An automatic screening machine for heat-insulating refractory bricks and its control method

Abstract

The present invention relates to the technical field of classified transportation, and discloses an automatic screening machine for heat-insulating refractory bricks and a control method thereof. The device includes: a conveying device, a negative pressure dust removal device, an image acquisition device, a heating device, a swinging screening device, a grid separation device, and a control device; wherein, the conveying device includes a first conveyor belt, a second conveyor belt, and a rotary transmission unit; the negative pressure dust removal device includes a fan and a negative pressure dust suction unit; the heating device is arranged on the second conveyor belt; the image acquisition device includes a surface image acquisition unit and an infrared image acquisition unit; the swinging screening device includes an aggregation grid, a swinging motor, an operating rod, and a swinging rod; the control device is used to control the screening and separation process of the heat-insulating refractory bricks. This application realizes real-time monitoring and adjustment of the conveying and classification links, ensuring the automation, high efficiency, and accuracy of the overall screening process. It solves the problems of insufficient precision, low efficiency, and unstable quality in traditional screening technologies.

Description

Technical Field

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

[0002] With the continuous development of industrialization, heat-insulating refractory bricks are increasingly widely used in industries such as metallurgy, chemical industry, building materials, and machinery. Especially, the demand for refractory materials in high-temperature environments is gradually increasing. Heat-insulating refractory bricks are usually used in fields such as high-temperature furnaces, heat treatment equipment, and boilers. Their main functions are heat insulation, resistance to high-temperature thermal shock, and improvement of the thermal efficiency of equipment. Therefore, the quality requirements for heat-insulating refractory bricks in the production process are getting higher and higher.

[0003] However, in the traditional production process of heat-insulating refractory bricks, most of the links such as inspection and zoned storage rely on manual labor, which not only has low efficiency but also cannot effectively ensure the screening and separation accuracy. Even when mechanical vision is used for screening, relying only on a single index, the equipment usually cannot achieve efficient and accurate screening when dealing with refractory bricks of different sizes, shapes, or uneven surface qualities, and it is easy to have situations of missed screening or mis-screening, resulting in some unqualified bricks being mis-screened as qualified products, or qualified bricks being mis-screened as unqualified products, affecting product quality.

[0004] Therefore, it is necessary to design an automatic screening machine for heat-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 provides an automatic screening machine for heat-insulating refractory bricks and a control method thereof, aiming to solve the problems that it is time-consuming and laborious to rely on manual screening during zoned storage after the production of heat-insulating refractory bricks is completed, and the machine vision has low accuracy and poor reliability.

[0006] On the one hand, the present invention provides an automatic screening machine for heat-insulating refractory bricks, including:

[0007] a conveying device, a negative pressure dust removal device, an image acquisition device, a heating device, a swinging screening device, a grid separation device, and a control device; wherein,

[0008] the conveying device includes a first conveyor belt, a second conveyor belt, and a rotary transfer unit. The rotary transfer unit is arranged between the first conveyor belt and the second conveyor belt, and the rotary transfer unit is made of rubber;

[0009] the negative pressure dust removal device is arranged on the first conveyor belt. The negative pressure dust removal device includes 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 heat-insulating refractory bricks;

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

[0011] The image acquisition device includes a surface image acquisition unit and an infrared image acquisition unit. The surface image acquisition unit is arranged on the first conveyor belt and is located on the right side of the blower. 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 includes an aggregation grid, a swing motor, an operating rod, and a swing rod. The swing motor is rotatably connected to the operating rod. The operating rod is used to control the swinging of the swing rod. The swing rod is flexibly connected to the aggregation 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. The control device is used to control the screening and separation process of the heat-insulating refractory bricks.

