An industrial furnace body data monitoring device

Abstract

The application provides an industrial furnace body data monitoring device, which comprises a protective shell, the protective shell comprises a protective shell body and an electrical protective shell, the protective shell body comprises an outer shell and an inner shell; an infrared-visible light dual-channel imaging tube is fixedly installed in the inner shell; the infrared-visible light dual-channel imaging tube is internally provided with a visible light imaging tube and an infrared light imaging tube; the visible light imaging tube is internally provided with an objective lens group, a plurality of relay lens groups and a visible light imaging chip, and the visible light imaging chip is in communication connection with an upper computer; the infrared light imaging tube is internally provided with an objective lens group, a plurality of relay lens groups, a reflection structure and an infrared light imaging chip, and the infrared light imaging chip is in communication connection with the upper computer. The application synchronously acquires temperature field information and appearance information of materials of interest in an industrial furnace, and realizes online monitoring of internal body data of the industrial furnace.

Description

Technical Field

[0001] The present invention relates to the technical field of industrial kiln equipment, and in particular to an industrial furnace body data monitoring device. Background Art

[0002] Industrial furnaces are vital energy-consuming equipment in process industries such as building materials, metallurgy, and chemicals. Complex physical and chemical reactions occur inside them under the action of high temperatures. During the reaction, the temperature field and morphology of the materials of interest in the furnace change dynamically in real time. This information directly reflects the operating status of the industrial furnace and provides important reference data for operators to control the industrial furnace. Therefore, online monitoring of the temperature field and morphology information of the materials in the furnace is crucial for the stable control of industrial furnaces.

[0003] Due to the high temperature, high pressure, and high dust closed reaction environment inside industrial furnaces, the internal temperature data and material depth data are mostly obtained through thermocouples and mechanical probes. However, this method can only obtain information from a limited number of points and cannot obtain the overall temperature field and morphology information of the material in the furnace. The temperature field or morphology information of the material in the furnace can be obtained through infrared or visible light endoscopes, but the existing detection methods mainly focus on the detection of single information without considering the correlation between different information. In fact, the temperature field and morphology of the material are not independent. Taking the blast furnace as an example, during the blast furnace reaction, the descending charge Moving in the opposite direction of the upward-flowing high-temperature coal gas, the coal gas flow at the lower part of the material surface is more vigorous and the temperature will be higher. At the same time, the change in the morphology of the charge may also cause temperature measurement errors. Therefore, considering the correlation between information can provide operators with more reliable and accurate reference data. In order to better describe the spatial distribution of multiple information and their coupling relationship, the present invention uses volume data as a representation method for the information in the furnace. Volume data is a structured data composed of information such as temperature, morphology and their coupling relationship. Its smallest component is a voxel with spatial geometric properties, such as the temperature field and morphology of the material in the furnace.

[0004] Furthermore, due to the significant differences in camera parameters such as field of view and focal length between infrared and visible light cameras, existing binocular 3D reconstruction methods cannot meet constraints such as epipolar constraints, requiring the design of complex algorithms to match heterogeneous images and estimate disparity. Therefore, the volumetric data monitoring device designed in this invention features identical structures for the infrared and visible light channels, ensuring that the acquired visible light and infrared image parameters are nearly identical. This eliminates the need for matching feature points or contours between heterogeneous images, simplifies the disparity estimation algorithm, reduces the burden on the host computer, and improves real-time performance.

[0005] Patent application publication number CN10365204A discloses an industrial endoscope for observing information inside a high-temperature furnace. It converts the original optical fiber backlighting method into a parallel light direct backlighting method, improving light energy utilization efficiency and eliminating constraints on the backlight source. This enables the endoscope to capture images of real furnace conditions inside closed, lightless industrial furnaces, providing strong guidance for on-site production. However, this patent can only obtain visible light images and cannot provide operators with key information such as the temperature distribution inside the furnace.

[0006] The patent application publication number CN104257341A discloses an endoscope device that can simultaneously monitor infrared light and visible light. The working principle of the endoscope device scheme disclosed in the patent is to form an infrared branch through a color separation plate, and at the same time reflect visible light to form a visible light path. Then, the infrared light beam is transmitted through the field lens and the secondary imaging lens group on the infrared branch, and the image is formed by the infrared camera. The visible light is transmitted through the imaging lens group on the visible light branch, and the image is formed by the CCD camera. This patent can obtain visible light and infrared images at the same time, but there is no high-temperature protection measure designed, and it cannot work in the complex environment of industrial furnaces.

[0007] The patent with authorization announcement number CN109031646B discloses a true-view infrared industrial endoscope and its imaging method. In the technical solution disclosed in the patent, infrared and visible light are simultaneously acquired through a spectrometer and a filter, and infrared images and visible light images are formed through an infrared core and a CCD camera. The internal image of the industrial furnace obtained with the help of a dual lens realizes the acquisition of depth of field information and completes three-dimensional reconstruction. However, the spectrometer will cause a certain loss of optical information, which will reduce the imaging quality of infrared and visible light. At the same time, the invention does not consider the relationship between the three-dimensional morphology of the furnace charge and the temperature. Summary of the Invention

[0008] The purpose of the present invention is to provide a monitoring device for industrial furnace body data, which can not only obtain richer furnace information in a larger field of view and reduce the attenuation and distortion during information transmission, obtain high-quality visible light images and infrared thermal images, thereby obtaining high-fidelity morphological voxels and temperature voxels, but also ensure long-term stable operation of the equipment in a high-temperature environment and avoid dust pollution of the optical system, as well as online reconstruction of the volume data inside the industrial furnace, while also solving the technical problem of low accuracy in constructing the surface volume data of materials in existing industrial furnaces.

[0009] The technical solutions of the present invention are as follows:

[0010] An industrial furnace body data monitoring device includes a protective shell, which includes a cylindrical protective shell shell located at the front end and an electrical protective shell located at the rear end, which is cylindrical and connected to the protective shell shell. The protective shell shell includes an outer shell and an inner shell shell fixedly installed inside the outer shell along its axial direction.

[0011] An infrared-visible light dual-channel imaging tube is fixedly installed along the axial direction inside the inner shell. The infrared-visible light dual-channel imaging tube is cylindrical, with its front end located in the inner cavity of the protective outer shell and forming a trumpet mouth between it and the front end of the inner protective shell, while the rear end extends outward to the inner cavity of the electrical protective shell.

[0012] The infrared-visible light dual-channel imaging tube has cylindrical visible light imaging tubes and infrared light imaging tubes distributed along its axial direction and in parallel up and down. The front end of the visible light imaging tube is provided with an objective lens group along its axial direction, the middle end of the tube is provided with multiple relay lens groups, the rear end of the tube extends outward and is connected to a visible light imaging chip on the end face. The visible light imaging chip is connected to the host computer for communication. The visible light imaging tube, the objective lens group and relay lens group provided in the visible light imaging tube, and the visible light imaging chip constitute a visible light camera. The infrared light imaging tube An objective lens group is arranged along the axial direction at the front end of the tube, multiple relay lens groups are arranged at the middle end of the tube, a bent tubular structure extends outward from the rear end of the tube, and a reflective structure is installed on the bent part of the tube. An infrared imaging chip is connected to the end face of the rear end of the tube. The infrared imaging chip is connected to the host computer through a power-data bus. The infrared imaging tube, the objective lens group and relay lens group arranged in the infrared imaging tube, and the infrared imaging chip constitute an infrared camera; spacers are provided between adjacent relay lens groups and between the relay lens group and the objective lens group.

[0013] The host computer includes an image acquisition module, an estimation module, a visible light clear image module, a compensation module and a volume data construction module, wherein the image acquisition module is used to synchronously acquire visible light images and infrared images inside the industrial furnace from the visible light imaging chip and the infrared imaging chip; the estimation module is used to estimate the dust transmittance of the visible light image based on the bright and dark channel prior principle; the visible light clear image module is used to obtain a visible light clear image according to the dust transmittance of the visible light image; the compensation module is used to map the dust transmittance of the infrared image according to the dust transmittance of the visible light image, and establish an infrared temperature measurement compensation model based on the dust transmittance of the infrared image; the volume data construction module is used to construct the industrial furnace material volume data based on the visible light clear image and the infrared temperature measurement compensation model.

