Automatic screening machine for heat-insulating refractory bricks and control method of automatic screening machine

Abstract

The invention relates to the technical field of classified transportation, and discloses an automatic screening machine for insulating refractory bricks and a control method thereof.The automatic screening machine comprises a conveying device, a negative pressure dust removal device, an image acquisition device, a heating device, a swing screening device, a grating separation device and a control device; the conveying device comprises a first conveying belt, a second conveying belt and a rotary transfer unit. The negative-pressure dust removal device comprises a fan and a negative-pressure dust collection unit; the heating device is arranged on the second conveying belt; the image acquisition device comprises a surface image acquisition unit and an infrared image acquisition unit; the swinging screening device comprises a gathering grid, a swinging motor, an operating rod and a swinging rod; and the control device is used for controlling the screening and separating process of the insulating refractory bricks. According to the invention, real-time monitoring and adjustment of conveying and classification links are realized, and automation, high efficiency and accuracy of the whole screening process are ensured. The problems of insufficient precision, low efficiency, unstable quality and the like in the traditional screening technology are solved.

Description

Technical Field

[0001] The invention relates to the technical field of classification and transportation, and in particular to an automatic screening machine for heat-insulating refractory bricks and a control method thereof. Background Art

[0002] With the continuous development of industrialization, the application of insulating refractory bricks in metallurgy, chemical industry, building materials, machinery and other industries is becoming more and more extensive, especially in high temperature environment, the demand for refractory materials is gradually increasing. Insulating refractory bricks are usually used in high temperature furnaces, heat treatment equipment, boilers and other fields. Their main functions are heat insulation, resistance to high temperature thermal shock and improvement of thermal efficiency of equipment. Therefore, the quality requirements for insulating refractory bricks in the production process are getting higher and higher.

[0003] However, in the traditional production process of insulating refractory bricks, inspection and partition storage are mostly done manually, which is not only inefficient, but also cannot effectively guarantee the screening and separation accuracy. Even if mechanical vision is used for screening, relying only on a single indicator, the equipment usually cannot achieve efficient and accurate screening when dealing with refractory bricks of different sizes, shapes or uneven surface quality. It is easy to miss or misscreen, resulting in some unqualified bricks being mistakenly screened as qualified products, or qualified bricks being mistakenly screened as unqualified products, affecting product quality.

[0004] Therefore, it is necessary to design an automatic screening machine for insulating refractory bricks and a control method thereof to solve the problems existing in the current technology. Summary of the invention

[0005] In view of this, the present invention proposes an automatic screening machine for insulating refractory bricks and a control method thereof, aiming to solve the problem that manual screening is time-consuming and labor-intensive when partitioning and storing insulating refractory bricks after production, and the machine vision has low accuracy and poor reliability.

[0006] In one aspect, the present invention provides an automatic screening machine for insulating refractory bricks, comprising:

[0007] Conveying device, negative pressure dust removal device, image acquisition device, heating device, swing screening device, grid separation device and control device; wherein,

[0008] The conveying device comprises a first conveyor belt, a second conveyor belt and a rotation transmission unit, wherein the rotation transmission unit is arranged between the first conveyor belt and the second conveyor belt, and the rotation transmission unit is made of rubber;

[0009] The negative pressure dust removal device is arranged on the first conveyor belt, and the negative pressure dust removal device comprises a fan and a negative pressure dust suction unit, and the negative pressure dust removal device is used to clean the dust on the surface of the insulating refractory bricks;

[0010] The heating device is arranged on the second conveyor belt;

[0011] The image acquisition device comprises a surface image acquisition unit and an infrared image acquisition unit, wherein the surface image acquisition unit is arranged on the first conveyor belt and is located on the right side of the fan, and the infrared image acquisition unit is arranged on the second conveyor belt and is located on the right side of the heating device;

[0012] The swing screening device comprises a gathering grid, a swing motor, an operating rod and a swing lever, wherein the swing motor is rotatably connected to the operating rod, the operating rod is used to control the swing of the swing lever, and the swing lever is flexibly connected to the gathering grid;

[0013] The control device is connected to the conveying device, the negative pressure dust removal device, the image acquisition device, the heating device and the swing screening device, and the control device is used to control the screening and separation process of the insulating refractory bricks.

[0014] Furthermore, the control device comprises:

[0015] a first control unit configured to collect transport speed and surface pressure data of the first conveyor belt, and determine the blowing volume of the fan according to the transport speed and surface pressure data;

[0016] A second control unit is configured to control the surface image acquisition unit to acquire a plurality of surface image data of the insulating refractory bricks, establish a three-dimensional model and compare it with a standard model to determine an appearance evaluation value;

[0017] A third control unit is configured to control the infrared image acquisition unit to acquire at least two infrared images of the insulating refractory bricks, obtain a refractory curve of the insulating refractory bricks according to the infrared images, and compare the refractory curve with historical data to determine a refractory evaluation value;

[0018] The fourth control unit is configured to obtain an overall evaluation value based on the appearance evaluation value and the refractory evaluation value, determine the quality type of the insulating refractory brick according to the overall evaluation value, and control the swing motor to swing and guide the insulating refractory brick into different areas of the grid separation device according to the quality type.

[0019] Furthermore, when the first control unit determines the air volume of the fan according to the transport rate and the surface pressure data, it includes:

[0020]

[0021] Wherein, Q represents the air volume, Q0 represents the minimum air volume of the fan, V represents the transport rate, Vmax represents the maximum transport rate of the first conveyor belt, P represents the surface pressure data, Pmax represents the maximum surface pressure data, a1 and a2 represent the speed amplification factor and the pressure amplification factor respectively, wherein the value range of a1 is [1, 3], the value range of a2 is [1, 3], and C1 and C2 represent constant terms, and the value range is [1, 2].

