A furnace monitoring system using an industrial television

Abstract

The application discloses a kind of industrial television monitoring systems for furnace, it is related to video monitoring system.Temperature sensor is used to collect the temperature in high temperature furnace;Pressure sensor is used to collect the gas pressure of air transmission pipeline in cooling device;PLC is associated with the temperature set value and the gas pressure set value of pre-set temperature signal and gas pressure signal, and generates pre-trigger signal, and is transmitted to pneumatic transmission device, and when pneumatic transmission device receives pre-trigger signal, output position limit signal to PLC;PLC compares position limit signal with limit set value, if position limit signal and limit set value do not match, then generate a start trigger signal, and send start trigger signal to pneumatic transmission device, so that it starts, to drive camera to enter high temperature furnace to collect in-furnace image.The application is flexible and reliable, and the system fault tolerance is high, which prevents the influence of high position in the furnace on the camera and increases the safety factor of the system during operation.

Description

Technical Field

[0001] This invention relates to video surveillance systems, and more specifically, to an industrial television surveillance system for furnaces. Background Technology

[0002] The existing high-temperature industrial television monitoring system for furnaces consists of five parts: a camera telescopic drive mechanism, a cooling device, an electrical control device, a human-machine interface device, and a terminal display device. The specific functions of each component are as follows: The camera telescopic drive mechanism comprises four main parts: a fixed component, a motor, a transmission component, and the camera. The camera, driven by the motor, extends into the furnace under permissible operating conditions or retracts when not in a working condition. The cooling device comprises three main parts: an air pressure regulating device, an air transmission pipeline, and an air pressure detection element. Its function is to provide high-pressure, low-temperature air to the camera for cooling. The electrical control device comprises three main parts: signal input / output terminals, a microcontroller, and an AC220 to 24V transformer. Its function is to receive input signals, including cooling air pressure, camera temperature sensor readings, extension commands, and retraction commands, process them through the built-in microcontroller's logic settings, and output temperature display and extension / retraction commands to the human-machine interface device. The human-machine interface device consists of extension / retraction buttons and a temperature display and setting panel. Its function is to input control commands and temperature judgment conditions. The terminal display device includes a display screen and a signal processor, which processes the view signals and displays them.

[0003] In operation, commands are input via a human-machine interface to control the camera's telescopic drive mechanism through an electrical control unit. A cooling system keeps the camera's telescopic drive mechanism cool. The electrical control unit transmits view signals to a terminal display device, which then displays these signals. However, this industrial television monitoring system still has some shortcomings and deficiencies in actual use.

[0004] (1) The on-site environment is relatively harsh, and the system processor is a microcontroller, which is not resistant to harsh environments, affecting system stability.

[0005] (2) The camera’s telescopic drive is powered by an electric energy source with a working voltage of AC220, which poses a safety hazard when operating in the gas area of ​​the heating furnace. Summary of the Invention

[0006] The technical problem to be solved by the present invention is to provide an industrial television monitoring system for furnaces, addressing the shortcomings of the existing technology.

[0007] The present invention provides an industrial television monitoring system for furnaces, comprising a camera, a cooling device, a human-machine interface device, a terminal display device, a PLC, a pneumatic transmission device, a temperature sensor, and a pressure sensor.

[0008] The temperature sensor is used to collect the temperature inside the high-temperature furnace and output a temperature signal; the pressure sensor is used to collect the gas pressure in the air transmission pipe of the cooling device and output a pressure signal; the PLC collects the temperature signal and the pressure signal, and associates the temperature signal and the pressure signal with preset temperature setpoints and pressure setpoints to generate a pre-trigger signal; the pre-trigger signal is transmitted to the pneumatic transmission device, and when the pneumatic transmission device receives the pre-trigger signal, it outputs a position limit signal to the PLC; the PLC compares the position limit signal with the limit setpoint, and if the position limit signal does not match the limit setpoint, it generates a start trigger signal and sends the start trigger signal to the pneumatic transmission device to start the pneumatic transmission device to drive the camera into the high-temperature furnace to collect images inside the furnace.

[0009] If the temperature signal is less than the temperature setpoint and the air pressure signal is less than the air pressure setpoint, the PLC generates a pre-trigger signal; otherwise, no pre-trigger signal is generated.

