A heat control system and method for a mesh belt furnace used in ceramic sintering

Abstract

The present invention relates to the field of intelligent control technology, and particularly relates to a heat control system and method for a mesh belt furnace used in ceramic sintering, including: a control terminal, a monitoring layer, an indication layer, and a coordination layer; the control terminal, which is the main control end of the system, is used to issue execution commands; the image data of the sintered ceramics in the mesh belt furnace is collected through the monitoring layer, and the monitoring layer synchronously extracts the contour image of the sintered ceramics from the collected image data of the sintered ceramics in the mesh belt furnace, and based on the contour image of the sintered ceramics, the image data of the sintered ceramics in the mesh belt furnace is segmented and stored, and the indication layer further receives the segmented image data of the sintered ceramics in the mesh belt furnace stored in the monitoring layer; the present invention independently controls the burners in the mesh belt furnace to improve the finished product rate and cost control of the sintered ceramics in the mesh belt furnace, and controls the mesh belt furnace in this way, effectively improving the intelligence in the process of executing the task of sintering ceramics in the mesh belt furnace.

Description

Technical Field

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

[0002] The mesh belt furnace is a commonly used device for sintering ceramics. It uniformly conveys ceramic green bodies through a mesh belt and passes through a preset high-temperature area to achieve uniform heat sintering. It has obvious advantages, can accurately control the temperature, ensure stable 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] In the invention patent with the application number 202310688592.X, a temperature control system for a semiconductor ceramic sintering furnace is disclosed. It is characterized by including 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 installed around the inner side of each layer of the ceramic sintering furnace to obtain ceramic videos in real time and transmit them 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-by-frame processing on the ceramic videos obtained in real time, obtain the gray values of each frame image pixel point Sij, marked as PSij, and transmit them to the data processing module. The data processing module is used to perform difference processing on PSij between adjacent pixel points Sij to obtain a value R, set the threshold limit value as K, analyze and compare the threshold R with K, store the pixel points Sij where the threshold R is greater than K, and fit the stored pixel points Sij. When the fitted graph is one or more curves intersecting and the same image appears continuously for multiple frames with curves, it is determined that the ceramic has cracks, and the data processing module sends an image abnormality signal to the temperature control module. Perform mean and variance processing on PSii, comprehensively analyze to obtain the image brightness value L, set the image brightness standard value as H, compare and analyze the image brightness value with H. 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 values 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 signals sent by the data processing module and analyze and process the temperature value TS, set the preset temperature range QS for 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, thermocouples, radiation pyrometers, etc. are often used to detect the temperature of ceramic sintering furnaces. Among them, as a contact temperature measurement device, the thermocouple can only achieve point measurement; the radiation pyrometer can only reflect the projected temperature of the flame. It can be seen that the existing technology for detecting the temperature inside the ceramic furnace is not accurate enough and does not perform real-time temperature control".

[0006] However, for sintering ceramics in a gas-heated mesh belt furnace, 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, thus affecting the qualification rate and cost of the sintered finished products of this sintering method.

[0007] Therefore, we propose a heat control system for a mesh belt furnace used in ceramic sintering. Summary of the Invention

[0008] In view of the above-mentioned disadvantages of the existing technology, the present invention provides a heat control system and method for a mesh belt furnace used in ceramic sintering, and solves the technical problems proposed in the above background technology.

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

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

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

[0012] The image data of the sintered ceramics in the mesh belt furnace is collected through the monitoring layer. The monitoring layer synchronously extracts the contour image of the sintered ceramics from the collected image data of the sintered ceramics in the mesh belt furnace, segments and stores the image data of the sintered ceramics 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 sintered ceramics in the mesh belt furnace stored in the monitoring layer, analyzes the heat distribution of the sintered ceramics based on the segmented image data of the sintered ceramics in the mesh belt furnace, matches the corresponding burners to be regulated based on the heat distribution of the ceramic sintering, and the coordination layer operates to receive the burners to be regulated and controls the burners to be regulated to perform temperature coordination inside 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 image data of the sintered ceramics in the mesh belt furnace stored in the monitoring layer. The analyzing module is used to traverse the segmented image data of the sintered ceramics in the mesh belt furnace and analyze the heat distribution state of the sintered ceramics in the image data. The matching module is used to receive the analysis result of the heat distribution state of the sintered ceramics in the analyzing module and match the burners to be regulated through the analysis result;

