An online flame monitoring instrument for industrial high temperature environments

Abstract

The invention discloses an online flame monitoring instrument in an industrial high-temperature environment. The monitoring instrument comprises an instrument body, an eyepiece with variable focus located at the top of the instrument body, and a lens located at the bottom of the instrument body; a flame filter is embedded in the lens, a dichroic prism is arranged in the instrument body, and a first lens group, an aperture, a second lens group, a shutter and an image sensor are arranged on the right side of the dichroic prism from left to right in sequence, and the first lens group and the second lens group are both moved left and right by a moving mechanism arranged on the instrument body; a control unit is built in the instrument body; the instrument body is connected to a background system through a communication interface arranged on its side; the monitoring instrument can perform high-definition, real-time and online monitoring of internal burning flames, high-temperature heated metals and other high-heat materials in industrial high-temperature environments such as high-temperature furnaces through a lens group with precisely adjustable focal length, a super-sensing image sensor and a high-definition network plus HD-SDI lossless dual-mode synchronous output.

Description

Technical Field

[0001] The present invention relates to the field of thermal measurement technology, in particular to an online flame monitoring instrument in an industrial high-temperature environment. Background Art

[0002] Currently, there are industrial television cameras used to view internal combustion flames, high-temperature heated metals, high-temperature molten metals, high-temperature molten glass, etc. in high-temperature kilns, incinerators, heating furnaces, blast furnaces, converters, etc. However, these devices generally have the following disadvantages:

[0003] The device has a large network transmission delay and places high demands on the back-end image processor hardware. When displaying multiple images simultaneously, the image display frame rate is only 5 frames. Because the brightness of the observed object is very high, especially the high-temperature flame is very vibrating, the image is not clear and ghosting-like phenomena may occur, which does not achieve the ideal observation effect and cannot provide ideal data for subsequent measurements. Summary of the Invention

[0004] The purpose of the present invention is to provide a monitoring instrument which is easy to install and has a reasonable structure, so as to overcome the shortcomings of the prior art.

[0005] To achieve the above object, the present invention provides the following technical solutions:

[0006] Disclosed is an online flame monitoring instrument for use in an industrial high-temperature environment. The monitoring instrument comprises an instrument body, a variable-focus eyepiece located at the top of the instrument body, and a lens located at the bottom of the instrument body, the lens being located directly below the eyepiece. A flame filter is embedded in the lens, and a dichroic prism is provided in the instrument body and is located directly above the flame filter. A first lens group, an aperture, a second lens group, a shutter, and an image sensor are provided on the right side of the dichroic prism in sequence from left to right, and the first lens group and the second lens group are both moved left and right by a moving mechanism provided on the instrument body. A control unit is built into the instrument body and is electrically connected to an actuator of the moving mechanism. The instrument body is connected to a background system via a communication interface provided on its side.

[0007] Preferably, the moving mechanism includes a stepping motor, a precision screw and a moving slider; the precision screw is fixed to a bracket provided in the instrument body through a precision ball bearing, and the stepping motor is connected to the precision screw through a planetary reduction box.

[0008] Preferably, the movable slider provided on the precision screw is fixed with the first lens group and the second lens group.

[0009] Preferably, the first lens group and the second lens group, the aperture, the beam splitter prism, the shutter and the image sensor are located on the same coaxial line.

[0010] Preferably, the beam splitter prism is a cube formed by gluing two isosceles right triangle prisms together, and the adjacent contact surfaces of the two prisms are coated with a beam splitter film, and the remaining side surfaces of the prism are coated with an anti-reflection film.

[0011] Preferably, the lens is fixed to the bottom of the instrument body through a threaded structure, and a clamping ring structure is provided at the front end of the lens.

[0012] Preferably, an air inlet is provided on the side of the instrument body and communicates with the interior of the instrument body.

[0013] Preferably, a cooling fan is provided in the instrument body and is located on the right side of the image sensor; the image sensor is connected to the control unit.

[0014] Preferably, the control unit is connected to the I / O interface board provided on the instrument body via the high-speed communication module provided therein, and the I / O interface board is connected to the background system via a communication interface.

[0015] Compared with the prior art, the present invention has the following beneficial effects:

[0016] The present invention adopts two groups of lens groups with precise adjustment of focal length. Through control of the control circuit, it can realize remote electric zoom adjustment of focal length and automatic, semi-automatic and manual focus adjustment of image clarity according to the field of view angle requirements on site. At the same time, it adopts a precise coaxial beam splitting optical path design to provide a what-you-see-is-what-you-get aiming eyepiece, which facilitates the adjustment of the installation angle during equipment installation and eliminates ghosting, without the need to adjust the beam splitter.

