Heat control system and method for mesh belt furnace for ceramic sintering

Abstract

The invention relates to the technical field of intelligent control, in particular to a mesh belt furnace heat control system and method for ceramic sintering, and the system comprises a control terminal, a monitoring layer, an indication layer and a coordination layer. The control terminal is a main control terminal of the system and is used for sending out an execution command; image data of sintered ceramics in the mesh-belt furnace are collected through the monitoring layer, the monitoring layer synchronously extracts a sintered ceramic contour image from the collected image data of the sintered ceramics in the mesh-belt furnace, and the image data of the sintered ceramics in the mesh-belt furnace are segmented and stored based on the sintered ceramic contour image. The indication layer further receives the segmented mesh-belt furnace sintered ceramic image data stored in the monitoring layer; according to the method, the combustor in the mesh belt furnace is independently controlled, so that yield improvement and cost control of ceramic sintering of the mesh belt furnace are achieved, the mesh belt furnace is controlled in this way, and intelligence in the execution process of the ceramic sintering task of the mesh belt furnace is effectively improved.

Description

Technical Field

[0001] The present invention relates to the field of intelligent control technology, and in particular to a heat control system and method of a mesh belt furnace for ceramic sintering. Background Art

[0002] The mesh belt furnace is a common equipment for sintering ceramics. It uses a mesh belt to uniformly transport ceramic blanks through a preset high-temperature area to achieve uniform heating and sintering. It has obvious advantages, can accurately control the temperature, ensure the stability of ceramic performance, and has high production efficiency. It is suitable for mass production of various ceramic products and is widely used in the field of ceramic processing.

[0003] The invention patent with application number 202310688592.X discloses a temperature control system for a semiconductor ceramic sintering furnace, which is characterized by comprising: an infrared camera, an image processing module, a data processing module, a temperature control module, a power control module, an execution module, an electric heating module and a cooling module; the infrared camera is placed around the inner side of each layer of the ceramic sintering furnace to obtain ceramic video in real time and transmit it to the image processing module;

[0004] The infrared camera is also used to obtain temperature values ​​in real time and transmit the obtained temperature values ​​to the data processing module; the image processing module is used to perform frame processing on the ceramic video obtained in real time, obtain the grayscale value of each frame of the image pixel Sij, mark it as PSij, and transmit it to the data processing module; the data processing module is used to perform difference processing on PSij between adjacent pixel points Sij to obtain the value R, and set the threshold limit value to K, analyze and compare the threshold R and K, store the pixel points Sij with the threshold R greater than K, fit the stored pixel points Sij, and when the fitting graph is the intersection of one or more curves, and curves appear in multiple consecutive frames of the same image, it is determined that there are cracks in the ceramic, and the data processing module sends an image abnormality signal to the temperature control module; perform mean and mean square error processing on PSii, obtain the image brightness value L through comprehensive analysis, set the image brightness standard value as H, compare and analyze the image brightness value with the sun, when the image brightness value L≠H, the image brightness does not meet the standard, and the data processing module sends an image abnormality signal to the temperature control module; the data processing module is also used to process the temperature value obtained in real time, obtain the temperature value TS of each layer of the ceramic sintering furnace, and transmit the temperature value TS to the temperature control module; the temperature control module is used to make decisions on the image abnormality signal sent by the data processing module and analyze and process the temperature value TS, set the preset temperature range QS of each layer of the ceramic sintering furnace, and compare and analyze the temperature value TS with the preset temperature range QS.

[0005] This application aims to solve the problem that "at present, the temperature detection of ceramic sintering furnaces often uses thermocouples, radiation pyrometers and other methods. Among them, thermocouples, as contact temperature measurement equipment, can only realize point measurement; radiation pyrometers can only reflect the projected temperature of the flame. It can be seen that the existing technology is not accurate enough in detecting the temperature in the ceramic furnace and there is no real-time control of the temperature."

[0006] However, for the gas-heated mesh belt furnace sintering ceramics, there is currently no independent control function for each burner on the mesh belt furnace, resulting in a certain amount of inevitable defective products in the ceramics sintered by the gas-heated mesh belt furnace, which affects the pass rate and cost of the sintered products of this sintering method.

[0007] Therefore, we proposed a heat control system for a mesh belt furnace for ceramic sintering. Summary of the invention

[0008] In view of the above-mentioned shortcomings of the prior art, the present invention provides a heat control system and method for a mesh belt furnace for ceramic sintering, which solves the technical problems raised in the above-mentioned background technology.

[0009] To achieve the above objectives, the present invention is implemented through the following technical solutions:

[0010] In a first aspect, a thermal control system of a mesh belt furnace for ceramic sintering includes: a control terminal, a monitoring layer, an indication layer, and a coordination layer;

[0011] The control terminal is the main control terminal of the system and is used to issue execution commands;

[0012] The image data of the ceramics sintered in the mesh belt furnace is collected through the monitoring layer, and the monitoring layer simultaneously extracts the contour image of the sintered ceramics from the collected image data of the ceramics sintered in the mesh belt furnace, and segments and stores the image data of the ceramics sintered in the mesh belt furnace based on the contour image of the sintered ceramics. The indication layer further receives the segmented image data of the ceramics sintered in the mesh belt furnace stored in the monitoring layer, and analyzes the sintering heat distribution of the ceramics based on the segmented image data of the ceramics sintered in the mesh belt furnace. The corresponding burner to be regulated is matched based on the ceramic sintering heat distribution. The coordination layer operates to receive the burner to be regulated, and controls the burner to be regulated to perform temperature coordination in the mesh belt furnace.

