Refining heating furnace flame state monitoring system and design method thereof

Abstract

The embodiment of the invention provides a refining heating furnace flame state monitoring system and a design method thereof, and belongs to the technical field of equipment monitoring. The system comprises a plurality of image acquisition devices extending into a hearth of the refining heating furnace, and each image acquisition device is fixed on the inner wall of the hearth through an adjustable mechanical arm and used for acquiring combustion flame images of a furnace nozzle in the hearth; wherein at least one image acquisition device in the plurality of image acquisition devices is arranged at the position of a hearth fire observation hole; and the man-machine interaction module is arranged at the fire observation hole of the hearth. According to the scheme, the state in the whole combustion furnace is sensed in real time, so that corresponding early warning and correction operation can be executed subsequently based on the real-time state, and the response speed of heating furnace supervision is increased.

Description

Technical Field

[0001] The present invention relates to the technical field of equipment monitoring, and in particular to a flame state monitoring system for a refinery heating furnace and a design method for the flame state monitoring system for a refinery heating furnace. Background Art

[0002] The refining heating furnace is one of the core equipment of the refining enterprise. The operating stability of the refining heating furnace is directly related to the operating stability of the entire refining enterprise. For the tubular heating furnace, multiple nozzles are set in the heating furnace, and the flame generated by the nozzle is used to heat the fluid in the tube. After heating it to the target temperature, subsequent refining operations are performed. It can be seen that for subsequent refining operations, it is necessary to ensure the stability of the front-end heating operation. The stability of the heating process depends on the normal flame of the nozzle and the normal fluid of the furnace tube. Only when both maintain the expected operation, the entire heating furnace can meet subsequent needs.

[0003] In the existing scheme, the operation information of the refining heating furnace is mainly collected and monitored through the enterprise DCS system. This monitoring scheme maps the monitoring results after coupling the operating status data of multiple devices. It needs to reversely infer the actual operating status based on the operating status parameters. This method is indeed very efficient for status monitoring, but because it needs to collect status parameters first, it is easy to cause short-term parameter abnormalities. And because the refining heating furnace itself is a special operating equipment with high temperature and high pressure, it not only affects the refining effect of subsequent refining equipment, but its abnormal operation is also easy to cause safety accidents, so the existing status monitoring scheme has the problem of slow response speed. In view of the problem of slow response speed of the existing refining heating furnace flame status monitoring scheme, it is necessary to create a new refining heating furnace flame status monitoring scheme. Summary of the invention

[0004] The purpose of the embodiments of the present invention is to provide a refinery heating furnace flame state monitoring system and a design method thereof, so as to at least solve the problem of slow response speed in the existing refinery heating furnace flame state monitoring scheme.

[0005] In order to achieve the above-mentioned purpose, the first aspect of the present invention provides a flame state monitoring system for a refining heating furnace, the system comprising: a plurality of image acquisition devices extending into the furnace of the refining heating furnace, each image acquisition device being fixed to the inner wall of the furnace through an adjustable mechanical arm, and being used for acquiring images of the combustion flames at the nozzle in the furnace; wherein at least one of the plurality of image acquisition devices is arranged at a fire viewing hole in the furnace; and a human-computer interaction module is arranged at the fire viewing hole in the furnace.

[0006] Optionally, the adjustable robotic arm is driven by a servo motor.

[0007] Optionally, each servo motor is controlled by a separate PLC controller.

[0008] Optionally, each PLC controller is preset with a corresponding control quantity threshold; each PLC controller performs servo motor control in the following manner: the PLC controller compares the control quantity corresponding to the input instruction with its preset control quantity threshold; if the control quantity of the input instruction is greater than the preset control quantity threshold, the input instruction is corrected based on the corresponding control quantity threshold, and servo motor control is performed based on the corrected input instruction.

[0009] Optionally, the control amount threshold of the PLC controller is determined based on the setting position of each image acquisition device, and the specific determination rules include: at the respective setting positions of each image acquisition device, adaptively driving the adjustable mechanical arm to move, and recording the position information of the image acquisition device in real time; when the image acquisition position information coincides with the furnace tube design position information or the furnace nozzle flame area design position information, taking the coincidence point as the control threshold point in one direction; traversing all movement directions of the adjustable mechanical arm to obtain the control threshold points in all directions; wherein, if there is no coincidence of the image acquisition position information with the furnace tube design position information or the furnace nozzle flame area design position information in a certain direction, taking the maximum movement point of the adjustable mechanical arm in that direction as the control threshold point in that direction; integrating the control threshold points in all directions to form the control amount threshold of the PLC controller corresponding to the image acquisition device.