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

[0015]

[0016] In the formula: 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 source of the surface heat Q of the sintered ceramic; L is the maximum diameter of the top surface of the sintered ceramic;

[0017] Among them, the acquisition time t of the image data for calculating the source of the surface heat Q of the sintered ceramic takes the value of 1, the reference ambient temperature T0 uses the ambient temperature in the current mesh belt furnace, and the average surface temperature T of the sintered ceramic s is determined 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 the image data of the sintered ceramic in the mesh belt furnace. The extraction module is used to receive the image data of the sintered ceramic in the mesh belt furnace collected by the camera module and extract the sintered ceramic contour image from the mesh belt furnace sintered ceramic image data. The segmentation module is used to receive the image data of the sintered ceramic in the mesh belt furnace collected by the camera module and the sintered ceramic contour image extracted by the extraction module, apply the sintered ceramic contour in the sintered ceramic contour image as the segmentation path, perform segmentation processing on the mesh belt furnace sintered ceramic image data, so as to obtain the local mesh belt furnace sintered ceramic image data corresponding to the position of the sintered ceramic contour image, and store the local mesh belt furnace sintered ceramic image data;

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

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

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

[0022]

[0023] Where: P (x,y) is the pixel value of the pixel (x, y) in the sintered ceramic image data in the mesh belt furnace; x and y are the row number and column number of the pixel (x, y); X is the contour pixel determination value; P norr is the pixel value of the contour pixel;

[0024] Among them, the pixel value P of the contour pixel norr is user-defined by the system end user. When X = 1, the pixel corresponding to the pixel value is the contour pixel. When X = 0, the pixel corresponding to the pixel value is the non-contour pixel. Based on the above formula, each pixel in the sintered ceramic image data in the mesh belt furnace is determined whether it is a contour pixel, so as to obtain the contour pixel set in the sintered ceramic image data 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 runs to segment the sintered ceramic image data in the mesh belt furnace based on the sintered ceramic contour image. After obtaining the local sintered ceramic image data in the mesh belt furnace, further use the local sintered ceramic image data in the mesh belt furnace as the capture area, and combine the coordinate axis network to pick up the burners distributed in the capture area.

[0027] Furthermore, the segmented sintered ceramic image data in the mesh belt furnace, that is, the local sintered ceramic image data in the mesh belt furnace;

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

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

[0030]

[0031] Where: m is the total number of pixels in the segmented sintered ceramic image data corresponding to the sintered ceramic; h jis the gray value of the j-th 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 determination threshold for the burner to be regulated is set in the matching module. The matching module runs to receive the analysis results of the heat distribution states of each group of sintered ceramics, and based on the comparison between the analysis results and the determination threshold for the burner to be regulated, determines the analysis results that meet the threshold;

[0033] Taking the target area where the heat distribution state of the sintered ceramics is analyzed corresponding to the analysis results that meet the threshold, and the burner where the target area is located 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 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 run again, and based on the image data of the sintered ceramics in the mesh belt furnace collected by the camera module running again, compare 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 groups of image data, and trigger the system to reset and run based on the difference identification result;

[0035] Among them, the identification module monitors the operation state of the control module during the operation stage, and performs the operation of controlling the camera module to run again after the control module finishes running. When the identification module controls the operation state of the camera module, the camera module runs continuously based on the user-defined operation frequency at the system end, continuously collects the image data of the sintered ceramics in the current mesh belt furnace, and applies the continuously collected image data of the sintered ceramics in the mesh belt furnace to compare the difference with the image data of the sintered ceramics in the mesh belt furnace collected before the burner to be regulated performs the regulation operation:

[0036]

[0037] In the formula: θ(a, b) is the difference between the two groups of images; R a 、R b are the values of the image a and the image b in the R channel; G a 、G b are the values of the image a and the image b in the G channel; B a 、B b are the values of the image a and the image b in the B channel; θ′ is the trigger determination value; ω1, ω2, ω3 are weights; max(·) represents taking the maximum value within the brackets;

[0038] Among them, the trigger determination value θ′ is user-defined 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′ holds, the recognition module triggers the system to reset and run.