[0017] The present invention adopts a super-sensitive image sensor to eliminate the influence of strong light, especially the very high frequency of high-temperature flame jumping; combined with a high-precision optical filter, it can highly restore the true color and shape of the flame, so that the imaging clarity achieves an ideal observation effect; at the same time, the monitoring instrument adopts the setting of high-speed communication module and communication interface, and utilizes high-definition network plus HD-SDI lossless dual-mode synchronous output to provide ideal data for subsequent measurements. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for describing the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0019] Figure 1 It is a schematic diagram of the overall structure of the monitoring instrument of the present invention.

[0020] Figure 2 Schematic diagram of the internal structure of the monitoring instrument of the present invention.

[0021] Figure 3 It is a schematic diagram of the structural framework of the control system in the monitoring instrument of the present invention.

[0022] Figure 4 Schematic diagram of the structure of the beam splitter prism of the present invention. DETAILED DESCRIPTION

[0023] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts shall fall within the scope of protection of the present invention.

[0024] See also Figure 1-4 , the present invention provides a technical solution:

[0025] A flame online monitoring instrument for industrial high-temperature environments, the monitoring instrument comprising an instrument body 1, an eyepiece 4 with variable focus located at the top of the instrument body 1, and a lens 3 located at the bottom of the instrument body 1, wherein the lens 3 is located directly below the eyepiece 4; the lens 3 is fixed to the bottom of the instrument body 1 via a threaded structure, and a retaining ring structure is provided at the front end of the lens 3.

[0026] Among them Figure 1-2 As shown, the lens 3 is embedded with a flame filter 31, and a dichroic prism 5 is provided in the instrument body 1 and is located directly above the flame filter 31; the right side of the dichroic prism 5 is provided with a first lens group 11, an aperture 12, a second lens group 13, a shutter 14 and an image sensor 17 from left to right, and the first lens group 11 and the second lens group 13 are both moved left and right by a moving mechanism 16 provided on the instrument body 1; the instrument body 1 is equipped with a control unit 6, and is electrically connected to the actuator of the moving mechanism 16; the instrument body 1 is connected to the background system through a communication interface 2 provided on its side.

[0027] In this embodiment, two groups of lens groups with precise focal length adjustment are used. Through control circuit control, remote electric zoom adjustment of focal length and automatic, semi-automatic, and manual focus adjustment of image clarity can be achieved according to the field of view requirements on site; 20 to 200mm focal length adjustment can be achieved; at the same time, the image sensor 17 adopts a super-sensitive image sensor to eliminate the influence of strong light, especially the very high frequency of high-temperature flame jumping; combined with high-precision optical filters, the true color and shape of the flame are highly restored, so that the imaging clarity achieves an ideal observation effect.

[0028] Among them Figure 2As shown, the moving mechanism 16 includes a stepping motor, a precision screw and a moving slider; the precision screw is fixed to a bracket set in the instrument body 1 through a precision ball bearing, and the stepping motor is connected to the precision screw through a planetary reduction gearbox; the moving slider set on the precision screw is fixed with the first lens group 11 and the second lens group 13; the first lens group 11 and the second lens group 13, the aperture 12, the dichroic prism 5, the shutter 14 and the image sensor 17 are located on the same coaxial line.

[0029] In this embodiment, the moving mechanism 16 adopts a miniature two-phase four-wire stepping motor, which drives the precision screw to rotate through a planetary reduction gearbox, thereby pushing the metal slider to move left and right, and then driving the first lens group 11 and the second lens group 13 to move left and right to fine-tune the focal length; the screw is fixed to a bracket set in the instrument body 1 using an ultra-micro precision ball bearing to ensure that the first lens group 11 and the second lens group 13 can move stably left and right.

[0030] Among them Figure 2 、 4 As shown, the spectroscopic prism 5 is a cube formed by gluing two isosceles right triangle prisms together, and the adjacent contact surfaces of the two prisms are coated with a spectroscopic film, and the remaining side surfaces of the prisms are coated with an anti-reflection film; a precision coaxial spectroscopic optical path design is adopted to provide a what-you-see-is-what-you-get aiming eyepiece, which is convenient for adjusting the installation angle during equipment installation and eliminating ghosting, without the need to adjust the spectrometer.

[0031] In this embodiment, the spectroscopic prism 5 is a cube formed by gluing two prisms in the shape of isosceles right triangles and made of K9 material, and the adjacent contact surfaces of the two prisms are coated with a spectroscopic film, and the remaining side surfaces of the prism are coated with an anti-reflection film; S is the incident light, R / T is the transmitted light, and the splitting ratio of R:T is 50:50; the prism surface is finely polished and has a surface finish of level 4; the transmitted light offset is less than ±5 minutes, and the reflected light offset is less than 90°±5 minutes.

[0032] Among them Figure 2 As shown, an air inlet 7 is provided on the side of the instrument body 1 and communicates with the interior of the instrument body 1 ; a cooling fan 15 is provided in the instrument body 1 and is located on the right side of the image sensor 17 ; the image sensor 17 is connected to the control unit 6 .

