Kiln equipment and intelligent inspection and diagnosis system thereof

Abstract

The invention discloses kiln equipment and an intelligent inspection and diagnosis system thereof, and relates to the technical field of kilns. Wherein the track assembly is annular in the vertical direction, and the track assembly is configured to be capable of being arranged above the kiln equipment and symmetrically arranged relative to the kiln equipment; the inspection assembly comprises an inspection robot, a first lifter, a second lifter, a first infrared thermal imaging camera, a second infrared thermal imaging camera and a first visible light camera, the inspection robot is configured to walk on the track assembly along an annular track, and the first lifter is arranged on the upper portion of the inspection robot; the first lifter is arranged on the lower portion of the inspection robot and used for driving the first infrared thermal imaging camera to ascend and descend, and the second lifter is arranged on the lower portion of the inspection robot and used for driving the second infrared thermal imaging camera and the first visible light camera to ascend and descend. According to the invention, automatic inspection of the side part and the top part of the kiln equipment can be realized, and the inspection efficiency and accuracy are high.

Description

Technical Field

[0001] The present invention relates to the technical field of kilns, and in particular to kiln equipment and an intelligent inspection and diagnosis system thereof. Background Art

[0002] Kilns are high-temperature equipment. During the firing process of ceramics, there may be hidden dangers such as fire leakage (such as damage to the refractory material of the kiln body, forming gaps or holes), broken conveyor rollers, and falling or breaking of ceiling tiles. These conditions will not only cause energy waste, but also burn the kiln body, resulting in the need to stop the kiln for repairs, thus bringing huge economic losses. Due to the increasing demand for production, kilns are getting longer and longer, most of which are over 300m. It is difficult to observe them manually. Therefore, it is urgent to discover and locate the above safety hazards early and reduce manual inspections.

[0003] The kiln equipment of the ceramic factory is compact and complex in layout, with large length, width and height, wide inspection area and many inspection points. The existing kilns are mainly inspected manually, but the height of the staff is much lower than the kiln roof, and they cannot directly observe the situation at the top or top of the equipment. There are many blind spots. In addition, the temperature around the kiln is high and the air quality is poor. Therefore, the manual inspection method has problems such as high labor intensity of workers (such as constantly walking back and forth along the kiln, climbing up and down the kiln roof to observe, etc.), low efficiency, and untimely detection of problems. At present, there is an urgent need for an automated inspection equipment that can replace manual inspection, so as to conduct all-round and efficient inspection of kiln equipment, reduce labor intensity, detect problems in time, improve inspection accuracy, and enhance the intelligence level of kilns. Summary of the invention

[0004] The present invention aims to solve at least one of the technical problems existing in the prior art. To this end, the present invention provides a kiln equipment and an intelligent inspection and diagnosis system thereof, which can realize automatic inspection of the side and top of the kiln equipment, and has high inspection efficiency and accuracy.

[0005] The first embodiment of the present invention provides an intelligent inspection and diagnosis system for kiln equipment, which includes: A track assembly, which is annular in shape when viewed from top to bottom, and is configured to be disposed above the kiln device and symmetrically disposed with respect to the kiln device; The inspection component includes an inspection robot, a first lifter, a second lifter, a first infrared thermal imaging camera, a second infrared thermal imaging camera and a first visible light camera. The inspection robot is configured to walk along a circular track on the track component. The first lifter is arranged at the upper part of the inspection robot and is used to drive the first infrared thermal imaging camera to rise and fall. The second lifter is arranged at the lower part of the inspection robot and is used to drive the second infrared thermal imaging camera and the first visible light camera to rise and fall.

[0006] According to the intelligent inspection and diagnosis system of kiln equipment of the first aspect of the embodiment of the present invention, there are at least the following beneficial effects: in the process of the inspection robot walking in a circle along the track assembly, the height position of the first infrared thermal imaging camera is adjusted by the first lifter to expand the observation field of the kiln roof, so that the first infrared thermal imaging camera can monitor the temperature of the kiln roof part of the kiln equipment in real time; at the same time, the height positions of the second infrared thermal imaging camera and the first visible light camera are adjusted by the second lifter to expand the observation field of the side wall, so that the second infrared thermal imaging camera can monitor the temperature of the side wall part of the kiln equipment in real time, and the first visible light camera can monitor the operation of the conveyor roller of the kiln equipment in real time; when the kiln equipment has at least one of the following situations, such as fire leakage, falling or breaking of ceiling tiles, and breaking of conveyor rollers, the inspection component can accurately detect and locate the fault position, which is conducive to reminding the staff to deal with safety issues in time and improve the inspection and diagnosis efficiency.