[0010] Optionally, the number of image acquisition devices set in the furnace is determined as follows: based on the furnace design information, the number of furnace nozzles, the preset fire viewing height information, the distance information between the furnace nozzles and the opposite wall, and the spacing information between the furnace nozzles are read, and the number of image acquisition devices set is calculated based on the read information, and the calculation rule is:

[0011]

[0012] Wherein, M is the number of image acquisition devices; N is the number of furnace nozzles; H is the preset fire viewing height; L burner L is the distance between the furnace nozzle and the opposite wall; linterval The distance between the furnace nozzles.

[0013] Optionally, the setting position of each image acquisition device in the furnace is determined by the following rules: based on the furnace design information, the heating furnace inner diameter information, the furnace nozzle arrangement radius information, the furnace fire design height information, the image acquisition device field of view angle information and the depression angle information are read, and the setting range information of each image acquisition device is determined based on the read information, and the determination rule is:

[0014] L lmonitor ≥tan(θ / 2-θ1)(R-R1) and L lmonitor ≥ 0.6 L vis

[0015] Among them, L lmonitor is the setting height of the image acquisition device; θ is the field of view of the image acquisition device; θ1 is the depression angle of the image acquisition device; R is the inner diameter of the heating furnace; R1 is the radius of the furnace nozzle; L vis Design the height for the fire.

[0016] Optionally, the human-computer interaction module includes: a control module for generating a control signal for the adjustable robotic arm; and a display module for displaying monitoring screen information of the corresponding image acquisition device in real time.

[0017] The second aspect of the present invention provides a method for designing a flame state monitoring system for a refining heating furnace, the method comprising: collecting design information of the heating furnace, and determining the number and location of image acquisition devices in the furnace based on the design information and parameter information of the selected image acquisition device; providing a corresponding adjustable mechanical arm for each image acquisition device, and determining a control quantity threshold of a PLC controller that controls the adjustable mechanical arm; designing a corresponding control loop for the adjustable mechanical arm, and designing a corresponding human-computer interaction module to control the control loop.

[0018] Optionally, the number of image acquisition devices set in the furnace is determined as follows: based on the furnace design information, the number of furnace nozzles, the preset fire viewing height information, the distance information between the furnace nozzles and the opposite wall, and the spacing information between the furnace nozzles are read, and the number of image acquisition devices set is calculated based on the read information, and the calculation rule is:

[0019]

[0020] Wherein, M is the number of image acquisition devices; N is the number of furnace nozzles; H is the preset fire viewing height; L burner L is the distance between the furnace nozzle and the opposite wall; linterval The distance between the furnace nozzles.

[0021] Optionally, the setting position of the image acquisition device in the furnace is determined by the following rules: based on the furnace design information, the heating furnace inner diameter information, the furnace nozzle arrangement radius information, the furnace fire design height information, the image acquisition device field of view angle information and the depression angle information are read, and the setting range information of each image acquisition device is determined based on the read information, and the determination rule is:

[0022] L lmonitor ≥tan(θ / 2-θ1)(R-R1) and L lmonitor ≥ 0.6 L vis

[0023] Among them, L lmonitoris the setting height of the image acquisition device; θ is the field of view of the image acquisition device; θ1 is the depression angle of the image acquisition device; R is the inner diameter of the heating furnace; R1 is the radius of the furnace nozzle; L vis Design the height for the fire.

[0024] Optionally, the determination of the control quantity threshold of the PLC controller that controls the adjustable robotic arm includes: adaptively driving the adjustable robotic arm to move at the respective setting positions of each image acquisition device, and recording the position information of the image acquisition device in real time; when the image acquisition position information coincides with the design position information of the furnace tube or the design position information of the furnace nozzle flame area, taking the coincidence point as a control threshold point in one direction; traversing all movement directions of the adjustable robotic arm to obtain control threshold points in all directions; wherein, if there is no coincidence of the image acquisition position information with the design position information of the furnace tube or the design position information of the furnace nozzle flame area in a certain direction, taking the maximum movement point of the adjustable robotic arm in that direction as the control threshold point in that direction; and integrating the control threshold points in all directions to form the control quantity threshold of the PLC controller of the corresponding image acquisition device.

[0025] Optionally, the human-computer interaction module includes: a control module for generating a control signal for the adjustable robotic arm; and a display module for displaying monitoring screen information of the corresponding image acquisition device in real time.

[0026] On the other hand, the present invention provides a computer-readable storage medium having instructions stored thereon, which, when executed on a computer, enables the computer to execute the above-mentioned method for designing a flame state monitoring system for a refining heating furnace.

[0027] Through the above technical solution, the solution of the present invention sets multiple image acquisition devices in the furnace to collect flame combustion status images in real time, so as to monitor the flame combustion status in real time based on the image recognition algorithm. Whether the flame is extinguished or burning abnormally, it can be detected by the flame combustion status. Furthermore, a corresponding adjustable mechanical arm is set for the image acquisition device, so that the supervisor can adjust the posture of the image acquisition device, improve its image acquisition range, ensure the acquisition quality, and realize real-time perception of the status of the entire combustion furnace, so as to perform corresponding early warning and correction operations based on the real-time status, thereby improving the response speed of heating furnace supervision.

