ordinary infrared: a vanadium oxide uncooled detector, 640x512 high resolution, and 0-800 ℃ temperature measurement range were selected. The development team designed a ring array Doppler ultrasound detection system 1 composed of 6 1P20 type probes, constructed an infrared and image recognition module 2, designed a cooling system module 3 including a high-pressure gas cooling component, and a communication and feedback module 4 supporting real-time data acquisition, alarm, and report generation. At the same time, the technical indicators of each module were clarified, including the size detection accuracy of bulk cement clinker ≤ 20 cm, position accuracy ≤ 10 cm, bed thickness detection accuracy ≤ 10 cm, and edge column red material position accuracy ≤ 20 cm.

[0029] S2: System integration and experimental verification The developed Doppler ultrasound probe, infrared detection, and cooling system were integrated and comprehensively tested in a laboratory environment. Different sizes of cement products were used to verify the accuracy of ultrasonic detection, and a high-temperature furnace was used to simulate red material working conditions (800 ℃, containing 50 mg / m³ dust) to verify the infrared recognition effect: the infrared module of the system had an accuracy rate of 98%, and the ordinary infrared had an accuracy rate of 72%. The cooling system was tested in a temperature-adjustable environment of 0-1000 ℃ to test its protection performance on the probe and circuit: the infrared module of the system worked continuously for 72 hours without failure, and the ordinary infrared had 2 data interruptions after working in an environment above 100 ℃ for 48 hours. The communication delay (≤ 2 seconds), data acquisition accuracy (≥ 99.9%), and false alarm rate (≤ 0.1%) of the system were recorded. Based on the experimental data, the system was optimized, and the ultrasonic echo analysis algorithm and infrared recognition threshold were adjusted.

[0030] S3: Industrial testing and optimization The system was tested in a real cement production environment, and the grate cooler of a cement plant was chosen as the test object. The probe box was installed separately on the top of the grate cooler kiln, and the circuit box was placed outside the kiln. The cooling system was connected to the kiln blower. During the 15-day continuous test, the system successfully detected ≥ 100 abnormal material events with a detection accuracy of ≥ 95% and an alarm response time of ≤ 1 second. Comparative tests showed that the ordinary infrared had a position deviation of ≥ 30 cm on the 3rd day and completely failed on the 7th day in this environment. Based on the test results, the algorithm and hardware were further optimized to improve the stability and reliability of the system in complex working conditions. Example 2

[0031] After the preliminary test and confirmation that the system meets the requirements, the system is actually applied to the material detection of the grate cooler actual production, and the specific steps are as follows: 1. System installation and deployment: first, a through hole is opened in the top of the grate cooler, the detection device (6 ultrasonic probes arranged in a ring array, and the infrared high-temperature camera is placed in the center of the array) integrated with the Doppler ultrasonic probe and the infrared high-temperature camera is installed in the hole through the probe box, and the circuit box is placed outside the grate cooler. The circuit and the probe are connected by a hard pipe, the pipe is laid with a line and a gas cooling channel is reserved. Then install the cooling system related equipment, place the fixed screw air compressor, air tank and dryer in order, connect them through the pipeline to form a cooling gas circuit, and at the same time, adopt a double-layer insulation structure of vacuum layer and thermal insulation cotton to wrap the related pipeline and the key parts of the detection device. Finally, lay the circuit, connect the signal acquisition lines of the Doppler ultrasonic detection module, the infrared and image recognition module with the data analysis and report module, the communication and feedback module, and fix the signal acquisition lines on the outside of the grate cooler through the bracket to ensure that the lines are away from the high-temperature area, and complete the data transmission link building between the modules.

[0032] 2. Function test and verification: first, high-temperature resistance test, start the cooling system, let the air compressor, air tank and dryer work together, cool the probe and circuit board through the split type external air flow, in the working environment of 200-1000℃ of the grate cooler, continuously run the equipment, observe whether the infrared and image recognition module and the Doppler ultrasonic detection module can work stably, without fault alarm or data anomaly. Use the actual cement clinker material in the grate cooler to observe whether the Doppler ultrasonic detection module can accurately identify the position and size of the large cement clinker and the thickness of the material bed, and at the same time, check whether the infrared and image recognition module can accurately identify the red material in the edge column, whether the identification result can be quickly transmitted to the grate cooler control system through the communication and feedback module, record the abnormal material event, check whether the system detection accuracy and alarm response meet the requirements, and continuously monitor the data acquisition during the period to ensure that there is no obvious data error or false alarm phenomenon.

[0033] 3. Daily maintenance and repair: during daily use, check the air compressor and air tank of the cooling system regularly, and timely discharge the water accumulated in the air tank to avoid affecting the cooling air quality and ensure the normal gas production of the air compressor and the stable pressure of the air tank. When the kiln is stopped, overhaul the detection device comprehensively, remove the infrared high-temperature camera and ultrasonic probe, check whether there is dust accumulation or damage on the surface, and clean or replace it if necessary; at the same time, check whether the circuit connection part is loose or aged, whether the gas circuit pipeline leaks, repair or replace the damaged or aged parts in time to ensure that the equipment can operate normally next time.

[0034] The abnormal material detection system of the grate cooler of the present application combines multi-technology fusion and strict development process, realizes accurate detection and real-time processing of abnormal materials of the grate cooler, effectively solves the defects of traditional manual detection and ordinary infrared technology, and significantly improves the stability and intelligent level of cement production.