[0014] The volume data construction module includes a parallax image acquisition unit, a three-dimensional point cloud acquisition unit and a furnace material volume data acquisition unit; wherein, the parallax image acquisition unit is used to perform stereo matching on the visible light clear image and the infrared image to obtain the parallax image; the three-dimensional point cloud acquisition unit is used to convert the parallax image into a depth image and perform coordinate transformation on the depth image to obtain the three-dimensional point cloud of the surface of the industrial furnace material; the furnace material volume data acquisition unit is used to map the target real temperature output by the infrared temperature measurement compensation model to the three-dimensional point cloud through coordinates to obtain the volume data of the surface of the industrial furnace material.

[0015] Furthermore, the objective lens group at the front end of the visible light imaging tube is a visible light objective lens group, and the relay lens group arranged at the middle end of the tube is a visible light relay lens group; the objective lens group arranged at the front end of the infrared light imaging tube is an infrared light objective lens group, and the relay lens group arranged at the middle end of the tube is an infrared light relay lens group.

[0016] Furthermore, the objective lens group includes lens I, lens II, lens III and lens IV, lens I and lens II are connected by spacer I, lens II and lens III are connected in turn by an aperture and spacer II, and lens III and lens IV are connected by spacer III; lens I, spacer I, lens II, aperture and spacer II, lens III, spacer III and lens IV are arranged in sequence in a front-to-back order and are sequentially matched to form an integrated structure.

[0017] Furthermore, the relay lens group is a cylindrical lens, and adjacent cylindrical lenses are connected by spacers IV; the cylindrical lens includes negative lenses located on both sides with concave surfaces facing inward and a thick biconvex lens located in the middle with convex surfaces on both sides facing outward, and the concave surface of the negative lens and the convex surfaces on both sides of the thick biconvex lens are matched to form an integrated structure.

[0018] Furthermore, lens I, lens II, and spacer I are all cylindrical, and lens I and lens II are bonded together in sequence; a conical opening is passed through the front and rear end faces of the aperture, and the bottom surface of the conical opening faces lens II and is bonded to lens II; the cross-section of lens III is fan-shaped, its bottom end face faces spacer II, and a groove is provided inwardly at the center of the bottom end face; spacer II is cylindrical, its front end face is bonded to the rear end face of the aperture, and the center position of its rear end face bulges outward, and the bulge cooperates with the groove on lens III; spacer III is cylindrical, and an arcuate groove is provided inwardly on its front end face, and the arcuate groove cooperates with the spherical surface on lens III; lens IV is cylindrical, and its front end face is bonded to spacer III; the central axes of lens I, spacer I, lens II, the aperture and spacer II, lens III, spacer III, and lens IV are located on the same straight line.

[0019] Furthermore, the annular chamber formed between the outer shell and the inner shell is a ventilation duct, which is connected to the air inlet arranged on the upper side of the outer surface of the electrical appliance protective shell through the air inlet hole on the rear end face of the protective outer shell, and the ventilation duct is connected to the outside through the dust outlet hole at the lower part of the front end face of the protective outer shell.

[0020] The annular chamber formed between the inner shell and the infrared-visible light dual-channel imaging tube is a water circulation pipe. The water circulation pipe is connected to the water inlet arranged on the lower side of the outer surface of the electrical appliance protective shell through the water inlet pipe on the rear end face of the protective outer shell. The water circulation pipe is connected to the water outlet arranged on the upper side of the outer surface of the electrical appliance protective shell through the water outlet pipe on the rear end face of the protective outer shell.

[0021] Furthermore, the estimation module includes an estimated infrared temperature measurement compensation model establishment unit, an atmospheric light value calculation unit, a bright and dark channel dust transmittance calculation unit, a bright and dark channel dust transmittance weight optimal value calculation unit, and a dust transmittance calculation unit.

[0022] Among them, the estimated infrared temperature measurement compensation model establishment unit is used to establish a dust transmittance estimation model based on bright and dark channel priors; the atmospheric light value calculation unit is used to calculate the atmospheric light values ​​of different brightness areas in the visible light image; the bright and dark channel dust transmittance calculation unit is used to calculate the bright and dark channel dust transmittances of different brightness areas in the visible light image based on the atmospheric light values ​​and dust transmittance estimation model of different brightness areas in the visible light image; the bright and dark channel dust transmittance weight optimal value calculation unit is used to construct a fitness function based on the image energy gradient, establish a particle swarm parameter optimization model, and calculate the optimal value of the bright and dark channel dust transmittance weight; the dust transmittance calculation unit is used to obtain the dust transmittance of the visible light image based on the optimal value of the bright and dark channel dust transmittance weight, and the bright and dark channel dust transmittances of different brightness areas in the visible light image.

[0023] The atmospheric light value calculation unit includes a region division subunit, a bright channel atmospheric light value calculation subunit, an edge region atmospheric light value calculation subunit, and an intermediate region atmospheric light value calculation subunit; wherein the region division subunit is used to divide the visible light image into an extremely bright central flame region J by double threshold segmentation. B , extremely dark edge areaJ D and the middle area J G The bright channel atmospheric light value calculation subunit is used to calculate the bright channel atmospheric light value in the central flame area and the middle area of ​​the visible light image according to the bright channel prior, as the atmospheric light value of the central flame area. The calculation formula is: A B =g(m(J B )), where A B is the atmospheric light value in the central flame area, m(J B ) represents the set JB The set of the top 0.1% of pixels with the largest grayscale value, g(m(J B )) represents m(J B ) grayscale average; edge area atmospheric light value calculation subunit, for calculating the dark channel atmospheric light value A in the edge area and middle area of ​​the visible light image based on the dark channel prior D , as the atmospheric light value in the edge area, the specific calculation formula is: A D =g(m(J D )), where A D is the atmospheric light value in the dark channel, m(J D ) represents the set J D The set of the top 0.1% of pixels with the largest grayscale value, g(m(J D )) represents m(J D ) grayscale average; the middle area atmospheric light value calculation subunit is used to average the bright channel atmospheric light value and the dark channel atmospheric light value to obtain the middle area atmospheric light value A G , and its calculation formula is:

[0024]

[0025] The bright and dark channel dust transmittance calculation unit calculates the bright and dark channel dust transmittance of different brightness areas in the visible light image based on the atmospheric light value and dust transmittance estimation model of different brightness areas in the visible light image. The calculation formula is:

[0026]

[0027]

[0028] Among them, τ dark and τ bright are the dust transmittances in the dark channel and bright channel of the visible light image, J dark (x) and J bright (x) are the dark channel and bright channel of the visible light image, x is the pixel point in the visible light image, and ω is the empirical value for preserving the depth of field of the image.

[0029] The optimal value calculation unit of the dust transmittance weight of the bright and dark channels includes a function construction subunit and a bright and dark channel dust transmittance weight optimal value acquisition subunit.

[0030] Among them, the function construction subunit is used to construct the fitness function, and the fitness function is specifically:

[0031]

[0032] Wherein, fit(J(x, a)) is the fitness function, I(x) is the original dust interference image, J(x, a) is the visible light image, τ dark and τ bright are the dark channel and bright channel dust transmittance of the visible light image respectively, a and a best are the bright-dark channel dust transmittance weight parameter and the weight optimal value respectively, G(J(x, a)) is the sum of the boundary intensity value after the edge detection of the visible light image using the Sobel operator, H(J(x, a)) is the entropy of the visible light image, and E(J(x, a)) is the energy gradient value of the visible light image.

[0033] The bright-dark channel dust transmittance weight optimal value acquisition subunit is configured to perform parameter optimization on the bright-dark channel dust transmittance weight of the visible light imaging path according to the fitness function, and obtain the bright-dark channel dust transmittance weight optimal value of the visible light imaging path.