[0028] Other features and advantages of the embodiments of the present invention will be described in detail in the following detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The accompanying drawings are used to provide a further understanding of the embodiments of the present invention and constitute a part of the specification. Together with the following specific embodiments, they are used to explain the embodiments of the present invention, but do not constitute a limitation on the embodiments of the present invention. In the accompanying drawings:

[0030] Figure 1 It is a structural schematic diagram of a flame state monitoring system for a refinery heating furnace provided by an embodiment of the present invention;

[0031] Figure 2 It is a flowchart of the steps of a method for designing a flame state monitoring system for a refinery heating furnace provided by an embodiment of the present invention.

[0032] Description of Reference Numerals

[0033] 10-furnace; 20-image acquisition device; 30-adjustable robotic arm; 40-furnace nozzle; 50-human-computer interaction module. DETAILED DESCRIPTION

[0034] The specific implementation of the present invention is described in detail below in conjunction with the accompanying drawings. It should be understood that the specific implementation described here is only used to illustrate and explain the present invention, and is not used to limit the present invention.

[0035] The refining heating furnace is one of the core equipment of the refining enterprise. The operating stability of the refining heating furnace is directly related to the operating stability of the entire refining enterprise. For the tubular heating furnace, multiple nozzles are set in the heating furnace, and the flame generated by the nozzle is used to heat the fluid in the tube. After heating it to the target temperature, subsequent refining operations are performed. It can be seen that for subsequent refining operations, it is necessary to ensure the stability of the front-end heating operation. The stability of the heating process depends on the normal flame of the nozzle and the normal fluid of the furnace tube. Only when both maintain the expected operation, the entire heating furnace can meet subsequent needs.

[0036] In the existing scheme, the operation information of the refining heating furnace is mainly collected and monitored through the enterprise DCS system. This monitoring scheme maps the monitoring results after coupling the operation status data of multiple devices. It needs to reversely infer the actual operation status based on the operation status parameters. This method is indeed very efficient for status monitoring, but because it needs to collect status parameters first, it is easy to cause short-term parameter abnormalities. And because the refining heating furnace itself is a special operating equipment with high temperature and high pressure, it not only affects the refining effect of subsequent refining equipment, but its abnormal operation is also easy to cause safety accidents, so the existing status monitoring scheme has the problem of slow response speed.

[0037] In view of the problem of slow response speed in the existing flame state monitoring scheme of the refining heating furnace, the present invention proposes a new flame state monitoring system for the refining heating furnace. The present invention sets a plurality of image acquisition devices 20 in the furnace to collect the flame combustion state image in real time, so as to monitor the flame combustion state in real time based on the image recognition algorithm. Whether the flame is extinguished or abnormal combustion, it can be detected by the flame combustion state. Furthermore, a corresponding adjustable mechanical arm 30 is set for the image acquisition device 20, so that the supervisor can adjust the posture of the image acquisition device 20, improve its image acquisition range, ensure the acquisition quality, and realize the real-time perception of the state in the entire combustion furnace, so as to perform the corresponding early warning and correction operations based on the real-time state, thereby improving the response speed of the heating furnace supervision.

[0038] Figure 1 1 is a system structure diagram of a flame state monitoring system for a refinery heating furnace provided by an embodiment of the present invention. Figure 1 As shown, an embodiment of the present invention provides a flame state monitoring system for a refining heating furnace, the system comprising: a plurality of image acquisition devices 20 extending into a furnace 10 of the refining heating furnace, for acquiring images of a combustion flame at a furnace nozzle 40 in the furnace 10; each image acquisition device 20 is fixed to an inner wall of the furnace 10 by an adjustable mechanical arm 30; among the plurality of image acquisition devices 20, at least one image acquisition device 20 is arranged at a fire viewing hole of the furnace 10; and a human-computer interaction module 50 is arranged at the fire viewing hole where the image acquisition device 20 is arranged.

[0039] Embodiment 1:

[0040] Preferably, the adjustable mechanical arm 30 is driven by a servo motor.

[0041] In the embodiment of the present invention, the servo motor can control the speed, and the position accuracy is very accurate. The voltage signal can be converted into torque and speed to drive the control object. The rotor speed of the servo motor is controlled by the input signal and can respond quickly. In the automatic control system, it is used as an actuator and has the characteristics of small electromechanical time constant and high linearity. The received electrical signal can be converted into angular displacement or angular velocity output on the motor shaft. It is divided into two categories: DC and AC servo motors. Its main characteristics are that there is no self-rotation when the signal voltage is zero, and the speed decreases uniformly with the increase of torque.