[0013] The indication layer includes a receiving module, an analyzing module and a matching module. The receiving module is used to receive the segmented mesh belt furnace sintered ceramic image data stored in the monitoring layer. The analyzing module is used to traverse the segmented mesh belt furnace sintered ceramic image data and analyze the heat distribution state of the sintered ceramic in the image data. The matching module is used to receive the heat distribution state analysis result of the sintered ceramic in the analyzing module and match the burner to be controlled through the analysis result.

[0014] The heat distribution state analysis logic of sintered ceramics in the analysis module is expressed as:

[0015]

[0016] Where: Q is the surface heat of the sintered ceramic; k is the thermal conductivity of the sintered ceramic raw material; A is the total surface area of ​​the sintered ceramic; T s is the average surface temperature of the sintered ceramic; T0 is the reference ambient temperature; α is the thermal diffusivity of the sintered ceramic; t is the acquisition time of the image data for calculating the surface heat Q of the sintered ceramic; L is the maximum diameter of the top surface of the sintered ceramic;

[0017] The surface heat Q of the sintered ceramic is calculated based on the image data acquisition time t, which is 1. The reference ambient temperature T0 is the ambient temperature in the current mesh belt furnace, and the average surface temperature of the sintered ceramic is T s The determination is made based on the segmented mesh belt furnace sintered ceramic image data corresponding to the sintered ceramic.

[0018] Furthermore, the monitoring layer includes a camera module, an extraction module, and a segmentation module. The camera module is used to collect image data of ceramics sintered in a mesh belt furnace. The extraction module is used to receive the image data of ceramics sintered in a mesh belt furnace collected by the camera module, and extract a sintered ceramic contour image from the image data of ceramics sintered in a mesh belt furnace. The segmentation module is used to receive the image data of ceramics sintered in a mesh belt furnace collected by the camera module, and the sintered ceramic contour image extracted in the extraction module, and use the sintered ceramic contour in the sintered ceramic contour image as a segmentation path, perform segmentation processing in the image data of ceramics sintered in a mesh belt furnace, so as to obtain local image data of ceramics sintered in a mesh belt furnace corresponding to the sintered ceramic contour image, and store the local image data of ceramics sintered in a mesh belt furnace.

[0019] Among them, the mesh belt furnace is a gas-heated mesh belt furnace, and the burners on the top surface of the mesh belt furnace are evenly distributed in an array. The burners evenly distributed in an array on the top surface of the mesh belt furnace are parallel to the transmission mesh belt surface of the mesh belt furnace. The image data of sintered ceramics in the mesh belt furnace collected by the camera module are synchronously configured with a coordinate axis network, which is a two-dimensional coordinate axis network. The positions of each group of burners on the top surface of the mesh belt furnace falling on the coordinate axis network from a top-down perspective are all known. When the camera module collects image data of sintered ceramics in the mesh belt furnace, the collection perspective is a top-down perspective.

[0020] Furthermore, during the operation phase of the extraction module, after receiving the ceramic image data sintered in the mesh belt furnace, the contour pixels in the ceramic image data sintered in the mesh belt furnace are identified based on the contour pixel recognition logic, and a sintered ceramic contour image is formed based on the contour pixels in the ceramic image data sintered in the mesh belt furnace;

[0021] The outline pixel recognition logic of the ceramic image data sintered in the mesh belt furnace is expressed as:

[0022]

[0023] Where: P (x,y) is the pixel value of the pixel (x, y) in the image data of ceramic sintering in the mesh belt furnace; x, y are the number of rows and columns of the pixel (x, y); X is the contour pixel judgment value; P norr is the pixel value of the contour pixel;

[0024] Among them, the pixel value P of the contour pixel norr It is defined by the system user. When X=1, the pixel value corresponding to the pixel is a contour pixel. When X=0, the pixel value corresponding to the pixel is a non-contour pixel. Based on the above formula, each pixel in the ceramic image data sintered in the mesh belt furnace is judged to be a contour pixel to obtain the contour pixel set in the ceramic image data sintered in the mesh belt furnace.

[0025] Furthermore, each ceramic contour in the sintered ceramic contour image is a closed contour;

[0026] After the sintered ceramic contour image is extracted by the extraction module, it is synchronously fed back to the segmentation module. The segmentation module operates to segment the mesh belt furnace sintered ceramic image data based on the sintered ceramic contour image. After obtaining the local mesh belt furnace sintered ceramic image data, the local mesh belt furnace sintered ceramic image data is further used as the capture area, and the burners distributed in the capture area are picked up in combination with the coordinate axis network.

[0027] Furthermore, the segmented mesh belt furnace sintered ceramic image data, i.e., the local mesh belt furnace sintered ceramic image data;

[0028] The segmented mesh-belt furnace sintered ceramic image data received by the receiving module is not unique. The analysis module receives a group of segmented mesh-belt furnace sintered ceramic image data each time it runs, and further maps the coordinates of the burners distributed in the capture area in the coordinate axis grid under the top-down perspective to the segmented mesh-belt furnace sintered ceramic image data, sets the burner heat distribution radius, and draws a circle with each group of mapped coordinates as the center of the circle and the burner heat distribution radius as the circle drawing radius. The area in the segmented mesh-belt furnace sintered ceramic image data corresponding to the circle is the target area for performing sintered ceramic heat distribution state analysis, and the heat distribution state analysis of the target area is performed based on the analysis logic.

[0029] Furthermore, the average surface temperature of the sintered ceramic is T s The calculation formula is:

[0030]

[0031] Where: m is the total number of pixels in the segmented mesh belt furnace sintered ceramic image data corresponding to the sintered ceramic; h jis the gray value of the jth pixel; r is the ratio of temperature to gray value;

[0032] Among them, the ratio r of temperature to gray value is a priori known parameter, and a judgment threshold of the burner to be regulated is set in the matching module. The matching module runs to receive the analysis results of the heat distribution state of each group of sintered ceramics, and compares the analysis results with the judgment threshold of the burner to be regulated to determine the analysis results that meet the threshold;

[0033] The target area for performing the sintered ceramic heat distribution state analysis corresponding to the analysis result that meets the threshold value, and the burner in the target area are used as the burner to be regulated.