[0034] Further, the compensation module comprises a visible light clear image acquisition unit, a dust transmittance acquisition unit, a correction unit, and an infrared temperature measurement compensation model establishment unit.

[0035] The visible light clear image acquisition unit obtains the visible light clear image according to the dust transmittance of the visible light image, and the specific calculation formula is as follows:

[0036]

[0037] Wherein, J 清晰 (x) is the visible light clear image, τ VIS is the dust transmittance of the visible light image, and τ VIS =a best ·τ bright +(1-a best )·τ dark , and I(x) is the original dust interference image.

[0038] Wherein, the dust transmittance acquisition unit is configured to obtain the dust transmittance τ′ IR (x) of the infrared image by mapping the dust transmittance of the visible light image in a coordinate mapping manner, and the specific calculation formula is as follows:

[0039]

[0040] Wherein, τ′ IR (x) and τ VIS (x) are the dust transmittances of the infrared image and the visible light image respectively, R1, t1 represents the relative position between the visible light camera and the world coordinate system, and R2, t2 represents the relative position between the infrared light camera and the world coordinate system.

[0041] The correction unit is used to correct the dust transmittance of the infrared image according to the baseline distance between the visible light camera and the infrared camera, the distance between the baseline center and the target, and the size of the infrared image.

[0042] The infrared temperature measurement compensation model establishment unit is used to establish an infrared temperature measurement compensation model according to the dust transmittance of the corrected infrared image, specifically:

[0043]

[0044] Where T is the target real temperature, T0 is the infrared temperature value under dust interference, ΔT represents the temperature difference of the infrared image under dust interference, a, b, c, d are fitting parameters, τ IR is the dust transmittance of the corrected infrared image.

[0045] The correction unit includes a correction coefficient calculation subunit and a correction subunit.

[0046] The correction coefficient calculation subunit is used to obtain the correction coefficient based on the baseline distance of the visible light camera and the infrared camera, the distance between the baseline center and the target, and the size of the infrared image. The calculation formula is:

[0047]

[0048] Among them, δ(τ′ IR ) is the correction coefficient, τ′ IR is the dust transmittance of the infrared image before correction, l is the baseline distance between the visible light camera and the infrared camera, s is the distance from the center of the baseline to the target, and w and h are the width and height of the infrared image size.

[0049] The correction subunit corrects the dust transmittance of the infrared image according to the correction coefficient. The calculation formula is:

[0050] τ IR (x) = τ′ IR (x)+δ(τ′ IR ),

[0051] Among them, τ IR (x) is the dust transmittance of the corrected infrared image.

[0052] Furthermore, the compensation module includes a dust transmittance acquisition unit, a correction unit, and an infrared temperature measurement compensation model establishment unit.

[0053] The dust transmittance acquisition unit is used to obtain the dust transmittance τ′ of the infrared image by mapping the dust transmittance of the visible light image using coordinate mapping. IR (x), the specific calculation formula is:

[0054]

[0055] where τ′ IR (x) and τ VIS (x) is the dust transmission of the infrared image and the visible light image, respectively. R1, t1 represents the relative position between the visible light camera and the world coordinate system. R2, t2 represents the relative position between the infrared camera and the world coordinate system.

[0056] The correction unit is used to correct the dust transmittance of the infrared image according to the baseline distance between the visible light camera and the infrared camera, the distance between the baseline center and the target, and the size of the infrared image.

[0057] The infrared temperature measurement compensation model establishment unit is used to establish an infrared temperature measurement compensation model according to the dust transmittance of the corrected infrared image, specifically:

[0058]

[0059] Where T is the target real temperature, T0 is the infrared temperature value under dust interference, ΔT represents the temperature difference of the infrared image under dust interference, a, b, c, d are fitting parameters, τ IR is the dust transmittance of the corrected infrared image. Further, the correction unit includes a correction coefficient calculation subunit and a correction subunit.

[0060] The correction coefficient calculation subunit is used to obtain the correction coefficient based on the baseline distance of the visible light camera and the infrared camera, the distance between the baseline center and the target, and the size of the infrared image. The calculation formula is:

[0061]

[0062] Among them, δ(τ′ IR ) is the correction coefficient, τ′ IR is the dust transmittance of the infrared image before correction, l is the baseline distance between the visible light camera and the infrared camera, s is the distance from the center of the baseline to the target, and w and h are the width and height of the infrared image size.

[0063] The correction subunit corrects the dust transmittance of the infrared image according to the correction coefficient. The calculation formula is:

[0064] τ IR (x) = τ′ IR (x)+δ(τ′ IR ),

[0065] Among them, τ IR (x) is the dust transmittance of the corrected infrared image.

[0066] In the present invention, the infrared light imaging tube and the visible light imaging tube have the same optical system structure, which consists of an objective lens group, multiple relay lens groups, and an imaging chip in sequence; the objective lens group is located at the front end of the imaging tube and is used to collect optical information in the harsh environment of an industrial furnace; the relay lens group is connected to the objective lens group via a spacer of appropriate length, and transmits the optical information acquired by the objective lens group to the imaging chip. The length of the infrared light imaging tube and the length of the visible light imaging tube are controlled by adjusting the number and focal length of the relay lens groups, and the relay lens groups are also connected by spacers; the rear end of the infrared light imaging tube extends to the outside of the dual-channel imaging tube and is connected to a reflective structure, which is then connected to the infrared light imaging chip. The visible light imaging tube extends to the rear of the reflective structure of the infrared light imaging tube and is then connected to the visible light imaging chip.

[0067] In the present invention, the objective lens group in the infrared light imaging tube and the visible light imaging tube has the same optical structure. The objective lens group adopts an asymmetric reverse telephoto structure. Along the optical axis, from the object side to the image side, the objective lens group comprises lens I for sealing protection, negative power lens II, an aperture, positive power lens III, and lens IV. The lenses are connected by spacers.

[0068] In the present invention, the relay lens group in the infrared light imaging tube and the visible light imaging tube has the same optical structure. The relay lens group adopts a Hopkins lens group structure and is composed of two identical cylindrical lenses. Each cylindrical lens is composed of a thick double convex lens and two identical negative lenses bonded together, and the cylindrical lenses are connected by spacers.

[0069] In the present invention, the electrical protection shell is located outside the furnace body of the industrial furnace, and includes an infrared light imaging chip, a visible light imaging chip, and a power-data bus. The lower end is provided with a water inlet connected to the water cooling channel, and the upper end is provided with an air inlet connected to the air cooling pipe and a water outlet connected to the water cooling channel.

[0070] In the present invention, the protective outer shell is cylindrical and divided into two layers. The outer shell contains a ventilation duct for air cooling, and the inner shell contains a water circulation duct for water cooling. The ventilation duct and the water circulation duct are respectively connected to the air inlet, water inlet and water outlet on the electrical protective shell; the front end of the shell is trumpet-shaped, the trumpet mouth faces the front end of the shell cavity and is connected to the outside, and a dust outlet is opened below the trumpet mouth; a dust cover that does not affect the imaging field of view is provided at the front end of the shell.

[0071] In the process of obtaining industrial furnace body data using the industrial furnace body data monitoring device described in the present invention, in order to improve the reconstruction accuracy of the three-dimensional morphology of the material in the furnace, the imaging method of obtaining infrared light and visible light information through a spectroscope after single-lens imaging is not adopted. Instead, an infrared and visible light binocular imaging method is adopted to obtain multimodal images with parallax, and the three-dimensional morphology of the material in the furnace is reconstructed through stereo matching.