[0007] Moreover, the first lifter and the second lifter are provided so that the inspection component can increase the observation field of view of the kiln top part, and at the same time, also increase the observation field of view of the side wall part, thereby expanding the monitoring range, avoiding hidden dangers and inspection loopholes, and helping to improve the inspection accuracy.

[0008] In some embodiments of the present invention, the track assembly comprises: Two first rails are provided, each of which is configured to extend along the length direction of the kiln device, and the two first rails are configured to be symmetrically arranged on both sides of the kiln device along the width direction; Two transition tracks are provided, wherein the transition track is arranged between the two first tracks, and the same end of the two first tracks is connected through the transition track so that the track assembly has a ring structure.

[0009] In some embodiments of the present invention, the inspection component further includes an anti-collision radar, and the anti-collision radar is arranged on the inspection robot; and / or, The inspection component also includes a smoke detector, which is arranged on the inspection robot.

[0010] In some embodiments of the present invention, the inspection component further includes a combustible gas detection sensor, and the combustible gas detection sensor is disposed on the inspection robot.

[0011] In some embodiments of the present invention, the inspection component further includes an identification member, which is configured to be disposed on an end surface of a conveying roller of the kiln equipment, and the first visible light camera is configured to detect whether the identification member is in a rotating state.

[0012] In some embodiments of the present invention, the intelligent inspection and diagnosis system for kiln equipment further includes a wireless transmission unit, which is disposed on the inspection robot and is electrically connected to the inspection component.

[0013] In some embodiments of the present invention, the intelligent inspection and diagnosis system of kiln equipment also includes a central control system, which is wirelessly connected to the wireless transmission unit. The central control system includes a display screen, and the display screen is configured to display information collected by the inspection component.

[0014] In some embodiments of the present invention, both the first lifter and the second lifter are electric push rods.

[0015] In some embodiments of the present invention, the first infrared thermal imaging camera, the second infrared thermal imaging camera, and the first visible light camera all have rotatable lenses.

[0016] A second aspect of the present invention provides a kiln equipment, which includes the intelligent inspection and diagnosis system for the kiln equipment as described in the first aspect of the present invention.

[0017] The kiln equipment according to the embodiment of the second aspect of the present invention has at least the following beneficial effects: through the operation of the intelligent inspection and diagnosis system of the kiln equipment, timely and accurate automatic inspections can be carried out on the kiln roof, side walls and conveyor roller parts of the kiln equipment. When abnormal conditions such as fire leakage, conveyor roller breakage, and falling or breaking of ceiling tiles in the kiln equipment are found, the kiln equipment can be located immediately and the staff can be notified in time to carry out maintenance to avoid causing greater harm.

[0018] Other features and advantages of the present invention will be described in the following description, and partly become apparent from the description, or understood by practicing the present invention. The purpose and other advantages of the present invention can be realized and obtained by the structures particularly pointed out in the description, claims and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 is a top view of a kiln equipment provided by an embodiment of the present invention when an intelligent inspection and diagnosis system is installed; Figure 2 is a schematic structural diagram of an inspection component provided according to an embodiment of the present invention when installed on a track component; Figure 3 is a schematic structural diagram of an identification element provided in an embodiment of the present invention when installed on a conveying roller; Figure 4 It is a schematic diagram of the structure of the electrical connection between the inspection component and the central control system provided according to an embodiment of the present invention.

[0020] Figure numerals: 100, kiln equipment; 110, conveying roller; 120, identification piece; 210, first track; 220, transition track; 300, inspection component; 310, inspection robot; 320, first lifter; 330, first infrared thermal imaging camera; 340, second lifter; 350, second infrared thermal imaging camera; 360, first visible light camera. DETAILED DESCRIPTION

[0021] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and cannot be understood as limiting the present invention.

[0022] In the description of the present invention, it is to be understood that a feature defined as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, unless otherwise specified, "plurality" means two or more.

[0023] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "connected" and "connection" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be an indirect connection through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0024] Reference below Figures 1 to 4 The invention describes a kiln equipment and an intelligent inspection and diagnosis system thereof provided according to an embodiment of the invention.

[0025] like Figures 1 to 4 As shown, the intelligent inspection and diagnosis system for kiln equipment according to the first aspect of the embodiment of the present invention can be applied to kiln equipment 100 used for ceramic product manufacturing, and can realize automatic inspection of the side and top of the kiln equipment 100 to check whether the kiln equipment 100 has at least one of the accidents such as breakage of the conveyor roller 110, fire leakage, and falling or breaking of ceiling tiles. Moreover, the intelligent inspection and diagnosis system for kiln equipment has high inspection efficiency and accuracy, and can promptly detect and locate the location of the accident, so that maintenance personnel can quickly resolve the accident problems of the kiln equipment 100, avoid untimely handling of the accident resulting in more energy waste and increased scrap rate of ceramic products, thereby reducing economic losses in the production of ceramic products.