[0034] Furthermore, the coordination layer includes a logic module, a control module and an identification module. The logic module is used to receive the burner to be regulated matched in the indication layer and set the control logic of the burner to be regulated. The control module is used to receive the control logic of the burner to be regulated set in the logic module and control the operation of the burner to be regulated based on the control logic of the burner to be regulated. The identification module is used to control the camera module to run again, compare the image data of the sintered ceramics in the mesh belt furnace collected by the camera module when it runs again with the image data of the sintered ceramics in the mesh belt furnace collected before the burner to be regulated performs the control operation, identify the difference between the two sets of image data, and trigger the system to reset the operation based on the difference recognition result;

[0035] Among them, the recognition module monitors the operating status of the control module during the operation phase, and executes the operation of controlling the camera module to run again after the control module ends. When the recognition module controls the camera module to run, the camera module runs continuously based on the user-defined operating frequency on the system side, continuously collects the image data of the ceramic sintered in the current mesh belt furnace, and uses the continuously collected image data of the ceramic sintered in the mesh belt furnace to compare the difference with the image data of the ceramic sintered in the mesh belt furnace collected before the burner to be controlled performs the control operation:

[0036]

[0037] Where: θ(a,b) is the difference between the two sets of images; R a , R b is the value of image a and image b in the R channel; G a , G b is the value of image a and image b in the G channel; B a , B b is the value of image a and image b in channel B; θ′ is the trigger judgment value; ω1, ω2, ω3 are weights; max(·) means taking the maximum value in the brackets;

[0038] Among them, the trigger judgment value θ′ is customized by the system user, the weights ω1, ω2, and ω3 are all greater than zero and the sum of the three groups of weights is 1. When θ(a, b)>θ′ is established, the identification module triggers the system to reset and run.

[0039] Furthermore, the control logic of the burner to be controlled set in the logic module is:

[0040] Obtain the T reflected by the segmented mesh belt furnace sintering ceramic image data corresponding to the burner to be regulated s The logic module stores the ceramic sintering standard temperature, and the standard temperature is compared with T s Comparison, standard temperature is greater than T s , the valve opening control of the burner to be regulated is expanded, the air door opening control is expanded, and the standard temperature is less than T s , the valve opening of the burner to be regulated is controlled to be reduced, and the air door opening is controlled to be reduced;

[0041] Among them, the damper of the burner to be regulated has priority over the valve in performing the regulation operation. During the adjustment process of the damper and valve of the burner to be regulated, the regulation rate remains unchanged and ends after the adjustment reaches the limit.

[0042] Furthermore, the receiving module is interactively connected to the analysis module and the matching module through a wireless network, the receiving module is interactively connected to the segmentation module through a wireless network, the segmentation module is interactively connected to the extraction module and the camera module through a wireless network, the matching module is interactively connected to the logic module through a wireless network, and the logic module is interactively connected to the control module and the identification module through a wireless network.

[0043] In a second aspect, a method for controlling heat of a mesh belt furnace for ceramic sintering comprises the following steps:

[0044] Collect image data of ceramics sintered in the mesh belt furnace, set contour image extraction logic, and extract the contour image of sintered ceramics from the image data of ceramics sintered in the mesh belt furnace based on the contour image extraction logic;

[0045] Using the sintered ceramic contour image as a segmentation path, segmenting the ceramic image data sintered in the mesh belt furnace to obtain local ceramic image data sintered in the mesh belt furnace, and saving it;

[0046] Acquire the stored image data of ceramics sintered in the LAN belt furnace, and analyze the heat distribution state of the sintered ceramics in each group of image data;

[0047] Configure the axis grid coordinates for the image data of ceramic sintering in the mesh belt furnace, determine the burner corresponding to each group of sintered ceramics based on the axis grid coordinates, and match the burner group to be controlled based on the analysis results of the heat distribution state of the sintered ceramics in the image data;

[0048] Select the area corresponding to the burner in the local mesh belt furnace sintering ceramic image data, and analyze whether the area temperature of each group of selected areas meets the ceramic sintering standard temperature;

[0049] In the burner cloud to be regulated, the burners corresponding to the areas that do not meet the standard temperature of ceramic sintering are captured, the regulation logic is set, and the captured burners are regulated based on the regulation logic.

[0050] Compared with the known public technology, the technical solution provided by the present invention has the following beneficial effects:

[0051] The present invention provides a heat control system and method for a mesh belt furnace for ceramic sintering. The system collects ceramic image data sintered in the mesh belt furnace during operation, extracts the sintered ceramic contour image, and segments the ceramic image data sintered in the mesh belt furnace with the extracted sintered ceramic contour image. The system further configures the burners in the mesh belt furnace corresponding to the segmented images in a coordinate axis network manner, further analyzes the areas corresponding to the burners in the segmented images, and finally determines the burners that need to be independently controlled. The determined burners are further used as control targets to independently control the burners, so as to improve the yield and control the cost of ceramic sintered in the mesh belt furnace. In addition, the control of the mesh belt furnace in this way effectively improves the intelligence of the mesh belt furnace in the process of executing the ceramic sintering task.