[0014] Furthermore, the control device includes:

[0015] A first control unit configured to collect the transportation rate and surface pressure data of the first conveyor belt, and determine the air volume of the blower according to the transportation rate and surface pressure data;

[0016] A second control unit configured to control the surface image acquisition unit to collect surface image data of a plurality of the heat-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 configured to control the infrared image acquisition unit to collect at least two infrared images of the heat-insulating refractory bricks, obtain a refractory curve of the heat-insulating refractory bricks according to the infrared images, and compare the refractory curve with historical data to determine a refractory evaluation value;

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

[0019] Furthermore, when the first control unit determines the air volume of the blower according to the transportation rate and 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 transportation rate, Vmax represents the maximum transportation rate of the first conveyor belt, P represents the surface pressure data, Pmax represents the maximum surface pressure data, a1 and a2 respectively represent the speed amplification factor and the pressure amplification factor, where 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].

[0022] Further, 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 defective areas, and obtains the area, defect depth, and defect roundness of each defective area, and obtains the appearance evaluation value through the following formula:

[0024]

[0025] Wherein, S1 represents the appearance evaluation value, Ai represents the normalized result of the area of the i-th defect, 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 depth of the i-th defect, and Az represents the normalized result of the total defect area.

[0026] Further, when the third control unit obtains the fire resistance curve of the heat-insulating refractory brick according to the infrared image and determines the fire resistance evaluation value by comparing the fire resistance curve with the historical data, it includes:

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

[0028] When there is data in the historical data that is the same as 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 in the historical data that is the same as the fire resistance curve, the third control unit screens similar data in the historical data. 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] Further, when the third control unit determines the fire resistance evaluation value according to the similar data, it includes:

[0031] The third control unit extracts the temperature values at the first moment and the second moment from the fire resistance curve, denoted as the first temperature and the second temperature, and extracts the temperature values at the same moments from the historical fire resistance curve, denoted as the historical first temperature and the historical second temperature. When one of the first temperature and the historical first temperature or the second temperature and the historical second temperature is the same, the historical fire resistance curve is used as the similar data;

[0032] Obtain the maximum slope of the fire resistance curve and the historical maximum slope of the historical fire resistance curve;

[0033] Classify the historical fire resistance curves with the historical maximum slope greater than the maximum slope into the first historical set;

[0034] Classify the historical fire resistance curves with the historical maximum slope equal to the maximum slope into the second historical set;

[0035] Classify the historical fire resistance curves with the historical maximum slope less than the maximum slope into the 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 historical set, the second historical set, and the third historical set.

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

[0038]

[0039] Where, S2 represents the fire resistance evaluation value, Sx represents the x-th historical fire resistance evaluation value in the first historical set, M1 represents the number of historical fire resistance evaluation values in the first historical set, S0 represents the average value of the historical fire resistance evaluation values in the second historical set, Sy represents the y-th historical fire resistance evaluation value in the third historical set, and M2 represents the number of historical fire resistance evaluation 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] Where, S2 represents the fire resistance evaluation value, Tmax represents the highest temperature of the fire resistance curve, Δt represents the duration for the highest temperature to recover 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, 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 heat-insulating and fire-resistant brick according to the overall evaluation value, it includes:

[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 heat-insulating and fire-resistant brick according to the overall evaluation value. The quality types include the first quality, the second quality, the third quality, and the fourth quality, and the first quality is superior to the second quality, the second quality is superior to the third quality, the third quality is superior to 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 as follows: By comprehensively applying a conveying device, a negative pressure dust removal device, an image acquisition device, a heating device, a swinging screening device, a grid separation device, and a control device, automated high-efficiency screening and quality control are achieved. Through the cooperation of the rotary transfer unit and multiple conveyor belts, the conveying accuracy and stability of the bricks are improved. The setting of the rotary transfer unit avoids the retention of bricks 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 contamination on the screening result; The image acquisition device combines the surface image and the infrared image and 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 swinging screening device realizes screening through the aggregating grid connected by a flexible connection and the swinging action, avoiding the occurrence of missed screening and mis-screening phenomena; The control device monitors and adjusts each link in real time, ensuring the automation, high efficiency, and accuracy of the overall screening process. It solves the problems of insufficient accuracy, low efficiency, and unstable quality in traditional screening technologies.