[0072] Since industrial furnaces in industrial production processes may experience high temperatures and high pressures, and considering the airtightness and safety of the furnace production process, the opening area of ​​the peephole used to install the monitoring device should not be too large. In order to operate normally in harsh environments, the infrared-visible light dual-channel imaging tube must be protected by a protective shell on the outside. These two points limit the longitudinal diameter of the dual-channel imaging tube. The infrared imaging tube and the visible light imaging tube must be arranged closely side by side. However, the imaging chip is large and cannot be installed in the infrared-visible light dual-channel imaging tube, nor can it be directly connected to the side-by-side imaging tubes. Therefore, the present invention designs a reflective structure to connect the infrared imaging tube and the imaging chip. The reflective structure is a right-angled cylinder with the same diameter as the imaging tube and a reflective lens installed at the right angle. The reflective structure allows the imaging chip to be installed on the side of the imaging tube, solving the problem of the imaging chip being unable to connect to the imaging tube due to space limitations, while ensuring that all optical information transmitted by the relay lens group enters the imaging chip.

[0073] In order to obtain an imaging lens with a wide viewing angle and a small focal length, the objective lens group adopts a reverse telephoto structure. Among them, the negative power lens II is used to scatter the incident light and reduce the field angle, and the positive power lens III and positive power lens IV are used to focus the light from the second lens, ensuring that the main light exits parallel to the optical axis after passing through the objective lens group, forming a telecentric beam path in the image space, and allowing all light to enter the relay lens group; this lens can effectively prevent the deterioration of the image edge, avoid causing large vignetting and destroying the uniformity of the off-axis image plane illumination.

[0074] Taking into account the thickness of the furnace wall, the difficulty of installation, the working life of the instrument and other conditions, the imaging chip is not directly connected to the objective lens group, but is set in the electrical protection shell outside the furnace wall. The optical information obtained by the objective lens group is transmitted to the imaging chip through multiple groups of relay lens groups; the relay lens group adopts a Hopkins lens group structure, in which the focal planes of the front and rear cylindrical lens groups need to remain overlapping. The light emitted from a point becomes parallel light after passing through the front cylindrical lens group. The parallel light passes through the rear cylindrical lens group and is focused again on the same point on the focal plane. The off-axis aberrations produced by cylindrical lenses with the same structure are of the same size and opposite direction, and can offset each other.

[0075] In order to ensure that the volume data monitoring device described in the present invention can work normally in the high-temperature environment of the industrial furnace, a cooling method combining circulating water cooling and through-air cooling is adopted; the circulating water cooling system takes in water through the water inlet arranged at the lower end of the electrical protective shell, and discharges it from the water outlet through the water circulation channel in the protective shell, thereby realizing the recycling of cooling water; the through-air cooling system ventilates through the air inlet arranged at the upper end of the electrical protective shell, and blows out from the trumpet mouth through the ventilation duct mouth. At the same time, the blown air flow can prevent scabbing of the lens and play a certain protective role on the lens.

[0076] In order to overcome the impact of high dust inside the industrial furnace, a dust cover is installed on the outside of the bell mouth, and a dust outlet is opened at the bottom. The air flow blown out by the air cooling will blow out the dust falling due to gravity, preventing dust from entering the optical system and causing lens contamination.

[0077] Finally, after the host computer obtains the multimodal image with parallax, the three-dimensional morphology of the material is reconstructed based on the principle of stereo vision, and volume data matching the three-dimensional morphology of the material is established based on the camera imaging model, thereby constructing morphological voxels and temperature voxels, realizing online monitoring of industrial furnace body data.

[0078] Compared with the existing technology, the industrial furnace body data monitoring device provided by the present invention can synchronously obtain temperature field information and charge morphology information inside the industrial furnace, and realize online reconstruction of body data on the host computer, providing effective guidance for operators. Its beneficial effects are:

[0079] 1. Use volume data to describe the temperature, morphology, and other information of the material of interest inside the industrial furnace, preserving the spatial coupling relationship between multiple types of information.

[0080] 2. An infrared-visible dual-channel imaging tube for binocular imaging was designed, in which the infrared imaging tube and the visible light imaging tube are arranged in parallel to synchronously acquire the temperature field information and visible light information of the material in the furnace, thereby realizing the acquisition of the volume data information in the furnace; the camera is composed of an infrared imaging tube or a visible light imaging tube, an objective lens group with an anti-telephoto structure, a relay lens group with a Hopkins lens group structure, and an imaging chip. It can obtain richer furnace information in a larger field of view and reduce the attenuation and distortion during information transmission, obtaining high-quality visible light images and infrared thermal images, thereby obtaining high-fidelity morphological voxels and temperature voxels, thereby synchronously acquiring multimodal optical information with parallax, providing data support for the three-dimensional reconstruction of material morphology based on the principle of stereo vision.

[0081] 3. In terms of the protective shell, a cooling system and a dust-proof system are designed. The cooling system adopts a combination of circulating water cooling and through-air cooling to enhance the cooling effect and improve the stability and service life of the equipment. The dust-proof system includes a dust cover that does not affect the field of view and a dust outlet under the lens, which reduces the possibility of dust covering the lens and contaminating the lens. Therefore, the protective shell ensures the long-term stable operation of the equipment in a high-temperature environment and avoids dust contamination of the optical system. At the same time, it can also operate stably in the harsh environment of high temperature, high pressure, high dust, closed and dark environment in industrial furnaces. It can simultaneously obtain the temperature field and morphology information of the material of interest inside the industrial furnace and transmit it to the host computer, reconstruct the volume data inside the industrial furnace online, and provide reliable guidance for operators.

[0082] 4. In the aspect of imaging, the objective lens group with reverse telephoto structure is used to obtain optical information in the furnace, and the objective lens group designed in the application can effectively prevent image edge deterioration, avoid causing large vignetting and destroy the uniformity of off-axis image plane illumination.

[0083] 5. In the aspect of light guide structure, the relay lens group with Hopkins lens group structure is used to transfer optical information, and the relay lens groups with the same structure have the same size and opposite direction of off-axis aberration, which can be offset.

[0084] 6. The reflective structure is designed to connect the infrared light imaging tube and the infrared light imaging chip, thereby solving the problem that the infrared light imaging chip cannot be installed in the case of serious space limitation, and ensuring the smooth imaging of the infrared light imaging chip.

[0085] 7. The application realizes material morphology three-dimensional reconstruction, temperature compensation and three-dimensional mapping through the host computer, obtains the temperature voxel and the morphology voxel of the material in the furnace, and realizes online monitoring of the material body data of interest in the industrial furnace, and the beneficial effects are embodied in:

[0086] (1) In view of the problem of difficult acquisition of industrial furnace material surface information, the application first applies the body data monitoring device to the industrial furnace material surface body data acquisition, uses the acquired visible light and infrared temperature information to construct high-fidelity material body data.

[0087] (2) In view of the influence of high dust in the industrial furnace on the temperature field detection, the application combines the bright-dark channel priori, proposes an atmospheric light value estimation method based on image brightness region differentiation, obtains the preliminary bright-dark channel dust transmittance, and combines the improved image energy gradient function and particle swarm optimization algorithm to optimize the bright-dark channel dust transmittance weight, to obtain accurate dust transmittance.

[0088] (3) The application establishes a visible light image sharpening model on the basis of calculating the dust transmittance of the visible light imaging path, restores the visible light image sharpness, and ensures the image quality.

[0089] (4) The application constructs a compensation model between dust transmittance and infrared temperature measurement error, realizes compensation of the infrared temperature measurement result under dust interference, and ensures the temperature accuracy in the body data.

[0090] (5) According to the baseline distance of the visible light camera and the infrared light camera, the distance between the baseline center and the target, and the size of the infrared image, the dust transmittance of the infrared image is corrected, so as to obtain accurate dust transmittance of the infrared image, and further improve the construction accuracy of the industrial furnace material body data.