[0039] Furthermore, the regulation logic of the burner to be regulated set in the logic module is as follows:

[0040] Obtain T reflected by the image data of the belt furnace sintered ceramics corresponding to the burner to be regulated s , and the standard temperature of ceramic sintering is stored in the logic module. Compare with T s , when the standard temperature is greater than T s , the valve opening control of the burner to be regulated is enlarged, and the air damper opening control is enlarged. When the standard temperature is less than T s , the valve opening control of the burner to be regulated is reduced, and the air damper opening control is reduced;

[0041] Among them, the air damper of the burner to be regulated executes the adjustment operation prior to the valve. During the adjustment process of the air damper and valve of the burner to be regulated, the adjustment rate remains unchanged and ends after reaching the limit.

[0042] Furthermore, the receiving module is wirelessly interconnected with an analysis module and a matching module. The receiving module is wirelessly interconnected with a segmentation module. The segmentation module is wirelessly interconnected with an extraction module and a camera module. The matching module is wirelessly interconnected with a logic module. The logic module is wirelessly interconnected with a control module and a recognition module.

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

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

[0045] Take the sintered ceramic contour image as the segmentation path, segment and obtain the local image data of the sintered ceramics in the belt furnace in the image data of the sintered ceramics in the belt furnace, and save it;

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

[0047] Configure axis grid coordinates for the image data of the sintered ceramics in the belt furnace, determine the burner corresponding to each group of sintered ceramics based on the axis grid coordinates, and match the group of burners to be regulated in combination with the analysis result of the heat distribution state of the sintered ceramics in the image data;

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

[0049] Capture the burner corresponding to the area that does not meet the standard temperature for ceramic sintering in the burner cloud to be regulated, set the regulation logic, and regulate the captured burner based on the regulation logic.

[0050] Adopting the technical solution provided by the present invention, compared with the known public technology, 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 sintered ceramic image data in the mesh belt furnace during operation, extracts the contour image of the sintered ceramic, segments the sintered ceramic image data in the mesh belt furnace with the extracted contour image of the sintered ceramic, and further configures it in the form of a coordinate axis network to determine the burners in the mesh belt furnace corresponding to the segmented images one by one. Further analyze the areas corresponding to the burners one by one in the segmented images to finally determine the burners that need to be independently controlled. Further, use the determined burners as the control targets to independently control the burners, so as to improve the yield and cost control of the sintered ceramics in the mesh belt furnace, and control the mesh belt furnace in this way, effectively improving the intelligence in the process of executing the task of sintering ceramics in the mesh belt furnace;

[0052] At the same time, during the execution of this method, it provides further operation logic support for the above system, ensures the stable operation of the system, and brings effective and real-time intelligent control for the sintering of ceramics in the mesh belt furnace. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the following drawings are only some embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.

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

[0055] Figure 2 It is a schematic flowchart of a heat control method for a mesh belt furnace for ceramic sintering;

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

[0057] Figure 4 It is a decision-making schematic diagram of the final regulated burner in the present invention;

[0058] The reference numerals in the figure denote: 1. the top surface of the sintering bin of the mesh belt furnace; 2. the burner; 3. the transmission station of the mesh belt furnace; 4. an example of sintered ceramics; 5. the target area for analyzing the heat distribution state of the sintered ceramics. Detailed implementation manners

[0059] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Apparently, the described embodiments are some, but not all, of the embodiments of the present invention. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without any creative efforts shall fall within the protection scope of the present invention.

[0060] The present invention will be further described below with reference to the embodiments.

[0061] Embodiment 1:

[0062] A heat control system for a mesh belt furnace for sintering ceramics in this embodiment, as Figure 1 shown, includes: a control terminal, a monitoring layer, an indication layer, and a coordination layer;

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

[0064] The image data of the sintered ceramics in the mesh belt furnace is collected through the monitoring layer. The monitoring layer synchronously extracts the contour image of the sintered ceramics from the collected image data of the sintered ceramics in the mesh belt furnace, segments and stores the image data of the sintered ceramics 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 sintered ceramics in the mesh belt furnace stored in the monitoring layer, analyzes the heat distribution of the sintered ceramics based on the segmented image data of the sintered ceramics in the mesh belt furnace, matches the corresponding burner to be regulated based on the heat distribution of the ceramic sintering, and the coordination layer operates to receive the burner to be regulated and control 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 the image data of the sintered ceramics in the mesh belt furnace. The extraction module is used to receive the image data of the sintered ceramics in the mesh belt furnace collected by the camera module and extract the contour image of the sintered ceramics from the image data of the sintered ceramics in the mesh belt furnace. The segmentation module is used to receive the image data of the sintered ceramics in the mesh belt furnace collected by the camera module and the contour image of the sintered ceramics extracted by the extraction module, apply the contour of the sintered ceramics in the contour image of the sintered ceramics as the segmentation path, perform segmentation processing on the image data of the sintered ceramics in the mesh belt furnace to obtain the local image data of the sintered ceramics in the mesh belt furnace corresponding to the position of the contour image of the sintered ceramics, and store the local image data of the sintered ceramics in the mesh belt furnace;