[0048] On the other hand, the present application also provides a control method for an automatic screening machine for heat-insulating and fire-resistant bricks, which is applied to the above-mentioned automatic screening machine for heat-insulating and fire-resistant bricks and includes:

[0049] Collect the transportation rate and surface pressure data of the first conveyor belt, and determine the air volume of the blower according to the transportation rate and surface pressure data;

[0050] Control the surface image acquisition unit to collect several surface image data of the heat-insulating and fire-resistant bricks, establish a three-dimensional model and compare it with the standard model to determine the appearance evaluation value;

[0051] Control the infrared image acquisition unit to acquire at least two infrared images of the heat-insulating refractory brick, obtain the refractory curve of the heat-insulating refractory brick according to the infrared images, and compare the refractory curve with historical data to determine the refractory evaluation value;

[0052] Obtain an overall evaluation value based on the appearance evaluation value and the refractory evaluation value, determine the quality type of the heat-insulating refractory brick according to the overall evaluation value, and control the swing motor to swing according to the quality type to guide the heat-insulating refractory brick into different areas of the grid separation device.

[0053] It can be understood that the above-mentioned automatic screening machine for heat-insulating refractory bricks and its control method have the same beneficial effects, which will not be elaborated here. Description of the Drawings

[0054] By reading the following detailed description of the preferred embodiments, various other advantages and benefits will become clear to those of ordinary skill in the art. The drawings are only for the purpose of showing the preferred embodiments and are not considered as limiting the present invention. Moreover, throughout the drawings, the same reference numerals are used to represent the same components. In the drawings:

[0055] Figure 1 is a schematic structural diagram of the automatic screening machine for heat-insulating refractory bricks provided by an embodiment of the present invention;

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

[0057] Figure 3 is Figure 2 an enlarged view of part A in

[0058] Figure 4 is a flowchart of the control method of the automatic screening machine for heat-insulating refractory bricks provided by an embodiment of the present invention.

[0059] Among them, 110, the first conveyor belt; 120, the second conveyor belt; 130, the rotary 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 collection unit; 300, the heating device; 410, the surface image acquisition unit; 420, the infrared image acquisition unit; 510, the aggregation grid; 520, the swing motor; 530, the operating rod; 540, the swing rod; 600, the grid separation device; 700, the control device. Detailed Embodiments

[0060] Exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. Although the exemplary embodiments of the present disclosure are shown in the 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 so that the present disclosure can be more thoroughly understood and the scope of the present disclosure can be fully conveyed to those skilled in the art. It should be noted that, without conflict, the embodiments in the present invention and the features in the embodiments can be combined with each other. The present invention will be described in detail below with reference to the drawings and in combination with the embodiments.

[0061] In some embodiments of the present application, referring to Figures 1-3 as shown, an automatic screening machine for heat-insulating refractory bricks includes: a conveying device, a negative pressure dust removal device, an image acquisition device, a heating device 300, a swinging 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 rotary transfer unit 130. The rotary transfer unit 130 is arranged between the first conveyor belt 110 and the second conveyor belt 120, and the rotary transfer unit 130 is made of rubber.

[0063] The negative pressure dust removal device is arranged on the first conveyor belt 110. 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 heat-insulating refractory bricks.

[0064] The heating device 300 is arranged 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 the surface image acquisition unit 410 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 the infrared image acquisition unit 420 is located on the right side of the heating device 300.

[0066] The swinging screening device includes an aggregation grid 510, a swinging motor 520, an operating rod 530, and a swinging rod 540. The swinging motor 520 is rotatably connected to the operating rod 530. The operating rod 530 is used to control the swinging of the swinging rod 540. The swinging rod 540 is flexibly connected to the aggregation 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 swinging screening device. The control device 700 is used to control the screening and separation process of the heat-insulating refractory bricks.