[0091] (6) The present invention incorporates cross-spectral visible light morphology information and temperature information into the same system through a volume data monitoring device, and then uses direct coordinate mapping to map the temperature data to a three-dimensional point cloud, effectively ensuring the accuracy of the volume data. BRIEF DESCRIPTION OF THE DRAWINGS

[0092] The accompanying drawings, which constitute a part of this application, are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute improper limitations of the present invention. In the accompanying drawings:

[0093] Figure 1 1 is a schematic diagram of the external structure of the industrial furnace body data monitoring device according to an embodiment of the present invention;

[0094] Figure 2 1 is a schematic diagram of the internal structure of the industrial furnace body data monitoring device according to an embodiment of the present invention;

[0095] Figure 3 1 is a schematic structural diagram of an infrared-visible light dual-channel imaging tube according to an embodiment of the present invention;

[0096] Figure 4 2 is a schematic structural diagram of an objective lens assembly according to an embodiment of the present invention;

[0097] Figure 5 It is a schematic structural diagram of the relay lens group according to an embodiment of the present invention.

[0098] In the accompanying drawings, 1. power-data bus; 2. electrical protective shell; 3. air inlet; 4. water outlet; 5. protective shell casing; 6. dust cover; 7. water inlet; 8. visible light imaging chip; 9. visible light imaging tube; 10. infrared-visible light dual-channel imaging tube; 11. ventilation duct; 12. water outlet pipe; 13. reflection structure; 14. infrared light imaging chip; 15. infrared light imaging tube; 16. water inlet pipe; 17. dust outlet hole; 18. visible light relay lens group; 19. visible light objective lens group; 20. infrared light relay lens group; 21. infrared light objective lens group; 22. lens I; 23. lens II; 24. lens III; 25. lens IV; 26. spacer I; 27. aperture; 28. spacer II; 29. ​​spacer III; 30. negative lens; 31. thick double convex lens; 32. spacer IV. DETAILED DESCRIPTION

[0099] The embodiments of the present invention are described in detail below with reference to the accompanying drawings. However, the present invention can be implemented in many different ways as defined and covered by the claims.

[0100] As attached Figure 1 and Figure 2As shown, an embodiment of the present invention provides an industrial furnace body data monitoring device, including a protection unit, which includes a protective outer shell 5 and an electrical protection shell 2 connected to the rear end of the shell. The electrical protection shell 2 is arranged on the outside of the furnace body, and includes an infrared light imaging chip 14, a visible light imaging chip 8 and a power-data bus 1 extending to the outside of the infrared-visible light dual-channel imaging tube 10. The lower end is provided with a water inlet 7 connected to the water cooling channel, and the upper end is provided with an air inlet 3 and a water outlet 4; the protective outer shell 5 extends into the furnace, and the shell is divided into two layers, the outer shell includes a ventilation duct 11 connected to the air inlet 3, and the inner shell includes a water outlet pipe 12 and a water inlet pipe 16 connected to the water inlet 7 and the water outlet 4; the front end of the shell is trumpet-shaped, the trumpet mouth faces the front end of the shell cavity and is connected to the outside, a dust outlet hole 17 is opened below the trumpet mouth, and a dust cover 6 that does not affect the imaging field of view is provided at the front end of the shell.

[0101] The visible light imaging chip 8 and the infrared light imaging chip 14 are connected to the host computer through the power-data bus 1. The host computer includes an image acquisition module, an estimation module, a visible light clear image module, a compensation module and a volume data construction module, wherein the image acquisition module is used to synchronously acquire the visible light image and the infrared image in the industrial furnace from the visible light imaging chip 8 and the infrared light imaging chip 14; the estimation module is used to estimate the dust transmittance of the visible light image based on the bright and dark channel prior principle; the visible light clear image module is used to obtain a visible light clear image based on the dust transmittance of the visible light image; the compensation module is used to map the dust transmittance of the infrared image based on the dust transmittance of the visible light image, and calculate the dust transmittance of the infrared image based on the dust transmittance of the infrared image. The infrared temperature measurement compensation model is established at a high rate; the volume data construction module is used to construct the volume data of industrial furnace materials based on the visible light clear image and the infrared temperature measurement compensation model; the volume data construction module includes a parallax image acquisition unit, a three-dimensional point cloud acquisition unit and a furnace material volume data acquisition unit; among them, the parallax image acquisition unit is used to perform stereo matching on the visible light clear image and the infrared image to obtain the parallax image; the three-dimensional point cloud acquisition unit is used to convert the parallax image into a depth image, and perform coordinate transformation on the depth image to obtain the three-dimensional point cloud of the surface of the industrial furnace material; the furnace material volume data acquisition unit is used to map the target real temperature output by the infrared temperature measurement compensation model to the three-dimensional point cloud through coordinates to obtain the volume data of the surface of the industrial furnace material.

[0102] As attached Figure 3As shown, the shell cavity contains a long strip-shaped infrared-visible light dual-channel imaging tube 10, including a visible light imaging tube 9 and an infrared light imaging tube 15, wherein the visible light imaging tube 9 includes a set of visible light objective lens groups 19 arranged at the front end thereof, a visible light imaging chip 8 arranged at the rear end thereof, four sets of visible light relay lens groups 18 connecting the visible light objective lens groups 19 and the visible light imaging chip 8, and the lens groups are connected by distance control rings.

[0103] As shown in the accompanying drawings Figure 4 As shown, the objective lens group adopts an asymmetric reverse telephoto structure, and along the optical axis from the object side to the image side, it is in sequence of lens I 22, lens II 23, diaphragm 27, lens III 24, lens IV 25, and the lenses are connected by distance control rings I 26, distance control rings II 28, distance control rings III 29 respectively; wherein, since the objective lens group is directly in contact with the furnace environment, the lens I 22 needs to be sealed and protected to prevent dust from polluting the optical system, and the lens I 22 is made of sapphire crystal with high temperature resistance, high hardness and wear resistance; the lens II 23 is used for scattering incident light and reducing the field angle; the lens III 24 and the lens IV 25 are used for focusing light from the lens II 23; in this way, the chief ray passes through the lens IV 25 and exits parallel to the optical axis, forming a telecentric beam path in the image space.

[0104] As shown in the accompanying drawings Figure 5 As shown, the relay lens group adopts a Hopkins lens group structure, which is composed of two identical cylindrical lenses, each cylindrical lens is composed of a thick biconvex lens 31 and two identical negative lenses 30 bonded together, the image space focal plane of the lens group overlaps with the object space focal plane of the rear lens group, the light rays emitted by an object point become parallel light rays after passing through the front lens group, and the parallel light rays are focused again on the same object point on the focal plane after passing through the rear lens group; the distance between the lenses is controlled by distance control ring IV 32.

[0105] The body data acquisition steps of the industrial furnace body data monitoring device described in the embodiment of the present application are as follows:

[0106] Step 1. Install the body data monitoring device on the industrial furnace wall, including entering the industrial furnace interior through the protective shell 5, and setting the electrical protection shell 2 on the outside of the furnace wall.

[0107] Step 2. Continuously input water and air into the water inlet 7 and the air inlet 3 to ensure smooth water circulation, and the heated water flows out through the water outlet 4, and the cooling system continuously works during the imaging process

[0108] Step 3. Visible light information is captured by the visible light objective lens group 19, and the visible light information enters the visible light relay lens group 18, and is transmitted to the visible light imaging chip 8 through the four groups of visible light relay lens groups 18 to generate a visible light digital image, and finally is transmitted to the host computer through the power-data bus 1; infrared light information is captured by the infrared light objective lens group 21, and the infrared light information enters the infrared light relay lens group 20, and is transmitted to the reflective structure 13 through the four groups of infrared light relay lens groups 20, and then the reflected infrared light information is received by the infrared imaging chip 14 to generate an infrared light digital image, and finally is transmitted to the host computer through the power-data bus 1.

[0109] Step 4. The host computer obtains volume data of the material inside the furnace through parallax matching and temperature mapping, constructing the internal volume data of the industrial furnace, which provides operators with a real-time and intuitive display of the actual operating conditions inside the furnace. In this embodiment, the main steps for obtaining volume data through the host computer are as follows:

[0110] (1) A multispectral camera calibration board suitable for both visible and infrared spectra is designed to calibrate the visible light camera and infrared camera in the volume data monitoring device separately to obtain the internal and external parameters of the dual-channel camera.