[0042] The reason why the present invention chooses a servo motor as the driving motor of the robot arm is that the environment inside the furnace is complex, including the furnace nozzle 40, furnace walls, pipes and other equipment. The image acquisition device 20 moves in such a complex environment, and it is necessary to ensure that there is no conflict with these equipment, so as to protect the image acquisition device 20 itself and avoid it from damaging the equipment in the furnace. Based on this, when the position of the equipment in the furnace remains unchanged, as long as the operating posture control of the image acquisition device is accurate, the robot arm can be controlled based on a predetermined route without contacting the equipment in the furnace. In order to achieve such high-precision control, the present invention selects a servo motor with higher control accuracy as the driving motor of the robot arm.

[0043] Furthermore, if the user has a certain point of interest and needs to adjust the image acquisition device 20 to align with the target, the user wants the robot arm to perform actions more quickly and accurately. These actions all need to rely on servo motors to achieve.

[0044] Preferably, each servo motor is controlled by a separate PLC controller.

[0045] In the embodiment of the present invention, the PLC controller is a programmable logic controller, which is a digital operation electronic system specially designed for use in industrial environments. It uses a programmable memory to store instructions for performing operations such as logic operations, sequential control, timing, counting and arithmetic operations, and controls various types of mechanical equipment or production processes through digital or analog input and output.

[0046] The solution of the present invention must first realize the precise operation of the robot arm. In addition to relying on the operating performance of the servo motor itself, there are also corresponding requirements for the precise output and execution of the control signal. The PLC controller can complete the task well to achieve precise control of the entire system. And because each image acquisition device has a different setting position, different monitoring tasks and different monitoring accuracy, each image acquisition device requires differentiated control. In order to ensure the accuracy of the posture adjustment of each image acquisition device, it is necessary to set a separate PLC controller for each image acquisition device robot arm.

[0047] Embodiment 2:

[0048] Each PLC controller is preset with a corresponding control quantity threshold; when executing servo motor control, each PLC controller needs to compare the control quantity corresponding to the input instruction with the preset control quantity threshold. If the control quantity of the input instruction is greater than the preset control quantity threshold, the input instruction is corrected based on the corresponding control quantity threshold, and servo motor control is executed based on the corrected input instruction.

[0049] In the scheme of the present invention, it has been explained above that the environment inside the furnace is extremely complex, and when the robot arm drives the image acquisition device to move, it is easy to cause conflicts with the equipment inside the furnace. The servo motor is controlled by the PLC controller, which can ensure that it moves along the preset route without conflicts, because it has a preset non-conflicting route and can perfectly execute the route later. However, if the user has a need for autonomous control, that is, when the user wants specific monitoring information in a certain direction, it is necessary to manually control the robot arm to move, and at this time the user cannot accurately perceive the environment inside the furnace, which is easy to cause movement conflicts.

[0050] Based on this, the solution of the present invention presets a corresponding control amount threshold for each PLC controller, which ensures that the robotic arm driven by the PLC controller can only move within a predetermined area, and the control signal exceeding the predetermined area will be automatically identified and corrected. Even if the user repeatedly triggers the continue moving signal, the robotic arm will be locked to the extreme position due to the control amount threshold, thereby avoiding movement conflicts caused by user misoperation.

[0051] When performing control subsequently, the system will automatically determine the control amount corresponding to the control signal input by the user. If the control amount does not exceed the preset threshold, the moving operation will be performed normally. If it exceeds the preset threshold, it means that there is a risk of collision if the movement continues. The control instruction is corrected based on the threshold. For example, the control amount corresponding to the control instruction that exceeds the threshold is directly corrected to the limit amount. No matter how large the control amount itself is, it needs to be limited to the limit amount. If the user continues to input control signals that exceed the threshold, an alarm message will be output to remind relevant personnel to stop the wrong operation.

[0052] Embodiment 3:

[0053] The control amount threshold is determined based on the setting position of each image acquisition device, and the specific determination rules include: at each setting position, adaptively driving the adjustable mechanical arm 30 to move, and recording the position information of the image acquisition device in real time; when the image acquisition position information coincides with the design position information of the furnace tube or the design position information of the flame area of ​​the furnace nozzle 40, the coincidence point is used as a control threshold point in one direction; traversing all movement directions of the adjustable mechanical arm 30, and obtaining control threshold points in all directions; wherein, if there is no coincidence with the design position information of the furnace tube or the design position information of the flame area of ​​the furnace nozzle 40 in a certain direction, the maximum movement point of the adjustable mechanical arm 30 in this direction is used as the control threshold point in this direction; integrating the control threshold points in all directions to form the control amount threshold of the PLC controller corresponding to the image acquisition device.

[0054] In the embodiment of the present invention, different image acquisition devices are set in different positions, and the collision risks that may exist in their movement process are also different. Based on this, it is necessary to determine the control amount threshold for applicable scenarios for different image acquisition devices. Therefore, the scheme of the present invention performs adaptive training of the operating state of each image acquisition device based on its actual operating conditions, traverses all movable directions, identifies all conflict situations, and generates a control amount threshold applicable to the current image acquisition device based on the conflict situation.