[0022] Furthermore, when the second control unit determines the appearance evaluation value, it includes:

[0023] The second control unit compares the three-dimensional model with the standard model, marks the defect area, and obtains the area, defect depth and defect roundness of each defect area, and obtains the appearance evaluation value through the following formula:

[0024] ;

[0025] Where S1 represents the appearance evaluation value, Ai represents the normalized result of the i-th defect area, β1 represents the adjustment unit, and the value range of β1 is [1, 2]. represents the normalized result of the roundness of the i-th defect, Di represents the normalized result of the i-th defect depth, and Az represents the normalized result of the total defect area.

[0026] Furthermore, the third control unit acquires the refractory curve of the insulating refractory brick according to the infrared image, and compares the refractory curve with historical data to determine the refractory evaluation value, including:

[0027] The third control unit compares the fire resistance curve with historical data and determines the fire resistance evaluation value according to the comparison result;

[0028] When the historical data contains data identical to the fire resistance curve, the third control unit determines the fire resistance evaluation value according to the historical data;

[0029] When there is no data identical to the fire resistance curve in the historical data, the third control unit screens similar data in the historical data, and when there is similar data in the historical data, the third control unit determines the fire resistance evaluation value according to the similar data.

[0030] Furthermore, when the third control unit determines the fire resistance evaluation value according to the similarity data, it includes:

[0031] The third control unit extracts the temperature values ​​of the first moment and the second moment in the refractory curve, records them as the first temperature and the second temperature, extracts the temperature values ​​of the same moment in the historical refractory curve, records them as the historical first temperature and the historical second temperature, and when the first temperature is the same as the historical first temperature or the second temperature is the same as the historical second temperature, uses the historical refractory curve as the similarity data;

[0032] Obtaining the maximum slope of the refractory curve and the historical maximum slope of the historical refractory curve;

[0033] Classifying the historical refractory curves whose historical maximum slope is greater than the maximum slope as a first historical set;

[0034] Classifying the historical refractory curves whose historical maximum slope is equal to the maximum slope as a second historical set;

[0035] Classifying the historical refractory curves whose historical maximum slope is less than the maximum slope as a third historical set;

[0036] The third control unit obtains the fire resistance evaluation value according to the historical fire resistance evaluation values ​​corresponding to the first history set, the second history set and the third history set.

[0037] Furthermore, when the third control unit obtains the fire resistance evaluation value according to the historical fire resistance evaluation values ​​corresponding to the first history set, the second history set and the point history set, it includes:

[0038] ;

[0039] Among them, S2 represents the fire resistance assessment value, Sx represents the x-th historical fire resistance assessment value in the first historical set, M1 represents the number of historical fire resistance assessment values ​​in the first historical set, S0 represents the mean of the historical fire resistance assessment values ​​in the second historical set, Sy represents the y-th historical fire resistance assessment value in the third historical set, and M2 represents the number of historical fire resistance assessment values ​​in the third historical set.

[0040] Further, when there is no similar data in the historical data, the third control unit obtains the fire resistance evaluation value according to the fire resistance curve, and the fire resistance evaluation value is calculated by the following formula:

[0041]

[0042] Wherein, S2 represents the fire resistance evaluation value, Tmax represents the maximum temperature of the fire resistance curve, Δt represents the time for the maximum temperature to return to room temperature, Tavg represents the average temperature of the fire resistance curve, ΔTmax represents the maximum temperature difference of the standard fire resistance curve, Vc represents the maximum cooling rate of the fire resistance curve, and Vcmax represents the maximum cooling rate of the standard fire resistance curve.

[0043] Further, the fourth control unit obtains an overall evaluation value based on the appearance evaluation value and the fire resistance evaluation value, and determines the quality type of the insulating refractory brick according to the overall evaluation value, including:

[0044]

[0045] Wherein, S represents the overall evaluation value, S1 represents the appearance evaluation value, S2 represents the fire resistance evaluation value, e1 and e2 represent weight coefficients, and e1+e2=1;

[0046] The fourth control unit determines the quality type of the insulating refractory brick according to the overall evaluation value, the quality types include first quality, second quality, third quality and fourth quality, and the first quality is better than the second quality, the second quality is better than the third quality, and the third quality is better than the fourth quality, and the overall evaluation value is inversely proportional to the quality type.

[0047] Compared with the prior art, the beneficial effects of the present invention are: through the comprehensive application of a conveying device, a negative pressure dust removal device, an image acquisition device, a heating device, a swing screening device, a grid separation device and a control device, automated efficient screening and quality control are achieved. The cooperation of the rotating transfer unit and the multiple conveyor belts improves the conveying accuracy and stability of the brick body. The setting of the rotating transfer unit avoids the bricks from being stranded between the conveyor belts, and a gap is formed between the first conveyor belt and the second conveyor belt to avoid dust accumulation. The negative pressure dust removal device effectively removes surface dust and avoids the influence of surface pollution on the screening results; the image acquisition device combines the surface image and the infrared image as well as the heating device to heat the brick body, captures the surface defects and temperature changes of the brick body, and provides a more accurate basis for subsequent screening; the swing screening device achieves screening through a flexible connected aggregation grid and a swinging action, avoiding the occurrence of missed screening and misscreening; the control device monitors and adjusts each link in real time to ensure the automation, efficiency and accuracy of the overall screening process. It solves the problems of insufficient accuracy, low efficiency and unstable quality in traditional screening technology.