[0111] (2) A dust transmittance estimation model based on bright and dark channel priors is established to calculate the atmospheric light values ​​in different areas of visible light image brightness. Then, the visible light bright and dark channel dust transmittances of the corresponding areas are calculated based on the bright and dark channel priors to obtain a preliminary dust transmittance distribution. Then, a fitness function is constructed based on the image energy gradient, and a particle swarm parameter optimization model is established to calculate the dust transmittance weights of the bright and dark channels of the visible light imaging path to obtain an accurate visible light imaging path dust transmittance.

[0112] (3) An image sharpening model is established, and the calculated dust transmittance of the visible light imaging path is used as input to restore the visible light image in a dust-free state.

[0113] (4) Combined with the camera calibration parameters, the visible spectrum dust transmittance distribution is mapped to the infrared scene through the homography matrix, and then an infrared temperature measurement compensation model is established to compensate for the temperature measurement error caused by dust and ensure the temperature accuracy of the constructed volume data.

[0114] (5) Use the clear visible light image and infrared image to perform cross-spectral stereo matching to obtain a disparity image, which is then converted into a depth image and a three-dimensional point cloud. Based on the internal and external parameters of the dual-channel camera obtained in step (1), the temperature data is directly mapped to the three-dimensional point cloud to form volume data.

[0115] The specific implementation scheme for obtaining volume data through the host computer is as follows:

[0116] (1) Calibrate the internal camera parameters of the volume data monitoring device

[0117] The Zhang Zhengyou calibration method is a mature and accurate camera parameter calibration method. For visible light camera calibration, a printed paper checkerboard is generally used as the calibration surface. However, because the infrared emissivity of the printed paper checkerboard is basically the same, it is difficult to clearly describe the characteristics such as the checkerboard corners during infrared imaging. Therefore, it is necessary to re-produce the checkerboard using materials with different emissivity to adapt it to the calibration of multispectral cameras.

[0118] Specifically, the present invention uses an aluminum plate with an emissivity of 0.11 to 0.19 at room temperature and matte black paint with an emissivity of about 0.95 at room temperature. After the surface of the aluminum plate is brushed, the black part of the checkerboard is evenly filled with paint. As shown in formula (1), Zhang's checkerboard calibration method can be described as:

[0119]

[0120] Assume that the camera calibration plate is in the plane of the world coordinate system XOY plane, that is, Z = 0, where [uv 1] T Represents the homogeneous coordinates of the point on the calibration plate plane projected onto the image plane, [XY 1] T Represents the homogeneous coordinates of the point on the calibration plate plane. K is the intrinsic parameter matrix of the camera, R = [r1 r2 r3] and t are the rotation matrix and translation vector of the camera coordinate system relative to the world coordinate system respectively. Let:

[0121]

[0122] Where H is the homography matrix. According to the properties of the rotation matrix, And ‖r1‖=‖r2‖=1, then each image has the following constraints on the camera intrinsic parameter matrix:

[0123]

[0124] By combining (2) and (3), according to the constraints of n images, we can obtain the intrinsic parameters of the camera, and further obtain the extrinsic parameters r1, r2, r3, t, where

[0125]

[0126] For the visible light channel and infrared channel, R1, t1 and R2, t2 are used to represent their external parameters, that is, R1, t1 represent the relative position between the visible light camera and the world coordinate system, and R2, t2 represent the relative position between the infrared camera and the world coordinate system. For any point P in the world coordinate system, let its non-homogeneous coordinates in the world coordinate system, visible light camera coordinate system and infrared camera coordinate system be x w , x1, x2, then:

[0127]

[0128] Eliminate x w Get the geometric relationship between the visible light camera and the infrared camera:

[0129]

[0130] (2) Calculation of dust transmittance in the visible light imaging path

[0131] The high dust environment within industrial furnaces affects the imaging and temperature measurement accuracy of equipment. Analysis of visible light images inside the furnace shows that there are both overly bright and overly dark areas, such as the gas flame (overly bright) and the edge of the material surface (overly dark). Therefore, the present invention integrates the bright and dark channel priors and first uses visible light images to estimate the dust transmittance in the imaging path.

[0132] According to the prior knowledge of dark channel, for image J, when there is no interference such as dust in the imaging path, the dark channel J of the image dark Tends to 0. When there is interference such as dust, the dark channel J of the image dark It will not tend to 0, that is, in the visible light and infrared images obtained by the present invention, the dark channel:

[0133]

[0134] Among them J C Represents the color channel of image J, and Ω(x) represents the window centered at pixel x. The model is formed based on the fog map:

[0135] I(x)=J(x)τ(x)+A(1-τ(x)) (8)

[0136] Where I(x) is the original foggy image, J(x) is the fog-free image, and A is the global value of atmospheric light. Using τ(x) to represent the transmittance of the imaging path, we have:

[0137]

[0138] Then take the minimum value of the area and color channel on both sides of the equation to obtain the dark channel transmittance τ dark The estimation formula is:

[0139]

[0140] Where ω = 0.95, which is an empirical value for preserving the depth of field of the image.

[0141] The bright channel prior corresponds to the dark channel prior, that is, in the local area of ​​most natural scenes, at least one color channel has a relatively large pixel value.bright It will not tend to 255, but rather to the local amount A(x) of atmospheric light value:

[0142]

[0143] Similar to the dark channel, the dust transmittance τ in the bright channel bright Estimated to be:

[0144]

[0145] Then, the weighted sum of the dust transmittance in the bright and dark channels is used as the dust transmittance distribution of the visible light imaging channel:

[0146] τ VIS =a·τ bright +(1-a)·τ dark (13)

[0147] Among them, the value range of a is 0≤a≤1.

[0148] According to the calculation formula for bright and dark transmission of dust, the atmospheric light value A is the key to calculating the two-channel dust transmittance. Since the brightness distribution of the visible light image on the surface of the industrial furnace material is uneven, the extremely bright flame area does not conform to the dark channel prior theory. Similarly, the extremely dark area at the edge of the image does not conform to the bright channel prior theory. Therefore, the basic steps for calculating the atmospheric light value of the differentiated image brightness area in the present invention are:

[0149] 1) The visible light image J is divided into the extremely bright central flame region J by double threshold segmentation B , extremely dark edge areaJ D and the middle area J G .

[0150] 2) According to the bright channel prior, the bright channel atmospheric light value A is calculated in the flame area and the middle area of ​​the image. B , as the atmospheric light value of the central flame area. Define a function m(P) to represent the top 0.1% of the largest values ​​in the set P, and use g(Q) to represent the grayscale average of the pixel set Q. Then A B for:

[0151] A B =g(m(J B )) (14)

[0152] 3) According to the dark channel prior, the dark channel atmospheric light value A is calculated in the edge area and the middle area of ​​the image D , as the atmospheric light value in the edge area:

[0153] A D =g(m(J D )) (15)

[0154] 4) Take the average of the atmospheric light value of the bright channel and the atmospheric light value of the dark channel to obtain the atmospheric light value A of the general brightness area G :

[0155]

[0156] After obtaining the atmospheric light value of the differentiated image brightness area, the dark channel transmittance of a pixel x in the visible light image is:

[0157]

[0158] The bright channel transmittance is calculated as:

[0159]

[0160] After obtaining the preliminary distribution of dust transmittance in the bright and dark channels, it is necessary to further determine the weight coefficients of the dust transmittance in the bright and dark channels. This embodiment of the present invention uses an intelligent algorithm and an effective evaluation criterion to measure the quality of the visible light image restored based on the dust transmittance. The fitness function fit is combined with image entropy, edge intensity, and image energy gradient:

[0161] fit(J(x,a))=log(log(G(J(x,a))))H(J(x,a))E(J(x,a)) (19)

[0162] Where J(x,a) is the visible light image to be evaluated, which is calculated from the weighted dust transmittance distribution:

[0163]

[0164] G(J(x,a)) is the sum of the boundary intensity values ​​after edge detection of the visible light image using the Sobel operator, H(J(x,a)) is the entropy of the visible light image, and E(J(x,a)) is the energy gradient value of the visible light image, which are calculated as follows:

[0165]

[0166]

[0167] E=∑ x ∑ y {‖f(x+1,y)-f(x,y)‖2+‖f(x,y+1)-f(x,y)‖2} (23)

[0168] where p i Indicates the proportion of pixels with grayscale value i (0≤i≤255) in the image.