[0068] Specifically, the heat-insulating refractory bricks enter the automatic screening machine for heat-insulating refractory bricks and are first conveyed by the first conveyor belt 110, which is driven by the first driving motor 140. On the first conveyor belt 110, during the forward movement of the brick body, through the negative pressure dust removal device arranged on the first conveyor belt 110, the fan 210 blows air onto the surface of the heat-insulating refractory bricks, and the dust is collected and discharged 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, effectively removing the dust and impurities on the surface of the brick body, ensuring that the subsequent screening, heating, and detection processes are not interfered by dust, and improving the screening accuracy and surface quality. Then it enters the acquisition range of the surface image acquisition unit 410 on the first conveyor belt 110, and several pieces of surface image data are acquired. Information such as surface defects, cracks, and missing corners is captured for subsequent analysis by the control device 700. Then the heat-insulating refractory bricks are transferred through the rotary transfer unit 130 arranged between the first conveyor belt 110 and the second conveyor belt 120. The rotary transfer unit 130 is driven by the second driving motor 150. The rotary transfer unit 130 is made of rubber material, with good friction and flexibility, and can smoothly transfer the brick body from one conveyor belt to another, avoiding damage to the surface of the brick body and ensuring the stable transmission of the brick body to the subsequent processing link.

[0069] Specifically, the brick body enters the second conveyor belt 120, which is driven by the third driving motor 160. After the brick body enters the second conveyor belt 120, through the aggregation of the aggregation grid 510, 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 chains to avoid damage to the second conveyor belt 120 by the heating device 300. 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 acquired to further identify the quality of the brick body. The swing screening device is the core part of this equipment. As the brick body passes through this area, according to the quality type of the brick body, the swing motor 520 is controlled to drive the operating rod 530 to rotate, and then the swing rod 540 generates a swinging action, guiding the brick body into the grid separation device 600, and realizing screening and classification through different areas.

[0070] It can be understood that by controlling the screening and classification link, the efficiency and accuracy of the screening process of the heat-insulating refractory bricks are improved. The combined work of the rotary 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 mis-screening 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 still maintain a high-efficiency 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 transportation rate and surface pressure data of the first conveyor belt 110, and determine the air volume of the blower 210 according to the transportation rate and the surface pressure data.

[0073] The second control unit is configured to control the surface image acquisition unit 410 to collect surface image data of a plurality of 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 collect at least two infrared images of the refractory bricks, obtain the refractory curve of the refractory bricks according to the infrared images, and compare the refractory curve with historical data to determine a 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, determine the quality type of the refractory bricks according to the overall evaluation value, and control the swing motor 520 to swing according to the quality type to guide the refractory bricks into different areas of the grille separation device 600.

[0076] Specifically, the first control unit adjusts the air volume of the blower 210 according to the transportation rate and surface pressure data of the first conveyor belt 110. By monitoring the transportation speed of the conveyor belt, the air volume output of the blower 210 is dynamically adjusted to ensure that the blower 210 always maintains the best dust removal effect at different transportation speeds. The surface pressure data reflects the distribution density of the 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 blower 210 to avoid the negative impacts caused by too strong or too weak dust removal. The second control unit controls the surface image acquisition unit 410 to acquire images of each heat-insulating refractory brick. By obtaining a number of surface image data of the brick body, a three-dimensional model of the brick body surface is built and compared with the pre-established standard model. By comparing the differences between the models, an appearance evaluation value is generated to evaluate whether there are surface problems such as defects, cracks, and missing corners on the brick body. The third control unit is responsible for controlling the infrared image acquisition unit 420 to acquire infrared image data of the heat-insulating refractory brick. According to the infrared image, the refractory performance curve of the brick body (i.e., the temperature change of the brick body after heating) is analyzed. By comparing these temperature data with the refractory performance data in the historical database, a refractory evaluation value is calculated to comprehensively evaluate the refractory performance of the brick body. The fourth control unit comprehensively evaluates the heat-insulating refractory brick based on the appearance evaluation value provided by the second control unit and the refractory evaluation value provided by the third control unit to obtain an overall evaluation value. According to this evaluation value, the quality type of the brick body (such as high-quality, defective, unqualified, etc.) is further determined. According to the evaluation result, the swing motor 520 is commanded to adjust the action of the swing rod 540 to guide the heat-insulating refractory brick into different areas of the grid separation device 600.