[0048] On the other hand, the present application also provides a control method for an automatic screening machine for insulating refractory bricks, which is applied to the automatic screening machine for insulating refractory bricks, comprising:

[0049] Collecting the transport speed and surface pressure data of the first conveyor belt, and determining the blowing volume of the fan according to the transport speed and surface pressure data;

[0050] Controlling the surface image acquisition unit to acquire a plurality of surface image data of the insulating refractory bricks, establishing a three-dimensional model and comparing it with a standard model to determine an appearance evaluation value;

[0051] Controlling the infrared image acquisition unit to acquire at least two infrared images of the insulating refractory bricks, obtaining the refractory curve of the insulating refractory bricks according to the infrared images, and comparing the refractory curve with historical data to determine the refractory evaluation value;

[0052] An overall evaluation value is obtained based on the appearance evaluation value and the refractory evaluation value, and the quality type of the insulating refractory brick is determined according to the overall evaluation value. According to the quality type, a swing motor is controlled to swing and guide the insulating refractory brick into different areas of the grid separation device.

[0053] It can be understood that the above-mentioned automatic screening machine for insulating refractory bricks and the control method thereof have the same beneficial effects, which will not be described in detail here. BRIEF DESCRIPTION OF THE DRAWINGS

[0054] Various other advantages and benefits will become apparent to those of ordinary skill in the art by reading the detailed description of the preferred embodiments below. The accompanying drawings are only for the purpose of illustrating the preferred embodiments and are not to be considered as limiting the present invention. Moreover, the same reference symbols are used throughout the accompanying drawings to represent the same components. In the accompanying drawings:

[0055] Figure 1 A schematic diagram of the structure of an automatic screening machine for heat-insulating refractory bricks provided in an embodiment of the present invention;

[0056] Figure 2 A front view of an automatic screening machine for heat-insulating refractory bricks provided by an embodiment of the present invention;

[0057] Figure 3 for Figure 2 Magnified view at A in the middle;

[0058] Figure 4 The present invention provides a flowchart of a control method for an automatic screening machine for insulating refractory bricks.

[0059] Among them, 110, the first conveyor belt; 120, the second conveyor belt; 130, the rotation transfer unit; 140, the first drive motor; 150, the second drive motor; 160, the third drive motor; 210, the fan; 220, the negative pressure dust suction unit; 300, the heating device; 410, the surface image acquisition unit; 420, the infrared image acquisition unit; 510, the gathering grille; 520, the swing motor; 530, the operating lever; 540, the swing lever; 600, the grille separation device; 700, the control device. DETAILED DESCRIPTION

[0060] Exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. Although exemplary embodiments of the present disclosure are shown in the accompanying drawings, it should be understood that the present disclosure can be implemented in various forms and should not be limited by the embodiments set forth herein. On the contrary, these embodiments are provided in order to enable a more thorough understanding of the present disclosure and to be able to fully convey the scope of the present disclosure to those skilled in the art. It should be noted that, in the absence of conflict, the embodiments of the present invention and the features described in the embodiments can be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0061] In some embodiments of the present application, see Figure 1-3 As shown, an automatic screening machine for insulating refractory bricks includes: a conveying device, a negative pressure dust removal device, an image acquisition device, a heating device 300, a swing screening device, a grid separation device 600 and a control device 700. Among them,

[0062] The conveying device includes a first conveyor belt 110, a second conveyor belt 120 and a rotation transmission unit 130. The rotation transmission unit 130 is disposed between the first conveyor belt 110 and the second conveyor belt 120, and the rotation transmission unit 130 is made of rubber.

[0063] The negative pressure dust removal device is arranged on the first conveyor belt 110, and the negative pressure dust removal device includes a fan 210 and a negative pressure dust suction unit 220. The negative pressure dust removal device is used to clean the dust on the surface of the insulating refractory bricks.

[0064] The heating device 300 is disposed on the second conveyor belt 120 .

[0065] The image acquisition device includes a surface image acquisition unit 410 and an infrared image acquisition unit 420. The surface image acquisition unit 410 is arranged on the first conveyor belt 110 and is located on the right side of the fan 210. The infrared image acquisition unit 420 is arranged on the second conveyor belt 120 and is located on the right side of the heating device 300.

[0066] The swing screening device includes a gathering grid 510, a swing motor 520, an operating rod 530 and a swing rod 540. The swing motor 520 is rotatably connected to the operating rod 530. The operating rod 530 is used to control the swing of the swing rod 540. The swing rod 540 is flexibly connected to the gathering grid 510.

[0067] The control device 700 is connected to the conveying device, the negative pressure dust removal device, the image acquisition device, the heating device 300 and the swing screening device. The control device 700 is used to control the screening and separation process of the insulating refractory bricks.