[0055] In the embodiment of the present invention, the adaptive training process may be adaptive control training performed in an actual heating furnace, or may be simulated adaptive training performed in a simulation model constructed based on a heating furnace, which is not limited here.

[0056] Embodiment 4:

[0057] The number of image acquisition devices set in the furnace 10 is determined by: based on the design information of the furnace 10, the number information of the furnace nozzles 40, the preset fire viewing height information, the distance information between the furnace nozzles 40 and the opposite wall, and the spacing information of the furnace nozzles 40 are read, and the number of image acquisition devices set is calculated based on this information. The calculation rule is:

[0058]

[0059] Wherein, M is the number of image acquisition devices; N is the number of furnace nozzles 40; H is the preset fire viewing height; L burner L is the distance between the furnace nozzle 40 and the opposite wall; linterval is the distance between the furnace nozzles 40.

[0060] Preferably, the setting position determination rule of each image acquisition device is: based on the design information of the furnace 10, the inner diameter information of the heating furnace, the arrangement radius information of the furnace nozzle 40, the design height information of the furnace fire, the field angle information and the depression angle information of the image acquisition device are read, and the setting range information of each image acquisition device is determined based on this information, and the determination rule is:

[0061] L lmonitor ≥tan(θ / 2-θ1)(R-R1) and L lmonitor ≥ 0.6 L vis

[0062] Among them, L lmonitor is the height of the image acquisition device; θ is the field of view of the image acquisition device; θ1 is the depression angle of the image acquisition device; R is the inner diameter of the heating furnace; R1 is the radius of the furnace nozzle 40; L vis Design the height for the fire.

[0063] Preferably, the human-machine interaction module 50 includes: a control module for generating a control signal for the adjustable mechanical arm 30; and a display module for displaying monitoring screen information of the corresponding image acquisition device in real time.

[0064] In the embodiment of the present invention, in order to facilitate the user to manually operate the robot arm, the control module is preferably a control joystick, and the user controls the movement direction and movement speed of the robot arm based on the joystick to improve the control efficiency and accuracy. In order to avoid damage to the structure of the heating furnace itself, the scheme of the present invention directly uses the fire viewing hole of the heating furnace to construct the collection device. However, this method will cause the original fire viewing hole to be unable to realize its function, so a corresponding display module is added to facilitate the intuitive display of the furnace status.

[0065] Figure 2 This is a method flow chart of a method for designing a flame state monitoring system for a refinery heating furnace provided by an embodiment of the present invention. Figure 2 As shown, an embodiment of the present invention provides a method for designing a flame state monitoring system for a refinery heating furnace, the method comprising:

[0066] Step S10: Collecting the design information of the heating furnace, and determining the number and installation positions of the image acquisition devices based on the design information and the parameter information of the selected image acquisition devices.

[0067] Specifically, the number of image acquisition devices set in the furnace 10 is determined as follows: based on the design information of the furnace 10, the number information of the furnace nozzles 40, the preset fire viewing height information, the distance information between the furnace nozzles 40 and the opposite wall, and the spacing information of the furnace nozzles 40 are read, and the number of image acquisition devices set is calculated based on this information. The calculation rule is:

[0068]

[0069] Wherein, M is the number of image acquisition devices; N is the number of furnace nozzles 40; H is the preset fire viewing height; L burner L is the distance between the furnace nozzle 40 and the opposite wall; linterval is the distance between the furnace nozzles 40.

[0070] Preferably, the setting position determination rule of each image acquisition device is: based on the design information of the furnace 10, the inner diameter information of the heating furnace, the arrangement radius information of the furnace nozzle 40, the design height information of the furnace fire, the field angle information and the depression angle information of the image acquisition device are read, and the setting range information of each image acquisition device is determined based on this information, and the determination rule is:

[0071] L lmonitor ≥tan(θ / 2-θ1)(R-R1) and L lmonitor ≥ 0.6 L vis

[0072] Among them, L lmonitor is the height of the image acquisition device; θ is the field of view of the image acquisition device; θ1 is the depression angle of the image acquisition device; R is the inner diameter of the heating furnace; R1 is the radius of the furnace nozzle 40; L vis Design the height for the fire.

[0073] Step S20 : ​​setting a corresponding adjustable mechanical arm 30 for each image acquisition device, and determining a control amount threshold of a PLC controller that controls the adjustable mechanical arm 30 .

[0074] Specifically, the adjustable mechanical arm 30 is driven by a servo motor.