[0077] It can be understood that the precise adjustment of the control unit can ensure the high efficiency and adaptability of the blower 210 under different working conditions, avoid the situations of over-cleaning or insufficient cleaning, thereby improving the cleanliness of the brick body surface and the accuracy of the subsequent screening and heating processes. Through the three-dimensional modeling of the image data and the comparison with the standard model, the second control unit can accurately identify the appearance defects of the brick body and determine the evaluation value. It is more accurate than the traditional manual inspection or single image recognition technology and can better ensure the appearance quality of the brick body. Through the infrared imaging technology, the temperature of the brick body is accurately monitored to identify the performance of the refractory brick in a high-temperature environment. By comparing with the historical data, the refractory performance of the brick body is judged to avoid the problem of insufficient refractory performance of the brick body. Through the intelligent sorting of the brick body based on the comprehensive evaluation result, the quality management of the heat-insulating refractory brick is ensured to be more refined and automated. Through the guidance and separation, the unqualified brick bodies can be accurately identified and removed in time, avoiding the situations of manual screening and misjudgment, and improving the screening efficiency and accuracy.

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

[0079]

[0080] Among them, Q represents the air volume of the blower, Q0 represents the minimum air volume of the blower 210, V represents the transportation rate, Vmax represents the maximum transportation rate of the first conveyor belt 110, P represents the surface pressure data, Pmax represents the maximum surface pressure data, a1 and a2 respectively represent the speed amplification factor and the pressure amplification factor, where 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].

[0081] It can be understood that by introducing a dynamic adjustment mechanism for the transportation rate and the surface pressure, the precise control of the air volume of the blower 210 is achieved. Compared with the traditional fixed air volume control method, the working state of the blower 210 is automatically adjusted according to the real-time changes in the production process, so as to more precisely match the requirements of different production links. When the conveyor belt speed is relatively fast or the surface pressure of the brick body is relatively large, the blower 210 will automatically increase the air volume to ensure that the cleaning effect is not affected; while under lower speed and pressure conditions, the blower 210 can maintain lower energy consumption and reasonable working intensity. The working efficiency of the blower 210 is improved, the energy consumption is reduced, the dust removal effect and the 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 defective areas, and obtains the area, defect depth, and defect roundness of each defective area, and obtains the appearance evaluation value through the following formula:

[0084]

[0085] Among them, S1 represents the appearance evaluation value, Ai represents the normalized result of the area of the i-th defect, 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 depth of the i-th defect, and Az represents the normalized result of the total defect area.

[0086] It can be understood that by calculating and analyzing various characteristics of the defects (such as area, depth, roundness, etc.), the evaluation of the appearance quality of the heat-insulating refractory bricks is realized. Compared with the traditional manual inspection method, the automatic evaluation based on three-dimensional image comparison and quantitative analysis can more accurately identify and quantify the surface defects of the bricks. Through normalization processing, different defect characteristics can be evaluated with a unified standard, avoiding the errors and inconsistencies brought by manual judgment. Through the appearance evaluation value, the appearance quality of the bricks can be effectively quantified, ensuring more accurate screening and quality control in the production process, improving the production efficiency and the consistency of product quality. At the same time, reducing manual intervention, reducing manual errors, and improving the automation and intelligent level of the production line.

[0087] In some embodiments of the present application, when the third control unit obtains the fire resistance curve of the heat-insulating refractory brick according to the infrared image and determines the fire resistance evaluation value by comparing the fire resistance curve with the historical data, it includes: the third control unit compares the fire resistance curve with the historical data and determines the fire resistance evaluation value according to the comparison result.

[0088] Specifically, when there is data in the historical data that is the same as the fire resistance curve, the third control unit determines the fire resistance evaluation value according to the historical data. When there is no data in the historical data that is the same as the fire resistance curve, the third control unit screens similar data in the historical data. When there is similar data 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 according to the similar data, it includes: the third control unit extracts the temperature values at the first moment and the second moment in the fire resistance curve, denoted as the first temperature and the second temperature, and extracts the temperature values at the same moments in the historical fire resistance curve, denoted as the historical first temperature and the historical second temperature. When one of the first temperature and the historical first temperature or the second temperature and the historical second temperature is the same, the historical fire resistance curve is used as the similar data.