[0010] The pneumatic transmission device includes a fixed bracket, an air source device, a cylinder, an extension / retraction sensor, and a retraction / retraction sensor. Both the air source device and the cylinder are mounted on the fixed bracket. The camera is mounted on the end of the cylinder's movable rod. The air source device is connected to the cylinder's air circuit, and a solenoid valve is installed on the air circuit of both the air source device and the cylinder. The control terminal of the solenoid valve receives a start trigger signal. The extension / retraction sensor is installed at the cylinder's extension / retraction end, and the retraction / retraction sensor is installed at the cylinder's closed end. Both the extension / retraction sensor and the retraction / retraction sensor are electrically connected to a PLC. The power supply terminal of the air source device is electrically connected to an external power source via a relay, and the control coil of the relay receives a pre-trigger signal.

[0011] Both the extended-in-position sensor and the retracted-in-position sensor are magnetic switches.

[0012] If the position limit signal does not match the limit setting value, specifically, the PLC collects the output signal of the extended position sensor as the position limit signal; if the value of the position limit signal is not equal to the limit setting value, the PLC generates a start trigger signal.

[0013] The camera lens is equipped with a camera head, and a mounting hole is opened on the furnace wall of the high-temperature furnace. A camera head cover is installed in the mounting hole, and a mounting base is fixed on the outside of the mounting hole. The mounting base has a mounting cavity that matches the camera, and the mounting base also has an air passage that communicates with the mounting cavity. The air passage is connected to an air transmission pipe.

[0014] The gun head sheath is a steel cylinder.

[0015] The human-machine interface device is connected to the PLC for communication; the human-machine interface device is equipped with a main operation interface, an alarm display interface and a historical data query interface.

[0016] The terminal display device is electrically connected to the camera.

[0017] Beneficial effects

[0018] The advantages of this invention are:

[0019] 1. This invention replaces traditional single-chip microcomputer control with a PLC, which has high resistance to harsh environments, ensuring stable overall equipment performance. Furthermore, by improving the PLC's control process for the pneumatic transmission device, this invention uses two trigger signals to achieve the camera's movement, making control more flexible and reliable. This effectively prevents the impact of high positions inside the furnace on the camera, increasing the system's safety factor during operation.

[0020] 2. The present invention uses a pneumatic transmission device consisting of an air source device, a cylinder, an extension position sensor, and a retraction position sensor to drive the camera's extension and retraction actions, which avoids the safety hazards caused by electrical sparks in the prior art and improves the system's safety attributes. Attached Figure Description

[0021] Figure 1 This is a structural block diagram of the industrial television monitoring system of the present invention;

[0022] Figure 2 This is a schematic diagram of the camera mounting structure of the present invention;

[0023] Figure 3 This is a schematic diagram of the pneumatic transmission device of the present invention.

[0024] Among them: 1-furnace wall, 2-camera, 3-camera gun head, 4-gun head cover, 5-mounting base, 6-mounting cavity, 7-air passage, 8-fixed bracket, 9-air source device, 10-cylinder. Detailed Implementation

[0025] The present invention will be further described below with reference to embodiments, but this does not constitute any limitation on the present invention. Any limited modifications made by any person within the scope of the claims of the present invention are still within the scope of the claims of the present invention.

[0026] See Figures 1-3This invention discloses an industrial television monitoring system for furnaces, comprising a camera 2, a cooling device, a human-machine interface device, a terminal display device, a PLC, a pneumatic transmission device, a temperature sensor, and a pressure sensor. The temperature sensor collects the temperature inside the high-temperature furnace and outputs a temperature signal. The pressure sensor collects the gas pressure in the air transmission pipe of the cooling device and outputs a pressure signal. The PLC collects the temperature and pressure signals and correlates them with preset temperature and pressure settings to generate a pre-trigger signal. Specifically, if the temperature signal is lower than the temperature setting value and the pressure signal is lower than the pressure setting value, the PLC generates a pre-trigger signal; otherwise, no pre-trigger signal is generated.

[0027] A pre-trigger signal is transmitted to the pneumatic drive device, and when the pneumatic drive device receives the pre-trigger signal, it outputs a position limit signal to the PLC. The PLC compares the position limit signal with the limit setting value. If the position limit signal does not match the limit setting value, it generates a start trigger signal and sends the start trigger signal to the pneumatic drive device to start the pneumatic drive device to drive the camera 2 into the high-temperature furnace to collect images inside the furnace.