[0026] In this embodiment, the kiln device 100 has a length direction and a width direction, wherein the length direction of the kiln device 100 is the front-to-back direction, and the width direction of the kiln device 100 is the left-to-right direction.

[0027] like Figure 1 and Figure 2 As shown, the intelligent inspection and diagnosis system of the kiln equipment includes a track component and an inspection component 300 .

[0028] The track assembly is annular when viewed from top to bottom. The track assembly is configured to be disposed above the kiln equipment 100 . Moreover, the track assembly is symmetrically disposed with respect to the kiln equipment 100 .

[0029] It is understandable that the track assembly can be installed on the kiln equipment 100 through a bracket, or can be fixedly connected to the ground or ceiling through a bracket. The track assembly not only provides support for the inspection assembly 300, but also provides a guide track for the automatic navigation walking of the inspection assembly 300, so that the inspection assembly 300 can walk in a circle along the circular guide track, so that the inspection assembly 300 can timely inspect the kiln wall, kiln roof and conveyor roller 110 of the kiln equipment 100 and other parts for potential safety hazards during the walking process, so as to avoid causing greater harm.

[0030] In the case of adopting the track assembly of the above structure, the inspection assembly 300 can start to move along the track assembly from one side of the kiln equipment 100 in the width direction, and move to the intersection between the first track 210 and the transition track 220. During this process, the inspection assembly 300 can inspect the kiln roof and a part of a side wall of the kiln equipment 100; then, through the transition track 220, the inspection assembly 300 reaches the other side of the kiln equipment 100, and inspects the kiln roof and another side wall of the kiln equipment 100; then, the inspection assembly 300 passes through another transition track 220 and returns to its original position, thereby completing a cycle of automatic inspection work.

[0031] Specifically, the structure of the track assembly includes a first track 210 and a transition track 220 .

[0032] Two first rails 210 are provided, each of which is configured to extend along the length direction of the kiln equipment 100, and the first rail 210 is arranged on one side of the kiln equipment 100 along the width direction. Specifically, the two first rails 210 are configured to be symmetrically arranged on both sides of the kiln equipment 100 along the width direction.

[0033] It is understandable that the first track 210 can be an I-type track, and the inspection component 300 can achieve rolling contact with the first track 210 through rollers and can move along the first track 210. The length of the first track 210 is equal to or greater than the length of the kiln equipment 100, and a first track 210 is provided on the outer side of the two side wall parts of the kiln equipment 100. When the inspection component 300 moves along the first track 210, the inspection component 300 can monitor the kiln roof and side wall parts of the kiln equipment 100 in real time. While the inspection component 300 moves, it detects whether there is fire leakage in the side wall part of the kiln equipment 100 or the conveying roller 110 is broken.

[0034] It can be understood that, in some examples, the two first rails 210 can be arranged on the same horizontal plane.

[0035] Two transition rails 220 are provided, and the function of the transition rails 220 is to connect the two first rails 210. Specifically, the transition rail 220 is provided between the two first rails 210, and the same end of the two first rails 210 is connected through the transition rail 220, so that the rail assembly has a ring structure. One of the transition rails 220 is provided at the head of the kiln equipment 100, and the other transition rail 220 is provided at the tail of the kiln equipment 100.

[0036] In this embodiment, if Figure 1 As shown, the transition track 220 is semicircular when viewed from top to bottom. Of course, it is not excluded that in other embodiments, the transition track 220 is arc-shaped when viewed from top to bottom. The two first tracks 210 are located above the two sides of the kiln equipment 100 and are symmetrically arranged along the kiln length direction with the center line of the kiln equipment as the boundary. The two first tracks 210 are connected with the two transition tracks 220 to form a closed-loop track assembly, so as to facilitate the inspection assembly 300 to run around the kiln equipment 100 for inspection and timely discover problems with the kiln equipment 100.

[0037] The inspection component 300 includes an inspection robot 310 , a first lifter 320 , a second lifter 340 , a first infrared thermal imaging camera 330 , a second infrared thermal imaging camera 350 , and a first visible light camera 360 .

[0038] The inspection robot 310 is movably arranged on the track assembly, and the inspection robot 310 is configured to be able to walk along a circular track on the track assembly. It can be understood that the inspection robot 310 is a prior art, and the inspection robot 310 can be suitable for being installed on the track assembly, and the inspection robot 310 can automatically move along the track assembly under the driving action of the motor to realize the automatic inspection function of the kiln equipment 100.