[0052] At the same time, during the execution of this method, further operation logic support is provided for the above system to ensure stable operation of the system and bring effective and real-time intelligent control to the mesh belt furnace sintering ceramics. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the prior art descriptions are briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention, and for ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0054] Figure 1 It is a schematic diagram of the structure of a heat control system of a mesh belt furnace for ceramic sintering;

[0055] Figure 2 It is a schematic flow chart of a method for controlling heat of a mesh belt furnace for ceramic sintering;

[0056] Figure 3 It is a schematic diagram of the local structure of the mesh belt furnace in the present invention;

[0057] Figure 4 It is a decision diagram for the final control of the burner in the present invention;

[0058] The numbers in the figure indicate: 1. Top surface of mesh belt furnace sintering bin; 2. Burner; 3. Mesh belt furnace transfer station; 4. Sintered ceramic example; 5. Target area for performing sintered ceramic heat distribution state analysis. DETAILED DESCRIPTION

[0059] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0060] The present invention will be further described below in conjunction with the embodiments.

[0061] Embodiment 1:

[0062] A thermal control system of a mesh belt furnace for ceramic sintering according to this embodiment, such as Figure 1 As shown, it includes: control terminal, monitoring layer, indication layer and coordination layer;

[0063] The control terminal is the main control terminal of the system and is used to issue execution commands;

[0064] The image data of the ceramics sintered in the mesh belt furnace is collected through the monitoring layer, and the monitoring layer simultaneously extracts the contour image of the sintered ceramics from the collected image data of the ceramics sintered in the mesh belt furnace, and segments and stores the image data of the ceramics sintered in the mesh belt furnace based on the contour image of the sintered ceramics. The indication layer further receives the segmented image data of the ceramics sintered in the mesh belt furnace stored in the monitoring layer, and analyzes the sintering heat distribution of the ceramics based on the segmented image data of the ceramics sintered in the mesh belt furnace. The corresponding burner to be regulated is matched based on the ceramic sintering heat distribution. The coordination layer operates to receive the burner to be regulated, and controls the burner to be regulated to perform temperature coordination in the mesh belt furnace.

[0065] The monitoring layer includes a camera module, an extraction module, and a segmentation module. The camera module is used to collect image data of ceramics sintered in a mesh belt furnace. The extraction module is used to receive the image data of ceramics sintered in the mesh belt furnace collected by the camera module, and extract the sintered ceramic contour image from the image data of ceramics sintered in the mesh belt furnace. The segmentation module is used to receive the image data of ceramics sintered in the mesh belt furnace collected by the camera module and the sintered ceramic contour image extracted in the extraction module, and use the sintered ceramic contour in the sintered ceramic contour image as a segmentation path, perform segmentation processing in the image data of ceramics sintered in the mesh belt furnace, so as to obtain the local mesh belt furnace sintered ceramic image data corresponding to the sintered ceramic contour image, and store the local mesh belt furnace sintered ceramic image data;

[0066] Among them, the mesh belt furnace is a gas-heated mesh belt furnace, and the burners on the top surface of the mesh belt furnace are evenly distributed in an array. The burners evenly distributed in an array on the top surface of the mesh belt furnace are parallel to the surface of the transmission mesh belt of the mesh belt furnace. The image data of ceramics sintered in the mesh belt furnace collected by the camera module are synchronously configured with a coordinate axis network. The coordinate axis network is a two-dimensional coordinate axis network. The positions of each group of burners on the top surface of the mesh belt furnace falling on the coordinate axis network from a bird's-eye view are all known. When the camera module collects the image data of ceramics sintered in the mesh belt furnace, the collection perspective is a bird's-eye view.

[0067] In the extraction module operation stage, after receiving the ceramic image data sintered in the mesh belt furnace, the contour pixels in the ceramic image data sintered in the mesh belt furnace are identified based on the contour pixel recognition logic, and the contour image of the sintered ceramic is formed based on the contour pixels in the ceramic image data sintered in the mesh belt furnace;

[0068] The contour pixel recognition logic of ceramic image data sintered in a mesh belt furnace is expressed as:

[0069]

[0070] Where: P (x,y) is the pixel value of the pixel (x, y) in the image data of ceramic sintering in the mesh belt furnace; x, y are the number of rows and columns of the pixel (x, y); X is the contour pixel judgment value; P norr is the pixel value of the contour pixel;

[0071] Among them, the pixel value P of the contour pixel norr It is defined by the user on the system end. When X=1, the pixel value corresponding to the pixel is a contour pixel. When X=0, the pixel value corresponding to the pixel is a non-contour pixel. Based on the above formula, each pixel in the ceramic image data sintered in the mesh belt furnace is judged to be a contour pixel, so as to obtain the contour pixel set in the ceramic image data sintered in the mesh belt furnace.

[0072] The indication layer includes a receiving module, an analyzing module and a matching module. The receiving module is used to receive the segmented mesh belt furnace sintered ceramic image data stored in the monitoring layer. The analyzing module is used to traverse the segmented mesh belt furnace sintered ceramic image data and analyze the heat distribution state of the sintered ceramic in the image data. The matching module is used to receive the analysis result of the heat distribution state of the sintered ceramic in the analyzing module and match the burner to be controlled through the analysis result.

[0073] The heat distribution state analysis logic of sintered ceramics in the analysis module is expressed as:

[0074]

[0075] Where: Q is the surface heat of the sintered ceramic; k is the thermal conductivity of the sintered ceramic raw material; A is the total surface area of ​​the sintered ceramic; T sis the average surface temperature of the sintered ceramic; T0 is the reference ambient temperature; α is the thermal diffusivity of the sintered ceramic; t is the acquisition time of the image data for calculating the surface heat Q of the sintered ceramic; L is the maximum diameter of the top surface of the sintered ceramic;

[0076] The surface heat Q of the sintered ceramic is calculated based on the image data acquisition time t, which is 1. The reference ambient temperature T0 is the ambient temperature in the current mesh belt furnace, and the average surface temperature of the sintered ceramic is T s Determining based on segmented mesh belt furnace sintered ceramic image data corresponding to the sintered ceramic;