[0075] In the embodiment of the present invention, the servo motor can control the speed, and the position accuracy is very accurate. The voltage signal can be converted into torque and speed to drive the control object. The rotor speed of the servo motor is controlled by the input signal and can respond quickly. In the automatic control system, it is used as an actuator and has the characteristics of small electromechanical time constant and high linearity. The received electrical signal can be converted into angular displacement or angular velocity output on the motor shaft. It is divided into two categories: DC and AC servo motors. Its main characteristics are that there is no self-rotation when the signal voltage is zero, and the speed decreases uniformly with the increase of torque.

[0076] The reason why the present invention chooses a servo motor as the driving motor of the robot arm is that the environment inside the furnace is complex, including the furnace nozzle 40, furnace walls, pipes and other equipment. The image acquisition device moves in such a complex environment, and it is necessary to ensure that there is no conflict with these equipment, so as to protect the image acquisition device itself and avoid it from damaging the equipment in the furnace. Based on this, when the position of the equipment in the furnace remains unchanged, as long as the operating posture control of the image acquisition device is accurate, the robot arm can be controlled based on a predetermined route without contacting the equipment in the furnace. In order to achieve such high-precision control, the present invention selects a servo motor with higher control accuracy as the driving motor of the robot arm.

[0077] Furthermore, if the user has a certain point of interest and needs to adjust the image acquisition device to align with the target, the user wants the robot arm to perform actions more quickly and accurately. These actions all need to rely on servo motors to achieve.

[0078] Embodiment 5:

[0079] Each servo motor is controlled by a separate PLC controller.

[0080] In the embodiment of the present invention, the PLC controller is a programmable logic controller, which is a digital operation electronic system specially designed for use in industrial environments. It uses a programmable memory to store instructions for performing operations such as logic operations, sequential control, timing, counting and arithmetic operations, and controls various types of mechanical equipment or production processes through digital or analog input and output.

[0081] The solution of the present invention must first realize the precise operation of the robot arm. In addition to relying on the operating performance of the servo motor itself, there are also corresponding requirements for the precise output and execution of the control signal. The PLC controller can complete the task very well and realize the precise control of the entire system. And because each image acquisition device has a different setting position, different monitoring tasks and different monitoring accuracy, each image acquisition device requires differentiated control. In order to ensure the accuracy of the posture adjustment of each image acquisition device, it is necessary to set a separate PLC controller for each image acquisition device robot arm.

[0082] Preferably, each PLC controller is preset with a corresponding control quantity threshold; when executing servo motor control, each PLC controller needs to compare the control quantity corresponding to the input instruction with the preset control quantity threshold. If the control quantity of the input instruction is greater than the preset control quantity threshold, the input instruction is corrected based on the corresponding control quantity threshold, and servo motor control is executed based on the corrected input instruction.

[0083] In the scheme of the present invention, it has been explained above that the environment inside the furnace is extremely complex, and when the robot arm drives the image acquisition device to move, it is easy to cause conflicts with the equipment inside the furnace. The servo motor is controlled by the PLC controller, which can ensure that it moves along the preset route without conflicts, because it has a preset non-conflicting route and can perfectly execute the route later. However, if the user has a need for autonomous control, that is, when the user wants specific monitoring information in a certain direction, it is necessary to manually control the robot arm to move, and at this time the user cannot accurately perceive the environment inside the furnace, which is easy to cause movement conflicts.

[0084] Based on this, the solution of the present invention presets a corresponding control amount threshold for each PLC controller, which ensures that the robotic arm driven by the PLC controller can only move within a predetermined area, and the control signal exceeding the predetermined area will be automatically identified and corrected. Even if the user repeatedly triggers the continue moving signal, the robotic arm will be locked to the extreme position due to the control amount threshold, thereby avoiding movement conflicts caused by user misoperation.

[0085] When performing control subsequently, the system will automatically determine the control amount corresponding to the control signal input by the user. If the control amount does not exceed the preset threshold, the moving operation will be performed normally. If it exceeds the preset threshold, it means that there is a risk of collision if the movement continues. The control instruction is corrected based on the threshold. For example, the control amount corresponding to the control instruction that exceeds the threshold is directly corrected to the limit amount. No matter how large the control amount itself is, it needs to be limited to the limit amount. If the user continues to input control signals that exceed the threshold, an alarm message will be output to remind relevant personnel to stop the wrong operation.

[0086] Preferably, the control amount threshold is determined based on the setting position of each image acquisition device, and the specific determination rules include: at each setting position, adaptively driving the adjustable mechanical arm 30 to move, and recording the position information of the image acquisition device in real time; when the image acquisition position information coincides with the design position information of the furnace tube or the design position information of the flame area of ​​the furnace nozzle 40, the coincidence point is used as a control threshold point in one direction; traverse all movement directions of the adjustable mechanical arm 30 to obtain control threshold points in all directions; wherein, if there is no coincidence with the design position information of the furnace tube or the design position information of the flame area of ​​the furnace nozzle 40 in a certain direction, the maximum movement point of the adjustable mechanical arm 30 in this direction is used as the control threshold point in this direction; the control threshold points in all directions are integrated to form the control amount threshold of the PLC controller corresponding to the image acquisition device.