[0039] The first lifter 320 is arranged at the upper part of the inspection robot 310, and the output end of the first lifter 320 is fixedly connected to the first infrared thermal imaging camera 330. The function of the first lifter 320 is to drive the first infrared thermal imaging camera 330 to rise and fall, so as to adjust the height position of the first infrared thermal imaging camera according to the actual situation. The second lifter 340 is arranged at the lower part of the inspection robot 310, and the output end of the second lifter 340 is fixedly connected to the second infrared thermal imaging camera 350 and the first visible light camera 360. The function of the second lifter 340 is to drive the second infrared thermal imaging camera 350 and the first visible light camera 360 to rise and fall, so as to adjust the height position of the second infrared thermal imaging camera 350 and the first visible light camera 360 according to the actual situation.

[0040] In this embodiment, the first lifter 320 and the second lifter 340 are both electric push rods, and the first infrared thermal imaging camera 330 can be installed on the movable rod of the first lifter 320 through a support. Through the operation of the first lifter 320, the up and down position of the first infrared thermal imaging camera 330 can be controlled with high precision, thereby expanding the observation field of the first infrared thermal imaging camera 330 on the kiln roof, so that the first infrared thermal imaging camera 330 can collect infrared thermal imaging data of the kiln roof part of the kiln equipment 100 in all directions, thereby realizing effective monitoring of the kiln roof part, and being able to promptly discover whether the kiln roof has fire leakage, ceiling bricks have fallen or broken.

[0041] The second infrared thermal imaging camera 350 and the first visible light camera 360 can be installed on the movable rod of the second lifter 340 through the support. Through the operation of the second lifter 340, the upper and lower positions of the second infrared thermal imaging camera 350 and the first visible light camera 360 can be controlled with high precision, thereby expanding the observation field of the second infrared thermal imaging camera 350 and the first visible light camera 360 on the side wall, so that the second infrared thermal imaging camera 350 can collect infrared thermal imaging data of the side wall part of the kiln equipment 100 in all directions, so as to realize effective monitoring of the side wall part, and timely discover whether there is fire leakage in the side wall, and enable the first visible light camera 360 to collect visible light data of the side wall part of the kiln equipment 100, so as to realize monitoring of the conveying roller 110 part, and timely discover whether the conveying roller 110 is broken and abnormal operation.

[0042] The first infrared thermal imaging camera 330, the second infrared thermal imaging camera 350 and the first visible light camera 360 all have rotatable lenses. In this embodiment, the first infrared thermal imaging camera 330, the second infrared thermal imaging camera 350 and the first visible light camera 360 are spherical cameras, which can adjust the rotation angle according to monitoring requirements and environmental characteristics to obtain image data more clearly and more widely. The first visible light camera 360 can be a high-definition camera.

[0043] It is understandable that the number of inspection components 300 provided on the track component is not limited to one. In the case where two inspection components 300 are provided, one inspection component 300 is provided on one of the first tracks 210, and the other inspection component 300 is provided on the other first track 210, then the kiln top part and the two side wall parts of the kiln equipment 100 can be monitored in real time at the same time. Of course, three or four inspection components 300 can also be provided.

[0044] The inspection component 300 is provided with a first lifter 320, so that the inspection component 300 can adjust the first infrared thermal imaging camera 330 up and down, thereby increasing the inspection component 300's observation field of view of the kiln top portion of the kiln equipment 100, and can also avoid various pipes on the upper portion of the kiln equipment 100. At the same time, the inspection component 300 is provided with a second lifter 340, so that the inspection component 300 can adjust the second infrared thermal imaging camera 350 and the first visible light camera 360 up and down, thereby increasing the inspection component 300's observation angle of the side wall portion of the kiln equipment 100, and can also avoid the kiln car entering or exiting the kiln, which is conducive to expanding the monitoring range, improving the accuracy of inspection diagnosis, and avoiding detection loopholes.

[0045] In the process of using the intelligent inspection and diagnosis system for kiln equipment, if the kiln equipment 100 has safety hazards such as fire leakage, falling or breaking of ceiling tiles, the kiln equipment 100 will directly manifest itself in a sharp rise in temperature. At this time, the first infrared thermal imaging camera 330 and the second infrared thermal imaging camera 350 are used to fully monitor the kiln roof and side walls of the kiln equipment 100, and the acquired infrared thermal imaging data are used to determine whether the kiln equipment 100 has the above-mentioned safety hazards, thereby being able to accurately detect and locate the hidden dangers of the kiln equipment 100, greatly improving the detection efficiency.