[0077] Average surface temperature of sintered ceramics T s The calculation formula is:

[0078]

[0079] Where: m is the total number of pixels in the segmented mesh belt furnace sintered ceramic image data corresponding to the sintered ceramic; h j is the gray value of the jth pixel; r is the ratio of temperature to gray value;

[0080] Among them, the ratio r of temperature to gray value is a priori known parameter, and a judgment threshold of the burner to be regulated is set in the matching module. The matching module runs to receive the analysis results of the heat distribution state of each group of sintered ceramics, and compares the analysis results with the judgment threshold of the burner to be regulated to determine the analysis results that meet the threshold;

[0081] A target area for performing sintered ceramic heat distribution state analysis corresponding to the analysis result that meets the threshold value, and a burner in the target area is used as a burner to be regulated;

[0082] The coordination layer includes a logic module, a control module and an identification module. The logic module is used to receive the burner to be controlled matched in the indication layer and set the control logic of the burner to be controlled. The control module is used to receive the control logic of the burner to be controlled set in the logic module and control the operation of the burner to be controlled based on the control logic of the burner to be controlled. The identification module is used to control the camera module to run again, compare the image data of the sintered ceramics in the mesh belt furnace collected by the camera module when it runs again with the image data of the sintered ceramics in the mesh belt furnace collected before the burner to be controlled performs the control operation, identify the difference between the two sets of image data, and trigger the system to reset the operation based on the difference recognition result;

[0083] Among them, the recognition module monitors the operating status of the control module during the operation phase, and executes the operation of controlling the camera module to run again after the control module ends. When the recognition module controls the camera module to run, the camera module runs continuously based on the user-defined operating frequency on the system side, continuously collects the image data of the ceramic sintered in the current mesh belt furnace, and uses the continuously collected image data of the ceramic sintered in the mesh belt furnace to compare the difference with the image data of the ceramic sintered in the mesh belt furnace collected before the burner to be controlled performs the control operation:

[0084]

[0085] Where: θ(a,b) is the difference between the two sets of images; R a , R b is the value of image a and image b in the R channel; G a , G b is the value of image a and image b in the G channel; B a , B b is the value of image a and image b in channel B; θ′ is the trigger judgment value; ω1, ω2, ω3 are weights; max(·) means taking the maximum value in the brackets;

[0086] Among them, the trigger judgment value θ′ is customized by the system end user, the weights ω1, ω2, and ω3 are all greater than zero and the sum of the three groups of weights is 1. When θ(a, b)>θ′ is established, the identification module triggers the system to reset and run;

[0087] The control logic of the burner to be controlled set in the logic module is:

[0088] Obtain the T reflected by the segmented mesh belt furnace sintering ceramic image data corresponding to the burner to be regulated s The logic module stores the ceramic sintering standard temperature, and the standard temperature is compared with T s Comparison, standard temperature is greater than T s , the valve opening control of the burner to be regulated is expanded, the air door opening control is expanded, and the standard temperature is less than T s , the valve opening of the burner to be regulated is controlled to be reduced, and the air door opening is controlled to be reduced;

[0089] Among them, the damper of the burner to be regulated has priority over the valve in performing the regulation operation. During the regulation of the damper and valve of the burner to be regulated, the regulation rate remains unchanged and ends after the regulation reaches the limit;

[0090] The receiving module is interactively connected to the analysis module and the matching module through a wireless network, the receiving module is interactively connected to the segmentation module through a wireless network, the segmentation module is interactively connected to the extraction module and the camera module through a wireless network, the matching module is interactively connected to the logic module through a wireless network, and the logic module is interactively connected to the control module and the recognition module through a wireless network.

[0091] In this embodiment, the camera module operates to collect image data of ceramics sintered in the mesh belt furnace, the extraction module operates to receive the image data of ceramics sintered in the mesh belt furnace collected by the camera module, and extracts the sintered ceramic contour image from the image data of ceramics sintered in the mesh belt furnace, the segmentation module further receives the image data of ceramics sintered in the mesh belt furnace collected by the camera module and the sintered ceramic contour image extracted in the extraction module, uses the sintered ceramic contour in the sintered ceramic contour image as the segmentation path, performs segmentation processing on the image data of ceramics sintered in the mesh belt furnace to obtain the local image data of ceramics sintered in the mesh belt furnace corresponding to the sintered ceramic contour image, and stores the local image data of ceramics sintered in the mesh belt furnace, the receiving module operates to receive the segmented mesh belt furnace sintered ceramic image data stored in the monitoring layer, and then the analysis module traverses the segmented mesh belt furnace sintered ceramic image data. The cut mesh belt furnace sintered ceramic image data is used to analyze the heat distribution state of the sintered ceramic in the image data. The matching module is post-operated to receive the analysis result of the heat distribution state of the sintered ceramic in the analysis module, and the burner to be controlled is matched through the analysis result. Finally, the burner to be controlled matched in the indication layer is received through the logic module, and the control logic of the burner to be controlled is set. The control module runs the control logic of the burner to be controlled set in the receiving logic module, and controls the operation of the burner to be controlled based on the control logic of the burner to be controlled. The recognition module controls the camera module to run again, and the image data of the sintered ceramic in the mesh belt furnace collected by the camera module after the re-run is compared with the image data of the sintered ceramic in the mesh belt furnace collected before the burner to be controlled performs the control operation, and the difference between the two sets of image data is identified, and the system reset operation is triggered based on the difference recognition result;

[0092] Through the operation of the system in the above embodiment, an intelligent control effect is provided for the process of sintering ceramics in the gas-heated mesh belt furnace, so that each burner in the gas-heated mesh belt furnace can be independently controlled, and on this basis, the state analysis of the ceramics sintered in the furnace is carried out, and then the temperature control is adaptively completed to ensure the yield of ceramics sintered in the gas-heated mesh belt furnace and reduce the comprehensive cost of firing ceramics in the gas-heated mesh belt furnace.