[0068] Specifically, the insulating refractory bricks entering the automatic screening machine for insulating refractory bricks are first transported by the first conveyor belt 110, which is driven by the first drive motor 140. On the first conveyor belt 110, during the process of the brick body moving forward, the fan 210 blows air to the surface of the insulating refractory bricks through the negative pressure dust removal device set on the first conveyor belt 110, and collects and discharges the dust through the negative pressure dust suction unit 220. The fan 210 and the negative pressure dust suction unit 220 are powered by an external power supply to effectively remove dust and impurities on the surface of the brick body, ensuring that the subsequent screening, heating and detection processes are not disturbed by dust, thereby improving the screening accuracy and surface quality. Then, the surface image acquisition unit 410 on the first conveyor belt 110 is entered into the acquisition range to collect several pieces of surface image data. The surface defects, cracks, missing corners and other information are captured for subsequent analysis by the control device 700. Then, the insulating refractory bricks are transferred through the rotating transfer unit 130 set between the first conveyor belt 110 and the second conveyor belt 120. The rotating transfer unit 130 is driven by the second driving motor 150. The rotating transfer unit 130 is made of rubber material and has good friction and flexibility. It can smoothly transfer bricks from one conveyor belt to another, avoid damaging the surface of the bricks, and ensure that the bricks are stably transmitted to subsequent processing links.

[0069] Specifically, the brick body enters the second conveyor belt 120, which is driven by the third drive motor 160. After the brick body enters the second conveyor belt 120, it is gathered by the gathering grid 510, and the brick body passes through the heating device 300 from the middle area. The heating device 300 heats the surface of the brick. The contact surface between the second conveyor belt 120 and the brick body is made of steel chain to prevent the heating device 300 from causing damage to the second conveyor belt 120. Then the brick body enters the acquisition range of the infrared image acquisition unit 420, and at least two infrared images of the brick body are collected to further identify the quality of the brick body. The swing screening device is the core part of the equipment. As the brick body passes through the area, the swing motor 520 is controlled to drive the operating rod 530 to rotate according to the quality type of the brick body, so that the swing rod 540 produces a swinging motion, guiding the brick body to enter the grid separation device 600, and pass through different areas to achieve screening and classification.

[0070] It is understandable that the efficiency and accuracy of the screening process of insulating refractory bricks are improved by controlling the screening and classification links. The joint work of the rotating transfer unit 130, the negative pressure dust removal device, the image acquisition device and the heating device 300 ensures the stability and accuracy of the brick body during transportation, cleaning, detection and heating. The swing screening device avoids the problems of missed screening and misscreening in traditional screening through intelligent screening and separation, ensuring high-quality screening results. In addition, the real-time adjustment function of the control device 700 enables the entire equipment to maintain an efficient and accurate working state in a complex production environment.

[0071] In some embodiments of the present application, the control device 700 includes: a first control unit, a second control unit, a third control unit and a fourth control unit, wherein:

[0072] The first control unit is configured to collect the transport speed and surface pressure data of the first conveyor belt 110 , and determine the blowing volume of the fan 210 according to the transport speed and surface pressure data.

[0073] The second control unit is configured to control the surface image acquisition unit 410 to acquire surface image data of a plurality of thermal insulation refractory bricks, establish a three-dimensional model and compare it with a standard model to determine an appearance evaluation value.

[0074] The third control unit is configured to control the infrared image acquisition unit 420 to acquire at least two infrared images of the insulating refractory bricks, obtain the refractory curve of the insulating refractory bricks according to the infrared images, and compare the refractory curve with historical data to determine the refractory evaluation value.

[0075] The fourth control unit is configured to obtain an overall evaluation value based on the appearance evaluation value and the refractory evaluation value, and determine the quality type of the insulating refractory brick according to the overall evaluation value, and control the swing motor 520 to swing and guide the insulating refractory brick into different areas of the grid separation device 600 according to the quality type.

[0076] Specifically, the first control unit adjusts the blowing volume of the fan 210 according to the transport rate and surface pressure data of the first conveyor belt 110. By monitoring the transport speed of the conveyor belt, the air volume of the fan 210 is dynamically adjusted to ensure that the fan 210 always maintains the best dust removal effect at different transport speeds. The surface pressure data reflects the distribution density of refractory bricks on the surface of the conveyor belt. By detecting the surface pressure in real time, the first control unit optimizes the operating state of the fan 210 to avoid the negative impact caused by excessive or weak dust removal. The second control unit controls the surface image acquisition unit 410 to collect images of each insulating refractory brick. By acquiring the surface image data of several brick bodies, the brick body surface is three-dimensionally modeled and compared with the pre-established standard model. By comparing the differences between the models, an appearance evaluation value is generated to evaluate whether the brick body has surface problems such as defects, cracks, and missing corners. The third control unit is responsible for controlling the infrared image acquisition unit 420 to collect infrared image data of the insulating refractory brick. According to the infrared image, the refractory performance curve of the brick body (that is, the temperature change of the brick body after heating) is analyzed. By comparing these temperature data with the fire resistance data in the historical database, the fire resistance evaluation value is calculated, thereby comprehensively evaluating the fire resistance of the brick body. The fourth control unit comprehensively evaluates the insulating refractory bricks based on the appearance evaluation value provided by the second control unit and the fire resistance evaluation value provided by the third control unit to obtain an overall evaluation value. Based on this evaluation value, the quality type of the brick body (such as high quality, defective, unqualified, etc.) is further determined. According to the evaluation results, the swing motor 520 is directed to adjust the action of the swing rod 540 to guide the insulating refractory bricks into different areas of the grid separation device 600.