[0090] Specifically, obtain the maximum slope of the fire resistance curve and the historical maximum slope of the historical fire resistance curve. The historical fire resistance curves with historical maximum slopes greater than the maximum slope are classified into the first historical set. The historical fire resistance curves with historical maximum slopes equal to the maximum slope are classified into the second historical set. The historical fire resistance curves with historical maximum slopes less than the maximum slope are classified into the 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 historical set, the second historical set, and the third 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 historical set, the second historical set, and the third historical set, it includes:

[0092]

[0093] Among them, S2 represents the fire resistance evaluation value, Sx represents the x-th historical fire resistance evaluation value in the first historical set, M1 represents the number of historical fire resistance evaluation values in the first historical set, S0 represents the average value of the historical fire resistance evaluation values in the second historical set, Sy represents the y-th historical fire resistance evaluation value in the third historical set, and M2 represents the number of historical fire resistance evaluation 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] Among them, S2 represents the fire resistance evaluation value, Tmax represents the highest temperature of the fire resistance curve, Δt represents the duration for the highest 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 characteristics such as the maximum slope and temperature value of the real-time fire resistance curve with the historical data, similar curves are flexibly selected from the historical data for analysis. Not only the overall shape of the curve is considered, but also the temporal characteristics of temperature change are introduced, making the fire resistance evaluation more accurate. The classification method of the maximum slope of the historical data enables more refined screening of similar data according to the difference in the maximum slope in different situations, thereby improving the accuracy and robustness of the evaluation results. For the case without similar data, the fire resistance evaluation value is calculated by a formula through multi-dimensional characteristics such as the maximum temperature, average temperature, recovery time, and cooling rate of the curve, which can still perform effective fire resistance evaluation without the support of historical data.

[0098] It can be understood that by introducing multi-dimensional data such as the maximum slope and temperature characteristics, a flexible and accurate fire resistance evaluation mechanism is constructed. Compared with the traditional single-characteristic evaluation method, it can not only accurately calculate the fire resistance evaluation value by comparison in the case of existing similar historical data, but also perform effective fire resistance evaluation relying on the characteristics of the curve when there is a lack of similar data. Through the classification and screening of historical data, more accurate evaluation results can be provided according to different curve characteristics. Finally, the accuracy of the fire resistance evaluation value is improved, which helps to monitor the quality of the heat-insulating firebrick in real time.

[0099] In some embodiments of the present application, when the fourth control unit obtains the overall evaluation value based on the appearance evaluation value and the fire resistance evaluation value, and determines the quality type of the heat-insulating firebrick 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 the weight coefficients, and e1 + e2 = 1.

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

[0103] It can be understood that through the comprehensive evaluation of these two key parameters, namely appearance and fire resistance performance, the quality grading of the heat-insulating refractory brick is accurately carried out. By introducing the weighting coefficient, a flexible adjustment space is provided, enabling the proportion of appearance and fire resistance performance to be optimized according to actual needs. Ensure that each type of brick body obtains an appropriate quality evaluation according to the actual application scenario, avoiding the one-sidedness existing in the traditional evaluation method. Further, through the automated overall evaluation and quality classification, the production efficiency can be improved, manual intervention can be reduced, and the consistency of product quality can be enhanced.

[0104] In the above embodiment, through the comprehensive application of the conveying device, the negative pressure dust removal device, the image acquisition device, the heating device, the swing screening device, the grid separation device and the control device, the automated high-efficiency screening and quality control are realized. Through the cooperation of the rotary transfer unit and the multi-conveyor belts, the conveying accuracy and stability of the brick body are improved. The setting of the rotary transfer unit avoids the retention of bricks 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 the surface dust, avoiding the influence of surface contamination on the screening result. The image acquisition device combines the surface image and the infrared image and 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 the subsequent screening. The swing screening device realizes the screening through the flexible connection of the aggregation grid and the swing action, avoiding the occurrence of missed screening and mis-screening phenomena. The control device monitors and adjusts each link in real time, ensuring the automation, high efficiency and accuracy of the overall screening process. Solve the problems of insufficient accuracy, low efficiency and unstable quality in the traditional screening technology.