[0093] See also Figure 3 As shown, based on the markings in the figure, the mesh belt furnace sintering bin top surface 1, the burner 2, the mesh belt furnace transmission station 3, and the sintered ceramic example 4 are displayed, further illustrating an example application scenario of the system in the above embodiment;

[0094] See also Figure 4 As shown, the target area 5 for performing the sintered ceramic heat distribution state analysis is further indicated based on the markings in the figure, and based on the arrows in the figure:

[0095] The arrow on the upper right side points to the target area 5 for performing the heat distribution state analysis of the sintered ceramics;

[0096] The lower right directional arrow and the lower left directional arrow point to the area corresponding to the burner to be regulated determined based on the system, i.e., the shaded filled mark;

[0097] The downward arrow points to show the burner to be regulated based on the system determination.

[0098] Embodiment 2:

[0099] In terms of specific implementation, based on Example 1, this example refers to Figure 1 The following is a further detailed description of a ceramic sintering mesh belt furnace heat control system in Example 1:

[0100] Each ceramic contour in the sintered ceramic contour image is a closed contour;

[0101] After the sintered ceramic contour image is extracted by the extraction module, it is synchronously fed back to the segmentation module. The segmentation module runs to segment the mesh belt furnace sintered ceramic image data based on the sintered ceramic contour image. After obtaining the local mesh belt furnace sintered ceramic image data, the local mesh belt furnace sintered ceramic image data is further used as the capture area, and the burners distributed in the capture area are picked up in combination with the coordinate axis network.

[0102] Through the above settings, during the operation of the system, the sintered ceramics are associated with the burners in the furnace based on the configured coordinate axis network, so that the system can make instant judgments on the corresponding targets based on the correlation between the sintered ceramic images and the burners.

[0103] Segmented mesh belt furnace sintered ceramic image data, that is, local mesh belt furnace sintered ceramic image data;

[0104] The segmented mesh belt furnace sintered ceramic image data received by the receiving module is not unique. The analysis module receives a group of segmented mesh belt furnace sintered ceramic image data each time it runs, and further maps the coordinates of the burners distributed in the capture area in the coordinate axis grid under the top-down perspective to the segmented mesh belt furnace sintered ceramic image data, sets the burner heat distribution radius, and draws a circle with each group of mapped coordinates as the center of the circle and the burner heat distribution radius as the circle drawing radius. The area in the segmented mesh belt furnace sintered ceramic image data corresponding to the circle is the target area for performing sintered ceramic heat distribution state analysis, and the heat distribution state analysis of the target area is performed based on the analysis logic.

[0105] In this embodiment, through the above settings, further operating data support is provided for the system in Example 1 to ensure stable operation of the system in Example 1. At the same time, based on the above, the source and determination logic of "target area 5 for performing sintered ceramic heat distribution state analysis" are further explained in detail.

[0106] Embodiment 3:

[0107] In terms of specific implementation, based on Example 1, this example refers to Figure 2 The heat control method of a mesh belt furnace for ceramic sintering in Example 1 is further specifically described as follows:

[0108] A method for controlling heat of a mesh belt furnace for ceramic sintering, comprising the following steps:

[0109] Collect image data of ceramics sintered in the mesh belt furnace, set contour image extraction logic, and extract the contour image of sintered ceramics from the image data of ceramics sintered in the mesh belt furnace based on the contour image extraction logic;

[0110] Using the sintered ceramic contour image as a segmentation path, segmenting the ceramic image data sintered in the mesh belt furnace to obtain local ceramic image data sintered in the mesh belt furnace, and saving it;

[0111] Acquire the stored image data of ceramics sintered in the LAN belt furnace, and analyze the heat distribution state of the sintered ceramics in each group of image data;

[0112] Configure the axis grid coordinates for the image data of ceramic sintering in the mesh belt furnace, determine the burner corresponding to each group of sintered ceramics based on the axis grid coordinates, and match the burner group to be controlled based on the analysis results of the heat distribution state of the sintered ceramics in the image data;

[0113] Select the area corresponding to the burner in the local mesh belt furnace sintering ceramic image data, and analyze whether the area temperature of each group of selected areas meets the ceramic sintering standard temperature;

[0114] In the burner cloud to be regulated, the burners corresponding to the areas that do not meet the standard temperature of ceramic sintering are captured, the regulation logic is set, and the captured burners are regulated based on the regulation logic.

[0115] In summary, in the above embodiment, the system collects image data of ceramics sintered in the mesh belt furnace during operation, extracts the contour image of sintered ceramics, and segments the image data of ceramics sintered in the mesh belt furnace with the extracted contour image of sintered ceramics, and further configures the burners in the mesh belt furnace corresponding to the segmented images in a coordinate axis network manner, and further analyzes the areas corresponding to the burners in the segmented images to finally determine the burners that need to be independently controlled, and further uses the determined burners as control targets to independently control the burners, so as to achieve the improvement of the yield and cost control of ceramics sintered in the mesh belt furnace, and controlling the mesh belt furnace in this way effectively improves the intelligence of the mesh belt furnace in the execution of ceramics sintering tasks. At the same time, during the execution of this method, further operation logic support is provided for the above system to ensure the stable operation of the system and bring effective and real-time intelligent control to the mesh belt furnace sintering ceramics.