[0028] In this embodiment, the pneumatic transmission device includes a fixed bracket 8, an air source device 9, a cylinder 10, and two position sensors. The two position sensors are an extension-to-position sensor and a retraction-to-position sensor. Both the extension-to-position sensor and the retraction-to-position sensor are magnetic switches. Magnetic switches are commercially available products and are sensors with one or more normally open and normally closed contacts that sense magnetic objects. When the magnetic object is approached, the normally open contact connects and the normally closed contact disconnects.

[0029] Both the air source device 9 and the cylinder 10 are mounted on the fixed bracket 8. The camera 2 is mounted on the end of the movable rod of the cylinder 10. The air source device 9 is connected to the air circuit of the cylinder 10, and a solenoid valve is installed on the air circuit of both the air source device 9 and the cylinder 10. The control terminal of the solenoid valve receives a start trigger signal. The extension position sensor is installed at the extension end of the cylinder 10, and the retraction position sensor is installed at the closed end of the cylinder 10. Both the extension position sensor and the retraction position sensor are electrically connected to the PLC. The power supply terminal of the air source device 9 is electrically connected to an external power source through a relay, and the control coil of the relay receives a pre-trigger signal.

[0030] Regarding the mismatch between the aforementioned position limit signal and the limit setting value, specifically, the PLC collects the output signal of the extension position sensor as the position limit signal; if the value of the position limit signal is not equal to the limit setting value, the PLC generates a start trigger signal. That is, when the movable rod of cylinder 10 extends to its longest position, the extension position sensor generates a position limit signal with a signal value of 1; while the limit setting value is 1; therefore, the two match, and the PLC does not issue a start trigger signal.

[0031] A camera head 3 is installed at the lens end of the camera 2. A mounting hole is opened on the furnace wall 1 of the high-temperature furnace, and a steel gun head sleeve 4 is installed in the mounting hole. A mounting base 5 is fixed on the outside of the mounting hole. A mounting cavity 6 matching the camera 2 is opened in the mounting base 5. An air passage 7 connected to the mounting cavity 6 is also provided in the mounting base 5. The air passage 7 is connected to an air transmission pipe.

[0032] In this embodiment, the temperature sensor, pressure sensor, extension sensor, and retraction sensor are electrically connected to the PLC via shielded signal cables.

[0033] The human-machine interface (HMI) is connected to the PLC. The HMI includes a main operation interface, an alarm display interface, and a historical data query interface. The alarm interface displays alarm information for signal anomalies; the historical data query interface stores and records the status of important system signal points over a continuous timeline, facilitating fault diagnosis and analysis; the main operation interface includes operation buttons, parameter settings, and equipment status indicators, enabling the acquisition of equipment status information and equipment operation. These three interfaces serve as the operating screen of the HMI, a window-based HMI that allows data interaction with industrial control equipment. Popular HMI software on the market includes WINCC and InTouch.

[0034] The terminal display device is electrically connected to camera 2. The terminal display device mainly consists of a monitor, signal cables, and connectors. The view signal from camera 2 is directly connected to the monitor via the signal cable, enabling remote view monitoring. A signal splitter and a video recorder can also be inserted as needed. The signal splitter can split the view signal source 1 into two or more parts, allowing for monitoring of the same scene from multiple locations; the video recorder can store the view signal to enable video playback.

[0035] Currently, signal splitters on the market generally have 1 input and 2 output or 1 input and 4 output ports. The view signal from camera 2 is connected to the input of the signal splitter, and the 2 or 4 output signals corresponding to the input are consistent with the input signal, so as to split the signal source without attenuation.

[0036] The working principle of this invention is as follows: When the system is working, the temperature sensor collects the temperature inside the furnace, and the pressure sensor collects the pressure of the gas in the air transmission pipeline. If the signal values ​​output by both sensors are less than the corresponding set values, the PLC will send a pre-trigger signal to the relay to activate it, thereby powering on the pneumatic transmission device. Next, the PLC collects the output signal of the extension position sensor. If the position limit signal does not match the limit set value, it outputs a start trigger signal to activate the solenoid valve. The air path between the air source device 9 and the cylinder 10 is connected, causing the cylinder 10 to actuate and push the camera head 3 into the high-temperature furnace. At this time, the camera 2 can be activated to collect images inside the furnace. The camera 2 outputs a view signal to the terminal display device so that monitoring personnel can monitor the operating conditions inside the high-temperature furnace.