[0087] In the embodiment of the present invention, different image acquisition devices are set in different positions, and the collision risks that may exist in their movement process are also different. Based on this, it is necessary to determine the control amount threshold for applicable scenarios for different image acquisition devices. Therefore, the scheme of the present invention performs adaptive training of the operating state of each image acquisition device based on its actual operating conditions, traverses all movable directions, identifies all conflict situations, and generates a control amount threshold applicable to the current image acquisition device based on the conflict situation.

[0088] In the embodiment of the present invention, the adaptive training process may be adaptive control training performed in an actual heating furnace, or may be simulated adaptive training performed in a simulation model constructed based on a heating furnace, which is not limited here.

[0089] Step S30: designing a corresponding control loop for the adjustable robotic arm 30 , and designing a corresponding human-machine interaction module 50 to control the control loop.

[0090] Specifically, the human-machine interaction module 50 includes: a control module for generating a control signal for the adjustable mechanical arm 30; and a display module for displaying monitoring screen information of the corresponding image acquisition device in real time.

[0091] In the embodiment of the present invention, in order to facilitate the user to manually operate the robot arm, the control module is preferably a control joystick, and the user controls the movement direction and movement speed of the robot arm based on the joystick to improve the control efficiency and accuracy. In order to avoid damage to the structure of the heating furnace itself, the scheme of the present invention directly uses the fire viewing hole of the heating furnace to construct the collection device. However, this method will cause the original fire viewing hole to be unable to realize its function, so a corresponding display module is added to facilitate the intuitive display of the furnace status.

[0092] The embodiment of the present invention further provides a computer-readable storage medium, on which instructions are stored, which, when executed on a computer, enable the computer to execute the above-mentioned method for designing a flame state monitoring system for a refining heating furnace.

[0093] Those skilled in the art will understand that all or part of the steps in the method for implementing the above-mentioned embodiments can be completed by instructing the relevant hardware through a program, and the program is stored in a storage medium, including several instructions for making a single-chip microcomputer, a chip or a processor (processor) perform all or part of the steps of the method described in each embodiment of the present invention. The aforementioned storage medium includes: U disk, mobile hard disk, read-only memory (ROM, Read-Only Memory), random access memory (RAM, Random Access Memory), disk or optical disk and other media that can store program codes.

[0094] The optional embodiments of the present invention are described in detail above in conjunction with the accompanying drawings. However, the embodiments of the present invention are not limited to the specific details in the above embodiments. Within the technical concept of the embodiments of the present invention, the technical scheme of the embodiments of the present invention can be subjected to a variety of simple modifications, and these simple modifications all belong to the protection scope of the embodiments of the present invention. It should also be noted that the various specific technical features described in the above specific embodiments can be combined in any suitable manner without contradiction. In order to avoid unnecessary repetition, the embodiments of the present invention will not further describe various possible combinations.

[0095] In addition, various embodiments of the present invention may be arbitrarily combined, and as long as they do not violate the concept of the embodiments of the present invention, they should also be regarded as the contents disclosed in the embodiments of the present invention.

Claims

1. A flame state monitoring system for a refining heating furnace, characterized in that: The system comprises: A plurality of image acquisition devices extending into the furnace of the refining heating furnace, each image acquisition device being fixed to the inner wall of the furnace through an adjustable mechanical arm, and being used for acquiring images of the combustion flames at the nozzle in the furnace; Among them, at least one of the multiple image acquisition devices is arranged at the position of the fire viewing hole in the furnace; The human-computer interaction module is arranged at the fire viewing hole of the furnace.

2. The system according to claim 1, characterized in that The adjustable mechanical arm is driven by a servo motor.

3. The system according to claim 2, characterized in that Each servo motor is controlled by a separate PLC controller.

4. The system according to claim 3, characterized in that Each PLC controller is preset with a corresponding control value threshold; each PLC controller performs servo motor control in the following manner: The PLC controller compares the control amount corresponding to the input instruction with its preset control amount threshold. If the control amount of the input instruction is greater than the preset control amount threshold, the input instruction is corrected based on the corresponding control amount threshold, and the servo motor control is performed based on the corrected input instruction.

5. The system according to claim 4, characterized in that The control amount threshold of the PLC controller is determined based on the setting position of each image acquisition device. The specific determination rules include: At the respective setting positions of the image acquisition devices, the adjustable mechanical arm is adaptively driven to move, and the position information of the image acquisition devices is recorded in real time; When the image acquisition position information coincides with the furnace tube design position information or the furnace nozzle flame area design position information, the coincidence point is used as a control threshold point in one direction; Traverse all movement directions of the adjustable robotic arm to obtain the control threshold points in all directions; among them, If there is no overlap between the image acquisition position information and the furnace tube design position information or the furnace nozzle flame area design position information in a certain direction, the maximum movement point of the adjustable mechanical arm in this direction is used as the control threshold point in this direction; The control threshold points in all directions are integrated to form the control value threshold of the PLC controller of the corresponding image acquisition device.