[0169] According to (20), the image quality is basically determined by the a value. The above fitness function is used to continuously optimize the a value. The a corresponding to the maximum value of the fitness function fit(J(x,a)) is taken as the optimal value of the weight, and τ is obtained. VIS The optimal result is the determined dust transmittance distribution in the visible light imaging channel.

[0170] (3) Visible light image clarity

[0171] Since the visible light imaging quality in the present invention is mainly affected by dust interference, based on the accurate calculation of dust transmittance, the present invention uses the image degradation model under dust interference to transform the dust transmittance distribution τ obtained in the previous step into the image degradation model under dust interference. VIS Substitute:

[0172]

[0173] Among them J 清晰 (x) is a clear image of visible light, τ VIS is the dust transmittance of the visible light image, and τ VIS =a best ·τ bright +(1-a best )·τ dark , I(x) is the original image disturbed by dust and fog, and the final visible light image without dust interference is obtained.

[0174] (4) Infrared temperature measurement compensation model

[0175] The dust distributions in the visible light and infrared imaging channels are similar, but there are still differences. In order to use the dust transmittance distribution of the visible light imaging channel to estimate the transmittance distribution of the infrared imaging channel, the present invention first uses the coordinate mapping method to obtain the dust transmittance τ′ of the corresponding pixel point in the infrared imaging channel through the obtained visible light channel dust transmittance mapping. IR (x):

[0176] τ′ IR (x) = τ VIS (x)·R+t (25)

[0177] Then, a correction term δ is defined, which is related to the baseline distance l between the two cameras, the distance s between the baseline center and the target, and the pixel transmittance τ′ IR , visible light is related to the infrared image size h, w, and is used to correct the transmittance difference caused by the difference in the viewing angle of the imaging system. It is obtained by experimental calibration:

[0178]

[0179] The dust transmittance of the infrared imaging channel can be expressed as:

[0180] τ IR (x) = τ' IR (x) + δ(τ' IR ) (27)

[0181] The infrared image reflects the thermal distribution of the surface of the measured object. Due to the nonlinear relationship between the infrared radiation received by the thermal imaging device and the temperature of the measured object, and the influence of environmental factors such as the emissivity of the object surface and atmospheric attenuation on the temperature measurement itself, the infrared image can only give a qualitative description of the surface radiation temperature of the measured object. Therefore, a method of comparison with a reference object must be used to calibrate the absolute temperature value of the measured object. In order to study the actual influence of dust on infrared temperature measurement, the embodiment of the present application uses a high-precision blackbody furnace as a reference object, and measures the temperature of the blackbody furnace with an infrared light camera. From the perspective of data modeling, a function between the dust transmittance τ IR , the infrared measurement data T0 and the target real temperature data T is constructed:

[0182]

[0183] Where ΔT represents the temperature difference of the pixel corresponding to the infrared image under the interference of dust. For ΔT, the present application fixes the position of the thermal imager and the blackbody furnace under constant environmental temperature, and respectively collects the blackbody furnace temperature data with and without dust interference. The measurement data is fitted by the least squares method to obtain the nearest fitting curve between the temperature difference and the dust transmittance, where a, b, c, and d are fitting parameters. Due to the nonlinearity of the fitting curve, the accuracy of this model is high.

[0184] (5) Body data construction based on coordinate direct mapping

[0185] After obtaining the clear visible light image of the industrial furnace material surface and the compensated temperature data, according to the general method of three-dimensional reconstruction of binocular stereo vision, the visible light image and the infrared image are stereomatched to obtain the visible light and infrared parallax image, and then the depth map is converted. Then, according to the coordinate system conversion relationship, the depth image is converted into a three-dimensional point cloud.

[0186] Let Z be the depth value of the corresponding point in the depth image of the industrial furnace material surface, p(x IR ,y IR ,T IR ) be a point in the infrared image containing real temperature information, f be the focal length of the infrared camera, and p W (x W ,y W ,z W ,T W ) be a point on the industrial furnace material surface containing temperature information. Then, according to the coordinate system mapping relationship obtained in the system calibration link, p(xIR ,y IR ,T IR ) is mapped onto the 3D point cloud to expand the 3D point cloud into a 3D temperature field:

[0187]

[0188] At this point, the construction of high-fidelity volume data is achieved.

[0189] The embodiment of the present invention designs an infrared-visible dual-channel imaging tube, which includes an objective lens group, a relay lens group and an imaging chip. The infrared imaging tube and the visible light imaging tube are arranged in parallel and independently imaged, thereby achieving synchronous acquisition of multimodal optical information with parallax to construct morphological voxels and temperature voxels; the infrared imaging tube and the imaging chip are connected by designing a reflective structure, which is a right-angle cylinder with the same diameter as the imaging tube and is equipped with a reflective lens at the right angle, thereby solving the problem that the imaging chip cannot be installed when the space is severely limited, and ensuring smooth imaging of the imaging chip; the objective lens group with an anti-telephoto structure is designed to obtain optical information inside the furnace; the objective lens group consists of lens I, negative-power lens II, positive-power lens III and lens IV, so that the imaging lens has the characteristics of a large field of view and a small focal length, effectively solving the problems of blurred image edges and uneven brightness. Topic; a relay lens group with a Hopkins lens group structure is designed to transmit the optical information obtained by the objective lens group. The relay lens group is composed of symmetrical cylindrical lenses, which reduces the loss in the optical information transmission process and avoids the influence of off-axis aberrations; in view of the harsh environment of high temperature, high pressure and high dust inside the industrial furnace, a protective outer shell with a cooling system and dust-proof design is designed; a dust estimation model combining bright and dark channel priors, an image quality evaluation clarity model, an infrared temperature measurement compensation model, and a volume data reconstruction model are constructed by the upper computer to realize the online reconstruction of the volume data of the material of interest inside the industrial furnace; in summary, the embodiment of the present invention uses the designed industrial furnace body data monitoring device to monitor the volume data inside the industrial furnace online, and realizes the synchronous acquisition of temperature field information and morphology information of the material of interest in the industrial furnace, thereby providing important basis conditions for industrial furnace condition judgment, furnace reaction regulation, etc.