[0046] When the kiln equipment 100 has a hidden danger of the conveyor roller 110 breaking, the conveyor roller 110 usually warps up. At this time, the conveyor roller 110 is continuously photographed by the first visible light camera 360, and some image data of the conveyor roller 110 is obtained, so that the position deviation of the conveyor roller 110 can be monitored through the existing image recognition and analysis technology. This can accurately detect and locate the fault position of the conveyor roller 110 on the kiln equipment 100, and remind the maintenance staff to replace the conveyor roller 110 in time.

[0047] In some embodiments, Figure 4 As shown, the structure of the inspection component 300 also includes a combustible gas detection sensor. The combustible gas detection sensor is arranged on the inspection robot 310, and the combustible gas detection sensor can move with the inspection robot 310. The combustible gas detection sensor is used to detect whether there is a combustible gas such as natural gas or water gas leakage in the kiln equipment 100, so that the maintenance staff can deal with the combustible gas leakage problem in time, avoiding the waste of energy, gas poisoning of personnel, and even explosion.

[0048] In addition, a second visible light camera may be arranged around the kiln equipment 100. The second visible light camera may be mounted on the kiln equipment 100 through a bracket, or may be mounted on a wall of a workshop through a bracket. The second visible light camera may be mounted in an important place that cannot be captured by the first visible light camera 360 but needs to be monitored. The second visible light camera may be arranged to monitor the environment in the workshop in real time.

[0049] In some embodiments, the inspection component 300 also includes an anti-collision radar. The anti-collision radar is provided on the inspection robot 310. The anti-collision radar may be an ultrasonic radar, which has a high real-time response capability and an obstacle detection capability of 2.5 meters. It is understandable that since the inspection robot 310 is equipped with an anti-collision radar, the anti-collision radar can move with the inspection robot 310. Therefore, the distance measurement calculation can be completed according to the ultrasonic reflection phenomenon, thereby obtaining a high-precision distance measurement result, so that the inspection component 300 has a safety anti-collision function during the automatic inspection process, and prevents the first infrared thermal imaging camera 330, the second infrared thermal imaging camera 350 and the first visible light camera 360 from being hit.

[0050] In some embodiments, the inspection component 300 further includes a smoke detector. The smoke detector is provided on the inspection robot 310. It is understood that the smoke detector can move with the inspection robot 310 and perform smoke detection during the automatic inspection process. If the real-time smoke value exceeds the threshold, the smoke detector can transmit it to the host computer, so that the host computer can issue a warning message in time. Such a design enables the inspection component 300 to have a smoke detection function.

[0051] In some embodiments, Figure 3 As shown, the structure of the inspection component 300 also includes an identification member 120. The identification member 120 is configured to be disposed on the end surface of the conveying roller 110 of the kiln equipment 100, and the first visible light camera 360 is configured to detect whether the identification member 120 is in a rotating state.

[0052] It is understandable that the identification member 120 may be a long strip made of metal or plastic and installed on the end surface of the conveying roller 110. The identification member 120 can rotate along with the conveying roller 110. When the conveying roller 110 of the kiln equipment 100 breaks, the conveying roller 110 will stop rotating. At this time, the conveying roller 110 may remain in a horizontal state without tilting up, and the identification member 120 will also stop rotating. Then, the visible light image data of the identification member 120 is continuously collected by the first visible light camera 360, and the image recognition and analysis technology is used to determine whether the collected image data is the same (that is, whether the angular position of the identification member 120 is the same). If it is determined to be the same, it indicates that the identification member 120 has stopped rotating; if it is inconsistent, it indicates that the identification member 120 is still in a rotating state.

[0053] When the inspection component 300 moves along the track component, the first visible light camera 360 takes real-time photos of the multiple conveyor rollers 110 and the identification parts 120 on the kiln equipment 100. When it is found that the image data obtained about the same identification part 120 are inconsistent, it is determined that the conveyor roller 110 corresponding to the identification part 120 is abnormal, and the maintenance staff is promptly reminded to disassemble and replace the conveyor roller 110. Through such a design, the inspection accuracy of the conveyor roller 110 can be improved, and inspection and diagnosis loopholes can be avoided.

[0054] Of course, it is not excluded that in other embodiments, a color line is drawn on the end surface of the conveying roller 110 or a notch is made to complete the setting of the identification element 120 on the conveying roller 110 .