6. The system according to claim 1, characterized in that The rule for determining the number of image acquisition devices to be set in the furnace is: Based on the furnace design information, the number of furnace nozzles, the preset fire viewing height, the distance between the furnace nozzle and the opposite wall, and the spacing between the furnace nozzles are read, and the number of image acquisition devices set is calculated based on the read information. The calculation rule is: Wherein, M is the number of image acquisition devices set; N is the number of furnace nozzles; H is the preset fire observation height; L burner is the distance between the furnace nozzle and the opposite wall; L linterval The distance between the furnace nozzles.

7. The system according to claim 1, characterized in that The rules for determining the location of each image acquisition device in the furnace are as follows: Based on the furnace design information, the heating furnace inner diameter information, the furnace nozzle layout radius information, the furnace fire design height information, the image acquisition device field angle information and the depression angle information are read, and the setting range information of each image acquisition device is determined based on the read information. The determination rule is: L lmonitor ≥tan(θ / 2-θ1)(R-R1) and L lmonitor ≥0.6L vis Among them, L lmonitor is the setting height of the image acquisition device; θ is the field of view of the image acquisition device; θ1 is the depression angle of the image acquisition device; R is the inner diameter of the heating furnace; R1 is the radius of furnace nozzle layout; L vis Design the height for the fire.

8. The system according to claim 1, characterized in that The human-computer interaction module comprises: A control module, for generating a control signal for the adjustable robotic arm; The display module is used to display the monitoring screen information of the corresponding image acquisition device in real time.

9. A design method for a flame state monitoring system for a refinery heating furnace, characterized in that: The method comprises: Collecting design information of the heating furnace, and determining the number and location of the image acquisition devices in the furnace based on the design information and parameter information of the selected image acquisition devices; Setting a corresponding adjustable mechanical arm for each image acquisition device, and determining a control amount threshold of a PLC controller that controls the adjustable mechanical arm; A corresponding control loop is designed for the adjustable robotic arm, and a corresponding human-computer interaction module is designed to control the control loop.

10. The method according to claim 9, characterized in that The number of image acquisition devices to be set in the furnace is determined as follows: Based on the furnace design information, the number of furnace nozzles, the preset fire viewing height, the distance between the furnace nozzle and the opposite wall, and the spacing between the furnace nozzles are read, and the number of image acquisition devices set is calculated based on the read information. The calculation rule is: Wherein, M is the number of image acquisition devices set; N is the number of furnace nozzles; H is the preset fire observation height; L burner is the distance between the furnace nozzle and the opposite wall; L linterval The distance between the furnace nozzles.

11. The method according to claim 9, characterized in that The determination rule of the setting position of the image acquisition device in the furnace is: Based on the furnace design information, the heating furnace inner diameter information, the furnace nozzle layout radius information, the furnace fire design height information, the image acquisition device field angle information and the depression angle information are read, and the setting range information of each image acquisition device is determined based on the read information. The determination rule is: L lmonitor ≥tan(θ / 2-θ1)(R-R1) and L lmonitor ≥0.6L vis Among them, L lmonitor is the setting height of the image acquisition device; θ is the field of view of the image acquisition device; θ1 is the depression angle of the image acquisition device; R is the inner diameter of the heating furnace; R1 is the radius of furnace nozzle layout; L vis Design the height for the fire.

12. The method according to claim 9, characterized in that Determining a control amount threshold of a PLC controller controlling an adjustable robotic arm includes: At the respective setting positions of the image acquisition devices, the adjustable mechanical arm is adaptively driven to move, and the position information of the image acquisition devices is recorded in real time; When the image acquisition position information coincides with the furnace tube design position information or the furnace nozzle flame area design position information, the coincidence point is used as a control threshold point in one direction; Traverse all movement directions of the adjustable robotic arm to obtain the control threshold points in all directions; among them, If there is no overlap between the image acquisition position information and the furnace tube design position information or the furnace nozzle flame area design position information in a certain direction, the maximum movement point of the adjustable mechanical arm in this direction is used as the control threshold point in this direction; The control threshold points in all directions are integrated to form the control value threshold of the PLC controller of the corresponding image acquisition device.

13. The method according to claim 9, characterized in that The human-computer interaction module comprises: A control module, for generating a control signal for the adjustable robotic arm; The display module is used to display the monitoring screen information of the corresponding image acquisition device in real time.

14. A computer-readable storage medium having instructions stored thereon, which, when executed on a computer, enables the computer to execute the method for designing a flame state monitoring system for a refinery heating furnace as described in any one of claims 9 to 13.

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