[0033] Among them, the instrument body 1 has a built-in cooling fan 15 to dissipate heat for the control unit 6 and the image sensor 17. When the temperature sensor detects that the temperature inside the instrument body 1 exceeds 40°C, the cooling fan 15 starts automatically to ensure stable operation of the equipment; at the same time, the air inlet 7 quickly connects to various cooling air sources to further ensure stable operation of the equipment.

[0034] Among them Figure 3As shown, the control unit 6 is connected to the I / O interface board 18 provided in the instrument body 1 through the high-speed communication module provided therein, and the I / O interface board 18 is connected to the background system through the communication interface 2.

[0035] In this embodiment, an ARM9 architecture SoC processor dual-core high-speed processing chip and an embedded Linux operating system are used; it is connected to the image sensor 17 and is responsible for data preprocessing; the imaging data is compressed to provide a high display frame rate while ensuring high image quality, and the network transmission bandwidth requirement is low; the I / O interface board 18 uses a high-definition network plus HD-SDI lossless dual-mode synchronous output, and the HD-SDI image signal can be directly connected to a monitor with an HD-SDI interface, so that the imaging clarity achieves the ideal observation effect; the high-definition network can realize remote control of the device's aperture size, focal length adjustment, focus, shutter speed, etc.

[0036] Throughout this specification, references to terms such as "one embodiment," "example," or "specific example" indicate that the specific features, structures, materials, or characteristics described in conjunction with that embodiment or example are included in at least one embodiment or example of the present invention. In this specification, schematic representations of these terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

[0037] The preferred embodiments of the present invention disclosed above are intended only to help illustrate the present invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the present invention to the specific embodiments described. Obviously, many modifications and variations are possible based on the content of this specification. These embodiments are selected and described in detail in this specification to better explain the principles and practical applications of the present invention, thereby enabling those skilled in the art to better understand and utilize the present invention. The present invention is limited only by the claims and their full scope and equivalents.

Claims

1. An online flame monitoring instrument for industrial high temperature environments, characterized by: The monitoring instrument comprises an instrument body (1), an eyepiece (4) located at the top of the instrument body (1) and capable of variable focus, and a lens (3) located at the bottom of the instrument body (1), wherein the lens (3) is located directly below the eyepiece (4); a flame filter (31) is embedded in the lens (3), and a dichroic prism (5) is arranged in the instrument body (1) and is located directly above the flame filter (31); a first lens group (11), an aperture (12), a second lens group (13), a shutter (14) and an image sensor (17) are arranged on the right side of the dichroic prism (5) from left to right, and the first lens group (11) and the second lens group (13) are both moved left and right by a moving mechanism (16) arranged on the instrument body (1); a control unit (6) is built into the instrument body (1) and is electrically connected to an actuator of the moving mechanism (16); and the instrument body (1) is connected to a background system via a communication interface (2) arranged on its side.

2. The flame online monitoring instrument for industrial high temperature environment according to claim 1, characterized in that: The moving mechanism (16) comprises a stepping motor, a precision screw and a moving slider; the precision screw is fixed to a bracket arranged in the instrument body (1) via a precision ball bearing, and the stepping motor is connected to the precision screw via a planetary reduction box.

3. The flame online monitoring instrument for industrial high temperature environment according to claim 2, characterized in that: A first lens group (11) and a second lens group (13) are fixed on a movable slider arranged on the precision screw rod.

4. The flame online monitoring instrument for industrial high temperature environment according to claim 3, characterized in that: The first lens group (11) and the second lens group (13), the aperture (12), the beam splitter prism (5), the shutter (14) and the image sensor (17) are located on the same coaxial line.

5. The flame online monitoring instrument for industrial high temperature environment according to claim 1, characterized in that: The beam splitter prism (5) is a cube formed by gluing two isosceles right triangle prisms together, and the adjacent contact surfaces of the two prisms are coated with a beam splitter film, while the remaining side surfaces of the prism are coated with an anti-reflection film.

6. The flame online monitoring instrument for industrial high temperature environment according to claim 1, characterized in that: The lens (3) is fixed to the bottom of the instrument body (1) via a threaded structure, and a clamping ring structure is provided at the front end of the lens (3).

7. The flame online monitoring instrument for industrial high temperature environment according to claim 1, characterized in that: An air inlet (7) is provided on the side of the instrument body (1) and is communicated with the interior of the instrument body (1).

8. The flame online monitoring instrument for industrial high temperature environment according to claim 7, characterized in that: A cooling fan (15) is provided in the instrument body (1) and is located on the right side of the image sensor (17); the image sensor (17) is connected to the control unit (6).

9. The flame online monitoring instrument for industrial high temperature environment according to claim 1, characterized in that: The control unit (6) is connected to an I / O interface board (18) provided on the instrument body (1) via a high-speed communication module provided therein, and the I / O interface board (18) is connected to a background system via a communication interface (2).

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