[0116] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features may be replaced by equivalents. Such modifications or replacements will not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A thermal control system for a mesh belt furnace for ceramic sintering, characterized in that: include: Control terminal, monitoring layer, indication layer and coordination layer; The control terminal is the main control terminal of the system and is used to issue execution commands; The image data of the ceramics sintered in the mesh belt furnace is collected through the monitoring layer, and the monitoring layer simultaneously extracts the contour image of the sintered ceramics from the collected image data of the ceramics sintered in the mesh belt furnace, and segments and stores the image data of the ceramics sintered in the mesh belt furnace based on the contour image of the sintered ceramics. The indication layer further receives the segmented image data of the ceramics sintered in the mesh belt furnace stored in the monitoring layer, and analyzes the sintering heat distribution of the ceramics based on the segmented image data of the ceramics sintered in the mesh belt furnace. The corresponding burner to be regulated is matched based on the ceramic sintering heat distribution. The coordination layer operates to receive the burner to be regulated, and controls the burner to be regulated to perform temperature coordination in the mesh belt furnace. The indication layer includes a receiving module, an analyzing module and a matching module. The receiving module is used to receive the segmented mesh belt furnace sintered ceramic image data stored in the monitoring layer. The analyzing module is used to traverse the segmented mesh belt furnace sintered ceramic image data and analyze the heat distribution state of the sintered ceramic in the image data. The matching module is used to receive the heat distribution state analysis result of the sintered ceramic in the analyzing module and match the burner to be controlled through the analysis result. The heat distribution state analysis logic of sintered ceramics in the analysis module is expressed as: Where: Q is the surface heat of the sintered ceramic; k is the thermal conductivity of the sintered ceramic raw material; A is the total surface area of ​​the sintered ceramic; T s is the average surface temperature of sintered ceramics; T0 is the reference ambient temperature; α is the thermal diffusivity of the sintered ceramic; t is the acquisition time of the image data for calculating the surface heat Q of the sintered ceramic; L is the maximum diameter of the top surface of the sintered ceramic; The surface heat Q of the sintered ceramic is calculated based on the image data acquisition time t, which is 1. The reference ambient temperature T0 is the ambient temperature in the current mesh belt furnace, and the average surface temperature of the sintered ceramic is T s The determination is made based on the segmented mesh belt furnace sintered ceramic image data corresponding to the sintered ceramic.

2. The thermal control system of a mesh belt furnace for ceramic sintering according to claim 1 is characterized in that: The monitoring layer includes a camera module, an extraction module, and a segmentation module. The camera module is used to collect image data of ceramics sintered in a mesh belt furnace. The extraction module is used to receive the image data of ceramics sintered in the mesh belt furnace collected by the camera module, and extract the sintered ceramic contour image from the image data of ceramics sintered in the mesh belt furnace. The segmentation module is used to receive the image data of ceramics sintered in the mesh belt furnace collected by the camera module and the sintered ceramic contour image extracted in the extraction module, and use the sintered ceramic contour in the sintered ceramic contour image as a segmentation path, perform segmentation processing in the image data of ceramics sintered in the mesh belt furnace, so as to obtain the local image data of ceramics sintered in the mesh belt furnace corresponding to the sintered ceramic contour image, and store the local image data of ceramics sintered in the mesh belt furnace; Among them, the mesh belt furnace is a gas-heated mesh belt furnace, and the burners on the top surface of the mesh belt furnace are evenly distributed in an array. The burners evenly distributed in an array on the top surface of the mesh belt furnace are parallel to the transmission mesh belt surface of the mesh belt furnace. The image data of sintered ceramics in the mesh belt furnace collected by the camera module are synchronously configured with a coordinate axis network, which is a two-dimensional coordinate axis network. The positions of each group of burners on the top surface of the mesh belt furnace falling on the coordinate axis network from a top-down perspective are all known. When the camera module collects image data of sintered ceramics in the mesh belt furnace, the collection perspective is a top-down perspective.

3. A ceramic sintering mesh belt furnace heat control system according to claim 2, characterized in that: In the operation stage of the extraction module, after receiving the ceramic image data sintered in the mesh belt furnace, the contour pixels in the ceramic image data sintered in the mesh belt furnace are identified based on the contour pixel recognition logic, and the contour image of the sintered ceramic is formed based on the contour pixels in the ceramic image data sintered in the mesh belt furnace; The outline pixel recognition logic of the ceramic image data sintered in the mesh belt furnace is expressed as: Where: P (x,y) is the pixel value of the pixel (x, y) in the image data of ceramic sintering in the mesh belt furnace; x, y are the number of rows and columns of the pixel (x, y); X is the contour pixel judgment value; P norr is the pixel value of the contour pixel; Among them, the pixel value P of the contour pixel norr It is defined by the system user. When X=1, the pixel value corresponding to the pixel is a contour pixel. When X=0, the pixel value corresponding to the pixel is a non-contour pixel. Based on the above formula, each pixel in the ceramic image data sintered in the mesh belt furnace is judged to be a contour pixel to obtain the contour pixel set in the ceramic image data sintered in the mesh belt furnace.

4. The thermal control system of a mesh belt furnace for ceramic sintering according to claim 1, characterized in that: Each ceramic contour in the sintered ceramic contour image is a closed contour; After the sintered ceramic contour image is extracted by the extraction module, it is synchronously fed back to the segmentation module. The segmentation module operates to segment the mesh belt furnace sintered ceramic image data based on the sintered ceramic contour image. After obtaining the local mesh belt furnace sintered ceramic image data, the local mesh belt furnace sintered ceramic image data is further used as the capture area, and the burners distributed in the capture area are picked up in combination with the coordinate axis network.