[0037] The above description is only a preferred embodiment of the present invention. It should be noted that those skilled in the art can make several modifications and improvements without departing from the structure of the present invention, and these will not affect the effectiveness of the implementation of the present invention or the practicality of the patent.

Claims

1. A furnace industrial television monitoring system, comprising a camera (2), a cooling device, a human-machine interaction device, and a terminal display device, characterized in that, It also includes a PLC, a pneumatic transmission device, a temperature sensor, and a pressure sensor; The temperature sensor is used to collect the temperature inside the high-temperature furnace and output a temperature signal; the pressure sensor is used to collect the gas pressure in the air transmission pipe of the cooling device and output a gas pressure signal; the PLC collects the temperature signal and the gas pressure signal, and associates the temperature signal and the gas pressure signal with preset temperature setpoints and gas pressure setpoints to generate a pre-trigger signal. The pre-trigger signal is transmitted to the pneumatic transmission device, and when the pneumatic transmission device receives the pre-trigger signal, it outputs a position limit signal to the PLC; the PLC compares the position limit signal with the limit setting value. If the position limit signal does not match the limit setting value, it generates a start trigger signal and sends the start trigger signal to the pneumatic transmission device to start the pneumatic transmission device to drive the camera (2) into the high-temperature furnace to collect images inside the furnace. The pneumatic transmission device includes a fixed bracket (8), an air source device (9), a cylinder (10), an extension-to-position sensor, and a retraction-to-position sensor; the air source device (9) and the cylinder (10) are both mounted on the fixed bracket (8), the camera (2) is mounted on the end of the movable rod of the cylinder (10), the air source device (9) is connected to the air circuit of the cylinder (10), and a solenoid valve is installed on the air circuit of the air source device (9) and the cylinder (10), and the control terminal of the solenoid valve inputs a start trigger signal; the extension-to-position sensor is installed on the extension end of the cylinder (10), the retraction-to-position sensor is installed on the closed end of the cylinder (10), and both the extension-to-position sensor and the retraction-to-position sensor are electrically connected to the PLC; the power supply terminal of the air source device (9) is electrically connected to an external power supply through a relay, and the control coil of the relay inputs a pre-trigger signal; If the position limit signal does not match the limit setting value, specifically, the PLC collects the output signal of the extended position sensor as the position limit signal; if the value of the position limit signal is not equal to the limit setting value, the PLC generates a start trigger signal.

2. The industrial television monitoring system for furnaces according to claim 1, characterized in that, If the temperature signal is less than the temperature setpoint and the air pressure signal is less than the air pressure setpoint, the PLC generates a pre-trigger signal; otherwise, no pre-trigger signal is generated.

3. The industrial television monitoring system for furnaces according to claim 1, characterized in that, Both the extended-in-position sensor and the retracted-in-position sensor are magnetic switches.

4. The industrial television monitoring system for furnaces according to claim 1, characterized in that, A camera gun head (3) is installed at the lens end of the camera (2). A mounting hole is opened on the furnace wall (1) of the high-temperature furnace. A gun head sleeve (4) is installed in the mounting hole. A mounting seat (5) is fixedly provided on the outside of the mounting hole. A mounting cavity (6) matching the camera (2) is opened in the mounting seat (5). An air passage (7) connected to the mounting cavity (6) is also provided in the mounting seat (5). The air passage (7) is connected to the air transmission pipe.

5. The industrial television monitoring system for furnaces according to claim 4, characterized in that, The gun head sheath (4) is a steel cylinder.

6. The industrial television monitoring system for furnaces according to claim 1, characterized in that, The human-machine interface device is connected to the PLC for communication; the human-machine interface device is equipped with a main operation interface, an alarm display interface and a historical data query interface.

7. The industrial television monitoring system for furnaces according to claim 1, characterized in that, The terminal display device is electrically connected to the camera (2).

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