[0066] Among them, the mesh belt furnace is a gas-heated mesh belt furnace. The burners on the inner top surface of the mesh belt furnace are evenly distributed in an array. The burners on the inner 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 the sintered ceramics in the mesh belt furnace collected by the camera module is synchronously configured with a coordinate axis network, and the coordinate axis network is a two-dimensional coordinate axis network. The positions of each group of burners on the inner top surface of the mesh belt furnace falling on the coordinate axis network under the top view are known. When the camera module collects the image data of the sintered ceramics in the mesh belt furnace, the collection angle is the top view;

[0067] During the operation stage of the extraction module, after receiving the image data of the sintered ceramics in the mesh belt furnace, the contour pixels in the image data of the sintered ceramics 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 image data of the sintered ceramics in the mesh belt furnace;

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

[0069]

[0070] In the formula: P (x,y) is the pixel value of the pixel (x, y) in the image data of the sintered ceramics in the mesh belt furnace; x and y are the row number and column number of the pixel (x, y); X is the contour pixel determination value; P norr is the pixel value of the contour pixel;

[0071] Among them, the pixel value P norr of the contour pixel is user-defined by the system end user. When X = 1, the pixel value corresponds to a contour pixel, and when X = 0, the pixel value corresponds to a non-contour pixel. Based on the above formula, each pixel in the image data of the sintered ceramics in the mesh belt furnace is determined whether it is a contour pixel to obtain the contour pixel set in the image data of the sintered ceramics in the mesh belt furnace;

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

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

[0074]

[0075] In the formula: Q is the surface heat of the sintered ceramics; k is the thermal conductivity of the sintered ceramic raw material; A is the total surface area of the sintered ceramics; T sT 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 for calculating the image data of the surface heat Q source of the sintered ceramic; L is the maximum diameter of the top surface of the sintered ceramic;

[0076] Among them, the acquisition time t for calculating the image data of the surface heat Q source of the sintered ceramic takes the value of 1, the reference ambient temperature T0 uses the ambient temperature in the current mesh belt furnace, and the average surface temperature T of the sintered ceramic s is determined based on the segmented mesh belt furnace sintered ceramic image data corresponding to the sintered ceramic;

[0077] The average surface temperature T of the sintered ceramic s The calculation formula is:

[0078]

[0079] In the formula: 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 j-th 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. There is a determination threshold for the burner to be regulated set in the matching module. The matching module runs to receive the analysis results of the heat distribution states of each group of the sintered ceramic, and based on the comparison between the analysis results and the determination threshold for the burner to be regulated, determines the analysis results that meet the threshold;

[0081] Taking the target area where the analysis of the heat distribution state of the sintered ceramic is executed corresponding to the analysis results that meet the threshold, and the burner where the target area is located as the 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 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 run again, compare the image data of the sintered ceramic in the mesh belt furnace collected based on the re-run of the camera module with the image data of the sintered ceramic in the mesh belt furnace collected before the burner to be regulated executes the regulation operation, identify the difference between the two groups of image data, and trigger the system to reset and run based on the difference identification result;

[0083] Among them, the recognition module monitors the operating status of the control module during its operation phase, and performs an operation to control the camera module to run again after the control module finishes running. When the recognition module controls the operating status of the camera module, the camera module continuously runs based on the user-defined operating frequency at the system end, continuously acquires image data of the sintered ceramics in the current mesh belt furnace, and applies the continuously acquired image data of the sintered ceramics in the mesh belt furnace for differential comparison with the image data of the sintered ceramics in the mesh belt furnace acquired before the control operation of the burner to be regulated:

[0084]

[0085] In the formula: θ(a,b) is the difference between the two groups of images; R a 、R b are the values of the image a and the image b in the R channel; G a 、G b are the values of the image a and the image b in the G channel; B a 、B b are the values of the image a and the image b in the B channel; θ′ is the trigger determination value; ω1, ω2, ω3 are weights; max(·) represents taking the maximum value within the brackets;