5. A thermal control system for a mesh belt furnace for ceramic sintering according to claim 1 or 4, characterized in that: The segmented mesh belt furnace sintered ceramic image data, that is, the local mesh belt furnace sintered ceramic image data; The segmented mesh-belt furnace sintered ceramic image data received by the receiving module is not unique. The analysis module receives a group of segmented mesh-belt furnace sintered ceramic image data each time it runs, and further maps the coordinates of the burners distributed in the capture area in the coordinate axis grid under the top-down perspective to the segmented mesh-belt furnace sintered ceramic image data, sets the burner heat distribution radius, and draws a circle with each group of mapped coordinates as the center of the circle and the burner heat distribution radius as the circle drawing radius. The area in the segmented mesh-belt furnace sintered ceramic image data corresponding to the circle is the target area for performing sintered ceramic heat distribution state analysis, and the heat distribution state analysis of the target area is performed based on the analysis logic.

6. The thermal control system of a mesh belt furnace for ceramic sintering according to claim 1, characterized in that: The average surface temperature of the sintered ceramic is T s The calculation formula is: Where: m is the total number of pixels in the segmented mesh belt furnace sintered ceramic image data corresponding to the sintered ceramic; h j is the gray value of the jth pixel; r is the ratio of temperature to gray value; Among them, the ratio r of temperature to gray value is a priori known parameter, and a judgment threshold of the burner to be regulated is set in the matching module. The matching module runs to receive the analysis results of the heat distribution state of each group of sintered ceramics, and compares the analysis results with the judgment threshold of the burner to be regulated to determine the analysis results that meet the threshold; The target area for performing the sintered ceramic heat distribution state analysis corresponding to the analysis result that meets the threshold value, and the burner in the target area are used as the burner to be regulated.

7. The thermal control system of a mesh belt furnace for ceramic sintering according to claim 1, characterized in that: The coordination layer includes a logic module, a control module and an identification module. The logic module is used to receive the burner to be regulated matched in the indication layer and set the regulation logic of the burner to be regulated. The control module is used to receive the control logic of the burner to be regulated set in the logic module and control the operation of the burner to be regulated based on the control logic of the burner to be regulated. The identification module is used to control the camera module to operate again, compare the image data of the sintered ceramics in the mesh belt furnace collected by the camera module when it is operated again with the image data of the sintered ceramics in the mesh belt furnace collected before the burner to be regulated performs the regulation operation, identify the difference between the two sets of image data, and trigger the system to reset the operation based on the difference recognition result; Among them, the recognition module monitors the operating status of the control module during the operation phase, and executes the operation of controlling the camera module to run again after the control module ends. When the recognition module controls the camera module to run, the camera module runs continuously based on the user-defined operating frequency on the system side, continuously collects the image data of the ceramic sintered in the current mesh belt furnace, and uses the continuously collected image data of the ceramic sintered in the mesh belt furnace to compare the difference with the image data of the ceramic sintered in the mesh belt furnace collected before the burner to be controlled performs the control operation: Where: θ(a,b) is the difference between the two sets of images; R a , R b is the value of image a and image b in the R channel; G a , G b is the value of image a and image b in the G channel; B a , B b is the value of image a and image b in channel B; θ′ is the trigger judgment value; ω1, ω2, ω3 are weights; max(·) means taking the maximum value in the brackets; Among them, the trigger judgment value θ′ is customized by the system user, the weights ω1, ω2, and ω3 are all greater than zero and the sum of the three groups of weights is 1. When θ(a, b)>θ′ is established, the identification module triggers the system to reset and run.

8. A ceramic sintering mesh belt furnace heat control system according to claim 7, characterized in that: The control logic of the burner to be controlled set in the logic module is: Obtain the T reflected by the segmented mesh belt furnace sintering ceramic image data corresponding to the burner to be regulated s The logic module stores the ceramic sintering standard temperature, and the standard temperature is compared with T s Comparison, standard temperature is greater than T s , the valve opening control of the burner to be regulated is expanded, the air door opening control is expanded, and the standard temperature is less than T s , the valve opening of the burner to be regulated is controlled to be reduced, and the air door opening is controlled to be reduced; Among them, the damper of the burner to be regulated has priority over the valve in performing the regulation operation. During the adjustment process of the damper and valve of the burner to be regulated, the regulation rate remains unchanged and ends after the adjustment reaches the limit.

9. The thermal control system of a mesh belt furnace for ceramic sintering according to claim 1, characterized in that: The receiving module is interactively connected to the analysis module and the matching module via a wireless network, the receiving module is interactively connected to the segmentation module via a wireless network, the segmentation module is interactively connected to the extraction module and the camera module via a wireless network, the matching module is interactively connected to the logic module via a wireless network, and the logic module is interactively connected to the control module and the identification module via a wireless network.

10. A method for controlling the heat of a mesh belt furnace for ceramic sintering, the method being an implementation method of a heat control system of a mesh belt furnace for ceramic sintering as claimed in any one of claims 1 to 9, characterized in that: The following steps are involved: Collect image data of ceramics sintered in the mesh belt furnace, set contour image extraction logic, and extract the contour image of sintered ceramics from the image data of ceramics sintered in the mesh belt furnace based on the contour image extraction logic; Using the sintered ceramic contour image as a segmentation path, segmenting the ceramic image data sintered in the mesh belt furnace to obtain local ceramic image data sintered in the mesh belt furnace, and saving it; Acquire the stored image data of ceramics sintered in the LAN belt furnace, and analyze the heat distribution state of the sintered ceramics in each group of image data; Configure the axis grid coordinates for the image data of ceramic sintering in the mesh belt furnace, determine the burner corresponding to each group of sintered ceramics based on the axis grid coordinates, and match the burner group to be controlled based on the analysis results of the heat distribution state of the sintered ceramics in the image data; Select the area corresponding to the burner in the local mesh belt furnace sintering ceramic image data, and analyze whether the area temperature of each group of selected areas meets the ceramic sintering standard temperature; In the burner cloud to be regulated, the burners corresponding to the areas that do not meet the standard temperature of ceramic sintering are captured, the regulation logic is set, and the captured burners are regulated based on the regulation logic.

Images