[0055] In some embodiments, the intelligent inspection and diagnosis system of kiln equipment also includes a wireless transmission unit. The wireless transmission unit is provided on the inspection robot 310, and the wireless transmission unit can move with the inspection robot 310. The wireless transmission unit is electrically connected to the inspection component 300 so as to remotely transmit the data collected by the inspection component 300 to the outside via WiFi or Bluetooth. It is understandable that the wireless transmission unit can be an existing wireless data transmission module.

[0056] Of course, it is not excluded that in other embodiments, an alarm and an image processing device are provided on the inspection robot 310, and the first infrared thermal imaging camera 330, the second infrared thermal imaging camera 350 and the first visible light camera 360 are respectively electrically connected to the image processing device, and the image processing device is electrically connected to the alarm, which can be an acoustic alarm or an acoustic and optical alarm. The image processing device is installed with existing image recognition and analysis software, which can recognize and analyze the acquired infrared thermal imaging data and visible light image data, and determine whether the kiln equipment 100 has an abnormal situation, such as fire leakage, broken conveyor roller 110 and dropped or broken ceiling tiles. If the kiln equipment 100 is found to have the above-mentioned abnormal state, the alarm is used to promptly notify the maintenance staff to handle the abnormal state of the kiln equipment 100.

[0057] Further, such as Figure 4 As shown, the intelligent inspection and diagnosis system of kiln equipment also includes a central control system. The central control system realizes wireless communication connection with the wireless transmission unit through WiFi, Bluetooth, etc., and can realize data transmission between the central control system and the wireless transmission unit. In this embodiment, the central control system is a host computer.

[0058] The central control system includes a host and a display screen, wherein the host is installed with existing integrated control software, multifunctional image processing software, etc. The host can perform wireless remote data transmission with the wireless transmission unit. The host can send control instructions to the inspection component 300 through the control software, so that the inspection robot 310 can move or stop moving, the first lifter 320 and the second lifter 340 can work, and the first infrared thermal imaging camera 330, the second infrared thermal imaging camera 350 and the first visible light camera 360 can perform image acquisition. Moreover, the host can process the acquired image data through the multifunctional image processing software, and complete the abnormal state diagnosis of the kiln equipment 100 through the existing image recognition and analysis technology.

[0059] The display screen is configured to display the information collected by the inspection component 300 so that the staff can clearly view it. The software interface of the display screen includes the following parts, such as a title area, a real-time video area, a test result area, an environmental data display area, a PTZ control area, and other information areas.

[0060] Among them, the role of the real-time video area is mainly to display the area of ​​the kiln equipment 100 that the current inspection robot 310 is inspecting, and can simultaneously display the real-time videos obtained by multiple inspection robots 310 through infrared thermal imaging cameras and high-definition cameras. The role of the test result area is to mainly display photos of abnormalities and mark the location of the abnormalities for quick positioning. The role of the environmental data display area is to display the air quality around the kiln equipment 100, so that the staff can clearly know whether there is a natural gas or water gas leak in the kiln equipment 100. The role of the pan-tilt control area is to control the position of the inspection robot 310, as well as the angle of the infrared thermal imaging camera and the high-definition camera. By switching the automatic mode to the manual mode, the staff can manually control the inspection of the inspection robot 310. The role of the other information area is to display the list of the inspection robots 310, the status of the inspection robots 310, and the statistics of the number of inspections.

[0061] In this embodiment, the robot hardware system includes an inspection robot 310, a first infrared thermal imaging camera 330, a second infrared thermal imaging camera 350 and a first visible light camera 360, which can collect visible light image data and infrared thermal imaging image data. The robot software system includes a multifunctional image processing software, which can process the collected image data to obtain inspection results. The robot software system transmits the inspection results to the display screen of the central control system.

[0062] According to the layout of the kiln equipment 100 in the factory area, in order to achieve the purpose of complete coverage and efficient detection, the intelligent inspection and diagnosis system of the kiln equipment of the first embodiment of the present invention lays a first track 210 around the side wall of the kiln equipment 100, and connects the two first tracks 210 through two transition tracks 220 to form a ring-shaped track component; and, a high-resolution infrared thermal imaging detection device (i.e., a first infrared thermal imaging camera 330 and a second infrared thermal imaging camera 350) and a high-definition camera (i.e., a first visible light camera 360) are installed on the inspection robot 310 moving along the track component, so that the inspection component 300 can detect while moving, so as to monitor the side walls and kiln roof of the kiln equipment 100.

[0063] By real-time monitoring of the temperature of the side walls and the kiln roof of the kiln equipment 100, as well as the operation of the conveyor rollers 110, it is determined whether the kiln equipment 100 has any potential safety hazards. When an abnormal state of the kiln equipment 100 is found, the intelligent inspection and diagnosis system of the kiln equipment immediately locates the potential hazard and issues an alarm.