[0077] It is understandable that the precise adjustment of the control unit can ensure the efficiency and adaptability of the fan 210 under different working conditions, avoid excessive or insufficient cleaning, and thus improve the cleanliness of the brick surface and the accuracy of subsequent screening and heating processes. Through stereo modeling of image data and comparison with standard models, the second control unit can accurately identify the appearance defects of the brick body and determine the evaluation value. It is more accurate than traditional manual inspection or single image recognition technology, and can better guarantee the appearance quality of the brick body. Accurate temperature monitoring of the brick body is carried out through infrared imaging technology to identify the performance of refractory bricks in high temperature environments. By comparing with historical data, the refractory performance of the brick body is judged to avoid problems caused by insufficient refractory performance of the brick body. Intelligent sorting of bricks is carried out through comprehensive evaluation results to ensure that the quality management of insulating refractory bricks is more refined and automated. Through guidance and separation, unqualified bricks can be accurately identified and removed in time, avoiding manual screening and misjudgment, and improving screening efficiency and accuracy.

[0078] In some embodiments of the present application, when the first control unit determines the blowing volume of the fan 210 according to the transport rate and the surface pressure data, it includes:

[0079]

[0080] Among them, Q represents the blowing volume, Q0 represents the minimum blowing volume of the fan 210, V represents the transport rate, Vmax represents the maximum transport rate of the first conveyor belt 110, P represents the surface pressure data, Pmax represents the maximum surface pressure data, a1 and a2 represent the speed amplification factor and the pressure amplification factor respectively, wherein the value range of a1 is [1, 3], the value range of a2 is [1, 3], C1 and C2 represent constant terms, and the value range is [1, 2].

[0081] It is understandable that by introducing a dynamic adjustment mechanism for the transport rate and surface pressure, precise control of the air volume of the fan 210 is achieved. Compared with the traditional fixed air volume control method, the working state of the fan 210 is automatically adjusted according to the real-time changes in the production process, so as to more accurately match the needs of different production links. When the conveyor belt speed is fast or the surface pressure of the brick body is high, the fan 210 will automatically increase the air volume to ensure that the cleaning effect is not affected; and under lower speed and pressure conditions, the fan 210 can maintain low energy consumption and reasonable work intensity. The working efficiency of the fan 210 is improved, energy consumption is reduced, the dust removal effect and overall stability are improved, and it adapts to the changing production environment.

[0082] In some embodiments of the present application, when the second control unit determines the appearance evaluation value, it includes:

[0083] The second control unit compares the three-dimensional model with the standard model, marks the defect area, and obtains the area, defect depth and defect roundness of each defect area, and obtains the appearance evaluation value through the following formula:

[0084] ;

[0085] Where S1 represents the appearance evaluation value, Ai represents the normalized result of the i-th defect area, β1 represents the adjustment unit, and the value range of β1 is [1, 2]. represents the normalized result of the roundness of the i-th defect, Di represents the normalized result of the i-th defect depth, and Az represents the normalized result of the total defect area.

[0086] It is understandable that the evaluation of the appearance quality of insulating refractory bricks is achieved by calculating and analyzing various characteristics of defects (such as area, depth, roundness, etc.). Compared with traditional manual inspection methods, automatic evaluation based on stereo image comparison and quantitative analysis can more accurately identify and quantify surface defects of bricks. Through normalization processing, different defect characteristics can be evaluated with unified standards, avoiding errors and inconsistencies caused by manual judgment. Through the appearance evaluation value, the appearance quality of the brick can be effectively quantitatively evaluated, ensuring that the screening and quality control in the production process are more accurate, and improving production efficiency and consistency of product quality. At the same time, it reduces manual intervention, reduces manual errors, and improves the automation and intelligence level of the production line.

[0087] In some embodiments of the present application, the third control unit obtains the refractory curve of the insulating refractory brick according to the infrared image, and compares the refractory curve with the historical data to determine the refractory evaluation value, including: the third control unit compares the refractory curve with the historical data, and determines the refractory evaluation value according to the comparison result.

[0088] Specifically, when the historical data contains data identical to the fire resistance curve, the third control unit determines the fire resistance evaluation value according to the historical data. When the historical data contains data identical to the fire resistance curve, the third control unit screens similar data in the historical data, and when similar data exists in the historical data, the third control unit determines the fire resistance evaluation value according to the similar data.

[0089] In some embodiments of the present application, when the third control unit determines the fire resistance evaluation value based on similar data, it includes: the third control unit extracts the temperature values ​​of the first moment and the second moment in the fire resistance curve, records them as the first temperature and the second temperature, extracts the temperature values ​​of the same moment in the historical fire resistance curve and records them as the historical first temperature and the historical second temperature; when the first temperature is the same as the historical first temperature or the second temperature is the same as the historical second temperature, the historical fire resistance curve is used as similar data.

[0090] Specifically, the maximum slope of the refractory curve and the historical maximum slope of the historical refractory curve are obtained. The historical refractory curves whose historical maximum slope is greater than the maximum slope are classified as the first historical set. The historical refractory curves whose historical maximum slope is equal to the maximum slope are classified as the second historical set. The historical refractory curves whose historical maximum slope is less than the maximum slope are classified as the third historical set. The third control unit obtains the refractory evaluation value according to the historical refractory evaluation values ​​corresponding to the first historical set, the second historical set and the point historical set.

[0091] In some embodiments of the present application, when the third control unit obtains the fire resistance evaluation value according to the historical fire resistance evaluation values ​​corresponding to the first history set, the second history set, and the third history set, it includes:

[0092] ;

[0093] Among them, S2 represents the fire resistance assessment value, Sx represents the x-th historical fire resistance assessment value in the first historical set, M1 represents the number of historical fire resistance assessment values ​​in the first historical set, S0 represents the mean of the historical fire resistance assessment values ​​in the second historical set, Sy represents the y-th historical fire resistance assessment value in the third historical set, and M2 represents the number of historical fire resistance assessment values ​​in the third historical set.