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

[0106] S100: Collect the transportation rate and surface pressure data of the first conveyor belt, and determine the air volume of the blower according to the transportation rate and surface pressure data;

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

[0108] S300: Control the infrared image acquisition unit to collect at least two infrared images of the heat-insulating refractory bricks, obtain the refractory curve of the heat-insulating refractory bricks according to the infrared images, and compare the refractory curve with the historical data to determine the refractory evaluation value;

[0109] S400: Obtain the overall evaluation value based on the appearance evaluation value and the refractory evaluation value, determine the quality type of the heat-insulating refractory bricks according to the overall evaluation value, and control the swing motor to swing according to the quality type to guide the heat-insulating refractory bricks into different areas of the grid separation device.

[0110] It can be understood that by comprehensively applying the conveying device, negative pressure dust removal device, image acquisition device, heating device, swing screening device, grid separation device and control device, automatic high-efficiency screening and quality control are realized. Through the cooperation of the rotary transfer unit and multiple conveyor belts, the conveying accuracy and stability of the bricks are improved. The setting of the rotary transfer unit avoids the retention of bricks 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 the surface dust and avoids the influence of surface contamination on the screening results; the image acquisition device combines the surface image and infrared image and the heating of the bricks by the heating device to capture the surface defects and temperature changes of the bricks, providing a more accurate basis for subsequent screening; the swing screening device realizes screening through the flexible connection of the aggregation grid and the swing action, avoiding the occurrence of missed screening and mis-screening phenomena; the control device monitors and adjusts each link in real time, ensuring the automation, high efficiency and accuracy of the overall screening process. It solves the problems of insufficient accuracy, low efficiency and unstable quality in traditional screening technologies.

[0111] Those skilled in the art should understand that the embodiments of the present application can be provided as methods, systems or computer program products. Therefore, the present application can adopt the form of a complete hardware embodiment, a complete software embodiment, or an embodiment combining software and hardware aspects. Moreover, the present application can adopt 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 code.

[0112] This application is described with reference to the flowcharts and / or block diagrams of methods, apparatuses (systems), and computer program products according to embodiments of the present application. It should be understood that each flow and / or block in the flowchart and / or block diagram can be implemented by computer program instructions, as well as the combination of flows and / or blocks in the flowchart and / or block diagram. These computer program instructions can be provided to the processor of a general-purpose computer, a special-purpose computer, an embedded processor, or other programmable data processing devices to generate a machine, such that the instructions executed by the processor of the computer or other programmable data processing devices generate means for implementing the functions specified in the Figure 1 one or more flows and / or blocks Figure 1 one or more blocks.

[0113] These computer program instructions can also be stored in a computer-readable memory that can direct a computer or other programmable data processing device to work in a specific manner, such that the instructions stored in the computer-readable memory generate a manufactured article including instruction means that implement the functions specified in the Figure 1 one or more flows and / or blocks Figure 1 one or more blocks.

[0114] These computer program instructions can also be loaded onto a computer or other programmable data processing device, such that a series of operation steps are executed on the computer or other programmable device to generate a computer-implemented process, so that the instructions executed on the computer or other programmable device provide steps for implementing the functions specified in the Figure 1 one or more flows and / or blocks Figure 1 one or more blocks.

[0115] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them. Although the present invention has been described in detail with reference to the above embodiments, those of ordinary skill in the art should understand that: the specific implementation manners of the present invention can still be modified or equivalently replaced, and any modification or equivalent replacement that does not depart from the spirit and scope of the present invention should be covered by the protection scope 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; 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.

2. The automatic screening machine for insulating refractory bricks according to claim 1 is 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; 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, the historical refractory curve is used as similar 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; When the third control unit determines the fire resistance evaluation value according to the similarity data, it includes: 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.

3. The automatic screening machine for insulating refractory bricks according to claim 1 is 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.

4. 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 3, 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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