[0064] It is understandable that the inspection component 300 adopts a wireless charging method to ensure that the inspection component 300 can work normally. The inspection cycle of the inspection component 300 is about 30 minutes, and wireless charging is performed after running for 30 minutes, and the cycle is repeated.

[0065] In the intelligent inspection and diagnosis system for kiln equipment provided by the embodiment of the first aspect of the present invention, since the height position of the first infrared thermal imaging camera 330 is adjusted by the first lifter 320 during the circular walking of the inspection robot 310 along the track assembly, the first infrared thermal imaging camera 330 can monitor the temperature of the kiln roof part of the kiln equipment 100 in real time. At the same time, the height positions of the second infrared thermal imaging camera 350 and the first visible light camera 360 are adjusted by the second lifter 340, so that the second infrared thermal imaging camera 350 can monitor the temperature of the side wall part of the kiln equipment 100 in real time, and the first visible light camera 360 can monitor the operation of the conveyor roller 110 of the kiln equipment 100 in real time. Therefore, when the kiln equipment 100 has at least one of the following situations: fire leakage, falling or breaking of ceiling tiles, and breaking of the conveyor roller 110, the inspection component 300 can accurately detect and locate the fault position, which is conducive to reminding the staff to deal with safety issues in time and improve the inspection and diagnosis efficiency.

[0066] In addition, the first lifter 320 and the second lifter 340 are provided so that the inspection component 300 can increase the observation field of the kiln top part, and at the same time, also increase the observation field of the side wall part, thereby expanding the monitoring range, avoiding hidden dangers and inspection loopholes, and helping to improve the inspection accuracy.

[0067] It is understandable that the inspection robot 310 is equipped with a high-definition camera, which can shoot high-definition video in real time and record the condition of the kiln equipment 100 and the environmental conditions. The high-definition camera has a wide-angle lens and can cover a larger monitoring range. The inspection images collected by the high-definition camera are transmitted to the host computer in real time, and support video recording and storage.

[0068] The inspection robot 310 is also equipped with an infrared thermal imaging camera, which can collect the surface temperature of the pipeline of the kiln equipment 100, upload the infrared image and temperature data to the host computer in real time, and warn of abnormal temperature. By using infrared thermal imaging technology to detect the changing characteristics of the temperature gradient diagram within a certain period of time, when the kiln equipment 100 has overheating, drastic temperature rise, gas leakage, etc., the abnormal temperature change information of the kiln equipment 100 can be captured in time, and the alarm information can be pushed in time.

[0069] A high-resolution infrared thermal imaging camera and a high-definition camera are used to capture the image data of the kiln roof and kiln wall of the kiln equipment 100 in real time, and the video stream is recorded in real time for subsequent analysis and processing. The captured infrared imaging image data is trained using existing deep learning algorithms such as deep neural networks to accurately identify the fire source. The training model can be trained to identify template features in different temperature ranges. A training set is constructed by collecting a large amount of image data of fire sources and non-fire sources. Among them, the training set includes flame images in various environments (such as different brightness, angles, backgrounds, etc.) and images of normal working conditions, so as to accurately detect fire conditions and issue warning information in a timely manner.

[0070] In addition, an environmental sensor may be provided on the inspection robot 310 so that the environmental sensor can monitor the temperature and humidity of the environment in real time.

[0071] Autonomous routine inspection is the most common application mode in the daily operation and maintenance of the inspection robot 310. The inspection robot 310 is equipped with a variety of detection equipment such as high-definition cameras, infrared thermal imaging cameras, smoke detectors, temperature and humidity sensors, etc. It performs appearance inspection and temperature diagnosis of the kiln equipment 100, and monitors the overall operating environment of the kiln equipment 100 in real time, and automatically transmits the inspection data to the host computer, allowing the host computer to generate a detection analysis report.

[0072] All inspection data and video surveillance data will be stored in the local storage system of the host computer, such as a data storage device. The local storage system has high security and reliability, ensuring the security and reliability of the data. The host computer system supports historical data query, and managers can retrieve historical data at any time for analysis and backtracking. The analysis of historical data helps to discover long-term trends and potential problems. The host computer system automatically generates inspection reports on a regular basis. The report content can include the operating status of the equipment, environmental parameters, abnormal conditions and processing results. Inspection reports can be generated on a daily, weekly and monthly basis to meet different management needs.