[0094] In some embodiments of the present application, when there is no similar data in the historical data, the third control unit obtains the fire resistance evaluation value according to the fire resistance curve, and the fire resistance evaluation value is calculated by the following formula:

[0095] ;

[0096] Wherein, S2 represents the fire resistance evaluation value, Tmax represents the maximum temperature of the fire resistance curve, Δt represents the time for the maximum temperature to return to room temperature, Tavg represents the average temperature of the fire resistance curve, ΔTmax represents the maximum temperature difference of the standard fire resistance curve, Vc represents the maximum cooling rate of the fire resistance curve, and Vcmax represents the maximum cooling rate of the standard fire resistance curve.

[0097] Specifically, by comparing the maximum slope, temperature value and other characteristics of the real-time fire resistance curve with those of historical data, similar curves can be flexibly selected from the historical data for analysis. Not only the overall shape of the curve is taken into account, but also the temporal characteristics of temperature changes are introduced to make the fire resistance assessment more accurate. The maximum slope classification method of historical data enables more detailed screening of similar data based on the difference in maximum slope in different situations, thereby improving the accuracy and robustness of the assessment results. For situations where there is no similar data, a formula is used to calculate the fire resistance assessment value through multi-dimensional characteristics of the curve, such as maximum temperature, average temperature, recovery time, cooling rate, etc., so that effective fire resistance assessment can be performed without the support of historical data.

[0098] It is understandable that by introducing multi-dimensional data such as maximum slope and temperature characteristics, a flexible and accurate refractory evaluation mechanism is constructed. Compared with the traditional single-feature evaluation method, it can not only accurately calculate the refractory evaluation value by comparison when there are similar historical data, but also rely on the characteristics of the curve to perform effective refractory evaluation when similar data is missing. By classifying and screening historical data, more accurate evaluation results can be provided based on different curve characteristics. Ultimately, the accuracy of the refractory evaluation value is improved, which helps to monitor the quality of insulating refractory bricks in real time.

[0099] In some embodiments of the present application, when the fourth control unit obtains an overall evaluation value based on the appearance evaluation value and the fire resistance evaluation value, and determines the quality type of the insulating refractory brick according to the overall evaluation value, it includes:

[0100]

[0101] Among them, S represents the overall evaluation value, S1 represents the appearance evaluation value, S2 represents the fire resistance evaluation value, e1 and e2 represent weight coefficients, and e1+e2=1.

[0102] The fourth control unit determines the quality type of the insulating refractory brick according to the overall evaluation value. The quality types include first quality, second quality, third quality and fourth quality. The first quality is better than the second quality, the second quality is better than the third quality, and the third quality is better than the fourth quality. The overall evaluation value is inversely proportional to the quality type.

[0103] It is understandable that the quality of insulating refractory bricks can be accurately graded through the comprehensive evaluation of the two key parameters of appearance and refractory performance. By introducing weighting coefficients, flexible adjustment space is provided so that the proportion of appearance and refractory performance can be optimized according to actual needs. It ensures that each type of brick body obtains appropriate quality evaluation according to the actual application scenario, avoiding the one-sidedness existing in traditional evaluation methods. Furthermore, through automated overall evaluation and quality classification, production efficiency can be improved, manual intervention can be reduced, and the consistency of product quality can be improved.

[0104] In the above embodiments, automated efficient screening and quality control are achieved by comprehensively applying a conveying device, a negative pressure dust removal device, an image acquisition device, a heating device, a swing screening device, a grid separation device and a control device. The conveying accuracy and stability of the brick body are improved by the cooperation of the rotating transfer unit and the multi-conveyor belt. The setting of the rotating transfer unit avoids the bricks from being stranded between the conveyor belts, and a gap is formed between the first conveyor belt and the second conveyor belt to avoid dust accumulation. The negative pressure dust removal device effectively removes surface dust and avoids the influence of surface pollution on the screening results. The image acquisition device combines the surface image and the infrared image as well as the heating of the brick body by the heating device to capture the surface defects and temperature changes of the brick body, providing a more accurate basis for subsequent screening. The swing screening device achieves screening through a flexible connected aggregation grid and a swinging action, avoiding the occurrence of missed screening and misscreening. The control device monitors and adjusts each link in real time to ensure the automation, efficiency and accuracy of the overall screening process. The problems of insufficient accuracy, low efficiency and unstable quality in traditional screening technology are solved.

[0105] In another preferred embodiment based on the above embodiment, refer to Figure 4 As shown, this embodiment provides a control method for an automatic screening machine for insulating refractory bricks, which is applied to the automatic screening machine for insulating refractory bricks, and includes:

[0106] S100: collecting the transport speed and surface pressure data of the first conveyor belt, and determining the blowing volume of the fan according to the transport speed and surface pressure data;

[0107] S200: Control the surface image acquisition unit to collect surface image data of a plurality of thermal insulation refractory bricks, establish a three-dimensional model and compare it with a standard model to determine an appearance evaluation value;

[0108] S300: Controlling the infrared image acquisition unit to acquire at least two infrared images of the thermal insulation refractory bricks, obtaining the refractory curve of the thermal insulation refractory bricks according to the infrared images, and comparing the refractory curve with historical data to determine the refractory evaluation value;

[0109] S400: obtaining an overall evaluation value based on the appearance evaluation value and the refractory evaluation value, determining the quality type of the insulating refractory bricks according to the overall evaluation value, and controlling the swing motor to swing and guide the insulating refractory bricks into different areas of the grid separation device according to the quality type.