[0035] The above shows and describes the basic principles and main features of the present application and the advantages of the present application. The various components mentioned in the present application are common techniques in the prior art, and those skilled in the art should understand that the present application is not limited to the above examples, and the above examples and descriptions in the specification are only to illustrate the principles of the present application. Without departing from the spirit and scope of the present application, various changes and improvements can be made to the present application, and these changes and improvements all fall within the scope of the claimed present application. The scope of protection of the present application is defined by the appended claims and their equivalents.

Claims

1. A grate abnormal material detection system, characterized in that The system comprises a Doppler ultrasonic detection module, an infrared and image recognition module, a cooling system module, a data analysis and reporting module, and a communication and feedback module, wherein the Doppler ultrasonic detection module, the infrared and image recognition module, and the cooling system module are integrated and arranged on the top of the cement kiln, the Doppler ultrasonic detection module is used for detecting the position of the large cement clinker, the size of the cement block, and the thickness of the material bed, the infrared and image recognition module is used for identifying the edge column red material, and the cooling system module is used for ensuring the normal operation of the detection system in a high-temperature environment, and the data analysis and reporting module is used for realizing data acquisition, processing, and alarm.

2. The grate abnormal material detection system according to claim 1, characterized in that A plurality of ultrasonic probes are arranged in the Doppler ultrasonic detection module, the number of the ultrasonic probes is 6, the 6 ultrasonic probes are arranged in the device in the form of a ring array, the signal acquisition lines in the Doppler ultrasonic detection module are separated from each probe and fixed to the outside of the grate cooler through a support, the position and size of the large cement clinker are determined according to the different reflectivity of the ultrasonic wave of a specific range of frequencies reflected by the boundary between the large cement clinker and the other part of the semi-fluid in the high-temperature semi-fluid, and the thickness and conveying speed of the material on the external conveying belt are detected.

3. The grate abnormal material detection system according to claim 2, characterized in that An infrared high-temperature camera is arranged in the infrared and image recognition module and arranged at the center of the 6 ultrasonic probes, the infrared and image recognition module combines machine vision and edge detection algorithm to identify the edge column continuous red material in the high-temperature semi-fluid cement clinker in real time and feed back to the material conveying control system in the cement production in real time, a vanadium oxide uncooled detector is arranged in the infrared and image recognition module and assembled at the center of the array of the Doppler ultrasonic probes to identify the edge column red material.

4. The grate abnormal material detection system of claim 1, wherein The cooling system module is configured with a 15-0.8 MPa fixed screw air compressor, a gas tank with a pressure of 0.84 MPa, and a dryer with a pressure of 1 MPa, and is double-insulated by a vacuum layer and thermal cotton, and the circuit boards of the Doppler ultrasonic probes and the infrared high-temperature camera are cooled by a split air flow to ensure that the infrared and image recognition module works stably in an environment of 200-1000 ℃.

5. The grate abnormal material detection system of claim 1, wherein The data analysis and reporting module supports real-time display of the thickness data of the cement block, the large block data, and the temperature of the edge column red material, has the functions of large block supercritical alarm and edge column red material positioning high-temperature alarm, and records data in real time and generates video reports in different time periods. The communication and feedback module transmits the recognition results to the grate cooler control system quickly through Profibus / Profinet / Modbus TCP protocol.

6. The grate abnormal material detection system of claim 1, wherein The specific implementation method of applying the system to the material detection of the grate cooler comprises the following steps: S1: develop a Doppler ultrasonic detection module with a 6-probe ring array, select an infrared and image recognition module with a non-cooled infrared detector, design a cooling system module containing high-pressure gas cooling, build a data analysis and reporting module supporting real-time data acquisition and alarm, and formulate detailed technical specifications and acceptance standards. S2: Integrate Doppler ultrasound probe, infrared detection and cooling system, use 1 ton of different block size of cement products to verify the accuracy of ultrasonic detection, simulate red material through high temperature furnace to verify the effect of infrared identification, test the performance of cooling system in 0-1000 ℃ adjustable temperature environment; carry out at least 72 hours of continuous operation test, record system stability, data accuracy and failure rate, and form detailed test report; S3: Open a diameter of 30 cm through hole at the top of the grate cooler kiln, install probe box and circuit box respectively, use kiln blower to connect cooling system (specific connection method); carry out 15 days of continuous test in real production environment, verify the detection accuracy and stability of the system under the working condition of 200-1000 ℃, record ≥ 100 times of abnormal material events, require the system detection accuracy ≥ 95 %, alarm response time ≤ 1 second.

7. The abnormal material detection system for a grate cooler according to claim 6, characterized in that: In the S1 stage, the Doppler ultrasonic detection module needs to meet the size detection accuracy of the large block cement clinker ≤ 20 cm, the position accuracy ≤ 10 cm, and the thickness detection accuracy of the material bed ≤ 10 cm; the infrared and image recognition module needs to meet the position accuracy of the side column red material ≤ 20 cm, the detection distance ≥ 15 m, and the detection angle ≥ 30 %; all modules need to pass CE certification and ISO9001 quality system certification.

8. The abnormal material detection system for a grate cooler according to claim 6, characterized in that: In the S2 stage, the cooling system needs to ensure that the detection equipment works stably under the working condition of 200-1000 ℃, the system communication delay ≤ 2 seconds; the data acquisition accuracy needs to reach more than 99.9 %, and the false positive rate ≤ 0.1 %.

9. The abnormal material detection system for a grate cooler according to claim 6, characterized in that: In the S3 stage, the circuit and probe head are connected by hard pipe, the wire is passed in the pipe and air cooling is implemented, to ensure the stability of signal transmission.

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