[0073] The inspection robot 310 is equipped with self-diagnosis and maintenance functions, which can detect and solve its own faults in time, ensuring the long-term stable operation of the inspection robot 310. It can be understood that through the built-in sensors and diagnostic algorithms, the operating status of each component of the inspection robot 310 is monitored in real time to detect potential faults in time. Once a fault is detected, the host computer will immediately send an alarm signal to notify the operator to conduct inspection and maintenance.

[0074] In addition, the operation and maintenance staff can remotely control the inspection robot 310 in real time through manual remote inspection. It can be understood that this application mode is suitable for the operation and maintenance staff and the management unit to lock and monitor the status of the equipment, especially when the equipment and environment status are abnormal during the autonomous inspection of the inspection robot 310 and the operation and maintenance staff are warned, the operation and maintenance staff will call the inspection robot 310 to quickly reach the equipment site, check the on-site equipment in time, and verify the alarm information, so as to quickly formulate a response strategy.

[0075] like Figures 1 to 4 As shown, the kiln equipment 100 according to the second embodiment of the present invention includes a kiln body and an intelligent inspection and diagnosis system for the kiln equipment as in the first embodiment.

[0076] The kiln body can fire ceramic products. The intelligent inspection and diagnosis system of the kiln equipment is installed on the kiln body. Through the operation of the intelligent inspection and diagnosis system of the kiln equipment, the kiln roof, side walls and conveyor roller 110 of the kiln body can be inspected automatically and accurately in a timely manner. When abnormal conditions such as fire leakage in the kiln body, breakage of the conveyor roller 110 and falling or breaking of the ceiling tiles are found, the kiln body can be located immediately and the staff can be notified in time to perform maintenance to avoid causing greater harm.

[0077] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "illustrative embodiments", "examples", "specific examples", or "some examples" means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner.

[0078] Although the embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the claims and their equivalents.

Claims

1. The intelligent inspection and diagnosis system of kiln equipment is characterized by: include: A track assembly, which is annular in shape when viewed from top to bottom, and is configured to be disposed above the kiln equipment and symmetrically disposed with respect to the kiln equipment; The inspection component includes an inspection robot, a first lifter, a second lifter, a first infrared thermal imaging camera, a second infrared thermal imaging camera and a first visible light camera. The inspection robot is configured to walk along a circular track on the track component. The first lifter is arranged at the upper part of the inspection robot and is used to drive the first infrared thermal imaging camera to rise and fall. The second lifter is arranged at the lower part of the inspection robot and is used to drive the second infrared thermal imaging camera and the first visible light camera to rise and fall.

2. The intelligent inspection and diagnosis system for kiln equipment according to claim 1 is characterized in that: The track assembly comprises: Two first rails are provided, each of which is configured to extend along the length direction of the kiln device, and the two first rails are configured to be symmetrically arranged on both sides of the kiln device along the width direction; Two transition tracks are provided, wherein the transition track is arranged between the two first tracks, and the same end of the two first tracks is connected through the transition track so that the track assembly has a ring structure.

3. The intelligent inspection and diagnosis system for kiln equipment according to claim 1 is characterized in that: The inspection component further includes an anti-collision radar, and the anti-collision radar is arranged on the inspection robot; and / or, The inspection component also includes a smoke detector, which is arranged on the inspection robot.

4. The intelligent inspection and diagnosis system for kiln equipment according to claim 1 is characterized in that: The inspection component also includes a combustible gas detection sensor, and the combustible gas detection sensor is arranged on the inspection robot.

5. The intelligent inspection and diagnosis system for kiln equipment according to claim 1 is characterized in that: The inspection component also includes an identification member, which is configured to be disposed on an end surface of a conveying roller of the kiln equipment, and the first visible light camera is configured to detect whether the identification member is in a rotating state.

6. The intelligent inspection and diagnosis system for kiln equipment according to any one of claims 1 to 5, characterized in that: It also includes a wireless transmission unit, which is arranged on the inspection robot and is electrically connected to the inspection component.

7. The intelligent inspection and diagnosis system for kiln equipment according to claim 6 is characterized in that: It also includes a central control system, which is wirelessly connected to the wireless transmission unit. The central control system includes a display screen, and the display screen is configured to display the information collected by the inspection component.

8. The intelligent inspection and diagnosis system for kiln equipment according to claim 1 is characterized in that: The first lifter and the second lifter are both electric push rods.

9. The intelligent inspection and diagnosis system for kiln equipment according to claim 1 is characterized in that: The first infrared thermal imaging camera, the second infrared thermal imaging camera and the first visible light camera all have rotatable lenses.

10. Kiln equipment, characterized in that, An intelligent inspection and diagnosis system for kiln equipment comprising any one of claims 1 to 9.

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