[0110] It can be understood that automated, efficient screening and quality control are achieved through the comprehensive application of conveying devices, negative pressure dust removal devices, image acquisition devices, heating devices, swing screening devices, grid separation devices and control devices. The cooperation of the rotating transfer unit and the multi-conveyor belts improves the conveying accuracy and stability of the brick body. The setting of the rotating transfer unit avoids the bricks from being stranded between the conveyor belts, and a gap is formed between the first conveyor belt and the second conveyor belt to avoid dust accumulation. The negative pressure dust removal device effectively removes surface dust and avoids the influence of surface pollution on the screening results; the image acquisition device combines the surface image and the infrared image as well as the heating device to heat the brick body, captures the surface defects and temperature changes of the brick body, and provides a more accurate basis for subsequent screening; the swing screening device achieves screening through the flexible connection of the gathering grid and the swinging action, avoiding the occurrence of missed screening and misscreening; the control device monitors and adjusts each link in real time to ensure the automation, efficiency and accuracy of the overall screening process. It solves the problems of insufficient accuracy, low efficiency and unstable quality in traditional screening technology.

[0111] Those skilled in the art will appreciate that the embodiments of the present application may be provided as methods, systems or computer program products. Therefore, the present application may take the form of a complete hardware embodiment, a complete software embodiment, or an embodiment combining software and hardware. Moreover, the present application may take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program codes.

[0112] The present application is described with reference to the flowcharts and / or block diagrams of the methods, devices (systems) and computer program products according to the embodiments of the present application. It should be understood that each process and / or box in the flowchart and / or block diagram, as well as the combination of processes and / or boxes in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor or other programmable data processing device to produce a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the processes in the flowchart and / or block diagram. Figure 1 A process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0113] These computer program instructions may also be stored in a computer-readable memory capable of directing a computer or other programmable data processing device to operate in a specific manner, so that the instructions stored in the computer-readable memory produce an article of manufacture comprising an instruction device, which implements the process Figure 1 A process or multiple processes and / or boxes Figure 1 A function specified in one or more boxes.

[0114] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operating steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing instructions for implementing the process. Figure 1 A process or multiple processes and / or boxes Figure 1 The steps for the functions specified in one or more boxes.

[0115] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the above embodiments, ordinary technicians in the relevant field should understand that the specific implementation methods of the present invention can still be modified or replaced by equivalents. Any modification or equivalent replacement that does not depart from the spirit and scope of the present invention should be covered within the scope of protection of the claims of the present invention.

Claims

1. An automatic screening machine for insulating refractory bricks, characterized in that: include: Conveying device, negative pressure dust removal device, image acquisition device, heating device, swing screening device, grid separation device and control device; wherein, The conveying device comprises a first conveyor belt, a second conveyor belt and a rotation transmission unit, wherein the rotation transmission unit is arranged between the first conveyor belt and the second conveyor belt, and the rotation transmission unit is made of rubber; The negative pressure dust removal device is arranged on the first conveyor belt, and the negative pressure dust removal device comprises a fan and a negative pressure dust suction unit, and the negative pressure dust removal device is used to clean the dust on the surface of the insulating refractory bricks; The heating device is arranged on the second conveyor belt; The image acquisition device comprises a surface image acquisition unit and an infrared image acquisition unit, wherein the surface image acquisition unit is arranged on the first conveyor belt and is located on the right side of the fan, and the infrared image acquisition unit is arranged on the second conveyor belt and is located on the right side of the heating device; The swing screening device comprises a gathering grid, a swing motor, an operating rod and a swing lever, wherein the swing motor is rotatably connected to the operating rod, the operating rod is used to control the swing of the swing lever, and the swing lever is flexibly connected to the gathering grid; The control device is connected to the conveying device, the negative pressure dust removal device, the image acquisition device, the heating device and the swing screening device, and the control device is used to control the screening and separation process of the insulating refractory bricks.

2. The automatic screening machine for insulating refractory bricks according to claim 1 is characterized in that: The control device comprises: a first control unit configured to collect transport speed and surface pressure data of the first conveyor belt, and determine the blowing volume of the fan according to the transport speed and surface pressure data; A second control unit is configured to control the surface image acquisition unit to acquire a plurality of surface image data of the insulating refractory bricks, establish a three-dimensional model and compare it with a standard model to determine an appearance evaluation value; A third control unit is configured to control the infrared image acquisition unit to acquire at least two infrared images of the insulating refractory bricks, obtain a refractory curve of the insulating refractory bricks according to the infrared images, and compare the refractory curve with historical data to determine a refractory evaluation value; The fourth control unit is configured to obtain an overall evaluation value based on the appearance evaluation value and the refractory evaluation value, determine the quality type of the insulating refractory brick according to the overall evaluation value, and control the swing motor to swing and guide the insulating refractory brick into different areas of the grid separation device according to the quality type.

3. The automatic screening machine for insulating refractory bricks according to claim 2 is characterized in that: When the first control unit determines the blowing volume of the fan according to the transport rate and the surface pressure data, it includes: ； Wherein, Q represents the air volume, Q0 represents the minimum air volume of the fan, V represents the transport rate, Vmax represents the maximum transport rate of the first conveyor belt, P represents the surface pressure data, Pmax represents the maximum surface pressure data, a1 and a2 represent the speed amplification factor and the pressure amplification factor respectively, wherein the value range of a1 is [1, 3], the value range of a2 is [1, 3], and C1 and C2 represent constant terms, and the value range is [1, 2].