Claims

1. An industrial furnace body data monitoring device, comprising a protective housing, the protective housing comprising a cylindrical protective housing shell (5) at the front end and a cylindrical electrical protection shell (2) at the rear end connected to the protective housing shell (5), the protective housing shell (5) comprising an outer shell and an inner shell fixedly mounted inside the outer shell along its axial direction, characterized in that: An infrared-visible light dual-channel imaging tube (10) is fixedly mounted inside the inner shell along its axial direction. The infrared-visible light dual-channel imaging tube (10) is cylindrical, with its front end located in the inner cavity of the protective outer shell (5) and forming a bell mouth with the front end of the inner protective shell, and its rear end extending outwardly to the inner cavity of the electrical appliance protective shell (2); A cylindrical visible light imaging tube (9) and an infrared light imaging tube (15) are arranged in parallel along the axial direction and in the upper and lower directions inside the infrared-visible light dual-channel imaging tube (10); an objective lens group is arranged at the front end of the visible light imaging tube (9) along the axial direction, a plurality of relay lens groups are arranged at the middle end of the tube, and a visible light imaging chip (8) is connected to the end surface of the rear end of the tube extending outward, and the visible light imaging chip (8) is connected to a host computer for communication; the visible light imaging tube (9), the objective lens group and the relay lens group arranged in the visible light imaging tube (9), and the visible light imaging chip (8) constitute a visible light camera; An infrared imaging tube (15) is provided with an objective lens group along its axial direction at the front end of the tube, a plurality of relay lens groups are provided at the middle end of the tube, a bent tubular structure is extended outward from the rear end of the tube, a reflective structure (13) is installed at the bent portion of the tube, an infrared imaging chip (14) is connected to the rear end face of the tube, and the infrared imaging chip (14) is connected to a host computer via a power-data bus (1); spacers are provided between adjacent relay lens groups and between the relay lens group and the objective lens group; the infrared imaging tube (15), the objective lens group and the relay lens group provided in the infrared imaging tube (15), and the infrared imaging chip (14) constitute an infrared camera; The host computer includes an image acquisition module, an estimation module, a visible light clear image module, a compensation module and a volume data construction module, wherein the image acquisition module is used to synchronously acquire a visible light image and an infrared image in an industrial furnace from a visible light imaging chip (8) and an infrared light imaging chip (14); the estimation module is used to estimate the dust transmittance of the visible light image based on the bright and dark channel prior principle; the visible light clear image module is used to obtain a visible light clear image based on the dust transmittance of the visible light image; the compensation module is used to map the dust transmittance of the infrared image based on the dust transmittance of the visible light image, and establish an infrared temperature measurement compensation model based on the dust transmittance of the infrared image; and the volume data construction module is used to construct the industrial furnace material volume data based on the visible light clear image and the infrared temperature measurement compensation model. The volume data construction module includes a parallax image acquisition unit, a three-dimensional point cloud acquisition unit and a furnace material volume data acquisition unit; wherein the parallax image acquisition unit is used to perform stereo matching on the visible light clear image and the infrared image to obtain a parallax image; the three-dimensional point cloud acquisition unit is used to convert the parallax image into a depth image and perform coordinate transformation on the depth image to obtain a three-dimensional point cloud of the surface of the industrial furnace material; the furnace material volume data acquisition unit is used to map the target real temperature output by the infrared temperature measurement compensation model to the three-dimensional point cloud through coordinates to obtain volume data of the surface of the industrial furnace material.

2. The industrial furnace body data monitoring device according to claim 1, characterized in that: The objective lens group at the front end of the visible light imaging tube (9) is a visible light objective lens group (19), and the relay lens group arranged at the middle end of the tube is a visible light relay lens group (18); the objective lens group at the front end of the infrared light imaging tube (15) is an infrared light objective lens group (21), and the relay lens group arranged at the middle end of the tube is an infrared light relay lens group (20).

3. An industrial furnace body data monitoring device according to claim 1 or 2, characterized in that: The objective lens group comprises a lens I (22), a lens II (23), a lens III (24) and a lens IV (25); the lens I (22) and the lens II (23) are connected via a spacer ring I (26); the lens II (23) and the lens III (24) are connected via an aperture (27) and a spacer ring II (28) in sequence; and the lens III (24) and the lens IV (25) are connected via a spacer ring III (29); the lens I (22), the spacer ring I (26), the lens II (23), the aperture (27) and the spacer ring II (28), the lens III (24), the spacer ring III (29) and the lens IV (25) are sequentially arranged in a front-to-back order and sequentially matched to form an integrated structure.

4. An industrial furnace body data monitoring device according to claim 1 or 2, characterized in that: The relay lens group is a cylindrical lens, and adjacent cylindrical lenses are connected by a spacer ring IV (32); the cylindrical lens includes negative lenses (30) located on both sides with concave surfaces facing inwards and a thick biconvex lens (31) located in the middle with convex surfaces on both sides facing outwards, and the concave surface of the negative lens (30) and the convex surfaces on both sides of the thick biconvex lens (31) are matched to form an integrated structure.

5. The industrial furnace body data monitoring device according to claim 3, characterized in that: The lens I (22), lens II (23), and spacer I (26) are all cylindrical, and the lens I (22) and lens II (23) are sequentially bonded together; the front and rear end faces of the aperture (27) are penetrated by a conical opening, the bottom face of the conical opening faces the lens II (23) and is bonded to the lens II (23); the cross section of the lens III (24) is fan-shaped, the bottom end face of the lens III (24) faces the spacer II (28), and the center position of the bottom end face is provided with a groove inwardly; the spacer II (28) is cylindrical, the front end face of the lens III (24) is bonded to the rear end face of the aperture (27), and the center position of the rear end face of the lens III (24) is fan-shaped. The lens of the embodiment of the present invention is characterized in that the lens of the embodiment of the present invention is provided with an outward protrusion, and the protrusion cooperates with the groove on the lens III (24); the spacer ring III (29) is cylindrical and its front end surface is provided with an arc surface groove inward, and the arc surface groove cooperates with the spherical surface on the lens III (24); the lens IV (25) is cylindrical and its front end surface is bonded to the spacer ring III (29); the central axes of the lens I (22), the spacer ring I (26), the lens II (23), the aperture (27) and the spacer ring II (28), the lens III (24), the spacer ring III (29) and the lens IV (25) are located on the same straight line.

6. The industrial furnace body data monitoring device according to claim 1, characterized in that: The annular chamber formed between the outer shell and the inner shell is a ventilation duct, which is connected to the air inlet (3) arranged on the upper side of the outer surface of the electrical appliance protective shell (2) through the air inlet hole on the rear end surface of the protective outer shell (5), and is connected to the outside through the dust outlet hole at the lower part of the front end surface of the protective outer shell (5); The annular chamber formed between the inner shell and the infrared-visible light dual-channel imaging tube (10) is a water circulation pipe. The water circulation pipe is connected to a water inlet (7) arranged on the lower side of the outer surface of the electrical appliance protective shell (2) through a water inlet pipe (16) on the rear end face of the protective outer shell (5). The water circulation pipe is connected to a water outlet (4) arranged on the upper side of the outer surface of the electrical appliance protective shell (2) through a water outlet pipe (12) on the rear end face of the protective outer shell (5).

7. The industrial furnace body data monitoring device according to claim 1, characterized in that: The compensation module includes a dust transmittance acquisition unit, a correction unit, and an infrared temperature measurement compensation model establishment unit; The dust transmittance acquisition unit is used to obtain the dust transmittance τ′ of the infrared image by mapping the dust transmittance of the visible light image using coordinate mapping. IR (x), the specific calculation formula is: where τ′ IR (x) and τ VIS (x) are the dust transmission of the infrared image and the visible light image, respectively. R1, t1 represents the relative position between the visible light camera and the world coordinate system. R2, t2 represents the relative position between the infrared camera and the world coordinate system. a correction unit for correcting the dust transmittance of the infrared image based on the baseline distance of the visible light camera and the infrared camera, the distance between the baseline center and the target, and the size of the infrared image; The infrared temperature measurement compensation model establishment unit is used to establish an infrared temperature measurement compensation model according to the dust transmittance of the corrected infrared image, specifically: Where T is the target real temperature, T0 is the infrared temperature value under dust interference, ΔT represents the temperature difference of the infrared image under dust interference, a, b, c, d are fitting parameters, τ IR is the dust transmittance of the corrected infrared image.

8. The industrial furnace body data monitoring device according to claim 7, characterized in that: The correction unit includes a correction coefficient calculation subunit and a correction subunit; The correction coefficient calculation subunit is used to obtain the correction coefficient based on the baseline distance of the visible light camera and the infrared camera, the distance between the baseline center and the target, and the size of the infrared image. The calculation formula is: Among them, δ(τ′ IR ) is the correction coefficient, τ′ IR is the dust transmittance of the infrared image before correction, l is the baseline distance between the visible light camera and the infrared camera, s is the distance from the baseline center to the target, w and h are the width and height of the infrared image size; The correction subunit corrects the dust transmittance of the infrared image according to the correction coefficient. The calculation formula is: t IR (x)=τ′ IR (x)+δ(τ′ IR ), Among them, τ IR (x) is the dust transmittance of the corrected infrared image.

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