4. The automatic screening machine for insulating refractory bricks according to claim 2, characterized in that: When the second control unit determines the appearance evaluation value, it includes: The second control unit compares the three-dimensional model with the standard model, marks the defect area, and obtains the area, defect depth and defect roundness of each defect area, and obtains the appearance evaluation value through the following formula: ； Where S1 represents the appearance evaluation value, Ai represents the normalized result of the i-th defect area, β1 represents the adjustment unit, and the value range of β1 is [1, 2]. represents the normalized result of the roundness of the i-th defect, Di represents the normalized result of the i-th defect depth, and Az represents the normalized result of the total defect area.

5. The automatic screening machine for insulating refractory bricks according to claim 2, characterized in that: The third control unit acquires the refractory curve of the insulating refractory brick according to the infrared image, and compares the refractory curve with historical data to determine the refractory evaluation value, including: The third control unit compares the fire resistance curve with historical data and determines the fire resistance evaluation value according to the comparison result; When the historical data contains data identical to the fire resistance curve, the third control unit determines the fire resistance evaluation value according to the historical data; When there is no data identical to the fire resistance curve in the historical data, the third control unit screens similar data in the historical data, and when there is similar data in the historical data, the third control unit determines the fire resistance evaluation value according to the similar data.

6. The automatic screening machine for insulating refractory bricks according to claim 5, characterized in that: When the third control unit determines the fire resistance evaluation value according to the similarity data, it includes: The third control unit extracts the temperature values ​​of the first moment and the second moment in the refractory curve, records them as the first temperature and the second temperature, extracts the temperature values ​​of the same moment in the historical refractory curve, records them as the historical first temperature and the historical second temperature, and when the first temperature is the same as the historical first temperature or the second temperature is the same as the historical second temperature, uses the historical refractory curve as the similarity data; Obtaining the maximum slope of the refractory curve and the historical maximum slope of the historical refractory curve; Classifying the historical refractory curves whose historical maximum slope is greater than the maximum slope as a first historical set; Classifying the historical refractory curves whose historical maximum slope is equal to the maximum slope as a second historical set; Classifying the historical refractory curves whose historical maximum slope is less than the maximum slope as a third historical set; The third control unit obtains the fire resistance evaluation value according to the historical fire resistance evaluation values ​​corresponding to the first history set, the second history set and the third history set.

7. The automatic screening machine for insulating refractory bricks according to claim 6, characterized in that: When the third control unit obtains the fire resistance evaluation value according to the historical fire resistance evaluation values ​​corresponding to the first history set, the second history set, and the point history set, it includes: ； Among them, S2 represents the fire resistance assessment value, Sx represents the x-th historical fire resistance assessment value in the first historical set, M1 represents the number of historical fire resistance assessment values ​​in the first historical set, S0 represents the mean of the historical fire resistance assessment values ​​in the second historical set, Sy represents the y-th historical fire resistance assessment value in the third historical set, and M2 represents the number of historical fire resistance assessment values ​​in the third historical set.

8. The automatic screening machine for insulating refractory bricks according to claim 6, characterized in that: When there is no similar data in the historical data, the third control unit obtains the fire resistance evaluation value according to the fire resistance curve, and the fire resistance evaluation value is calculated by the following formula: ； Wherein, S2 represents the fire resistance evaluation value, Tmax represents the maximum temperature of the fire resistance curve, Δt represents the time for the maximum temperature to return to room temperature, Tavg represents the average temperature of the fire resistance curve, ΔTmax represents the maximum temperature difference of the standard fire resistance curve, Vc represents the maximum cooling rate of the fire resistance curve, and Vcmax represents the maximum cooling rate of the standard fire resistance curve.

9. The automatic screening machine for insulating refractory bricks according to claim 2, characterized in that: When the fourth control unit obtains an overall evaluation value based on the appearance evaluation value and the fire resistance evaluation value, and determines the quality type of the insulating refractory brick according to the overall evaluation value, the method includes: ； Wherein, S represents the overall evaluation value, S1 represents the appearance evaluation value, S2 represents the fire resistance evaluation value, e1 and e2 represent weight coefficients, and e1+e2=1; The fourth control unit determines the quality type of the insulating refractory brick according to the overall evaluation value, the quality types include first quality, second quality, third quality and fourth quality, and the first quality is better than the second quality, the second quality is better than the third quality, and the third quality is better than the fourth quality, and the overall evaluation value is inversely proportional to the quality type.

10. A control method for an automatic screening machine for insulating refractory bricks, applied to the automatic screening machine for insulating refractory bricks as claimed in any one of claims 1 to 9, characterized in that: include: Collecting the transport speed and surface pressure data of the first conveyor belt, and determining the blowing volume of the fan according to the transport speed and surface pressure data; Controlling the surface image acquisition unit to acquire a plurality of surface image data of the insulating refractory bricks, establishing a three-dimensional model and comparing it with a standard model to determine an appearance evaluation value; Controlling the infrared image acquisition unit to acquire at least two infrared images of the insulating refractory bricks, obtaining the refractory curve of the insulating refractory bricks according to the infrared images, and comparing the refractory curve with historical data to determine the refractory evaluation value; An overall evaluation value is obtained based on the appearance evaluation value and the refractory evaluation value, and the quality type of the insulating refractory brick is determined according to the overall evaluation value. According to the quality type, a swing motor is controlled to swing and guide the insulating refractory brick into different areas of the grid separation device.

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