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

[0087] The regulation logic of the burner to be regulated set in the logic module is:

[0088] Obtain T reflected by the image data of the sintered ceramics in the mesh belt furnace corresponding to the burner to be regulated. The ceramic sintering standard temperature is stored in the logic module. Compare the standard temperature with T s 。 If the standard temperature is greater than T s , the valve opening control of the burner to be regulated is enlarged and the air damper opening control is enlarged. If the standard temperature is less than T s , the valve opening control of the burner to be regulated is reduced and the air damper opening control is reduced; s Among them, the air damper of the burner to be regulated takes precedence over the valve to perform the regulation operation. During the regulation process of the air damper and the valve of the burner to be regulated, the regulation rate remains unchanged and ends after reaching the limit; [[ID=�7]]

[0089] Among them, the air damper of the burner to be regulated takes precedence over the valve to perform the regulation operation. During the regulation process of the air damper and the valve of the burner to be regulated, the regulation rate remains unchanged and ends after reaching the limit;

[0090] The receiving module is wirelessly interconnected with the analysis module and the matching module. The receiving module is wirelessly interconnected with the segmentation module. The segmentation module is wirelessly interconnected with the extraction module and the camera module. The matching module is wirelessly interconnected with the logic module. The logic module is wirelessly interconnected with the control module and the recognition module.

[0091] In this embodiment, the camera module runs to collect image data of the sintered ceramics in the mesh belt furnace. The extraction module runs later to receive the image data of the sintered ceramics in the mesh belt furnace collected by the camera module, and extracts the contour image of the sintered ceramics from the image data of the sintered ceramics in the mesh belt furnace. The segmentation module further receives the image data of the sintered ceramics in the mesh belt furnace collected by the camera module and the contour image of the sintered ceramics extracted by the extraction module, applies the contour of the sintered ceramics in the contour image of the sintered ceramics as the segmentation path, and performs segmentation processing on the image data of the sintered ceramics in the mesh belt furnace to obtain local image data of the sintered ceramics in the mesh belt furnace corresponding to the position of the contour image of the sintered ceramics, and stores the local image data of the sintered ceramics in the mesh belt furnace. The receiving module runs to receive the segmented image data of the sintered ceramics in the mesh belt furnace stored in the monitoring layer, and then the analysis module traverses the segmented image data of the sintered ceramics in the mesh belt furnace to analyze the heat distribution state of the sintered ceramics in the image data. The matching module runs later to receive the analysis result of the heat distribution state of the sintered ceramics in the analysis module, matches the burner to be regulated through the analysis result, and finally the logic module receives the burner to be regulated matched in the indication layer, sets the control logic of the burner to be regulated, and the control module runs to receive the control logic of the burner to be regulated set in the logic module, and controls the operation of the burner to be regulated based on the control logic of the burner to be regulated. The recognition module controls the camera module to run again, compares the image data of the sintered ceramics in the mesh belt furnace collected again by the camera module with the image data of the sintered ceramics in the mesh belt furnace collected before the regulation operation of the burner to be regulated, recognizes the difference between the two groups of image data, and triggers the system to reset and run based on the recognition result of the difference;

[0092] Through the operation of the system in the above embodiment, during the process of sintering ceramics in a gas-heated mesh belt furnace, an intelligent control effect is provided, enabling each burner in the gas-heated mesh belt furnace to be independently controlled, and based on this, analyzing the state of the sintered ceramics in the furnace, and then adaptively completing temperature regulation, ensuring the yield of the sintered ceramics in the gas-heated mesh belt furnace and reducing the comprehensive cost of firing ceramics in the gas-heated mesh belt furnace.

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

[0094] See Figure 4 As shown, based on the markings in the figure, the target area 5 for analyzing the heat distribution state of the sintered ceramics is further represented. Based on the arrow indication in the figure:

[0095] The arrow pointing in the upper right direction shows the target area 5 for analyzing the heat distribution state of the sintered ceramics;

[0096] The right - lower - direction arrow and the left - lower - direction arrow point, showing the area corresponding to the burner to be regulated determined by the system, that is, the shaded - filled identifier;

[0097] The downward - direction arrow points, showing the burner to be regulated determined by the system.

[0098] Embodiment 2:

[0099] At the specific implementation level, on the basis of Embodiment 1, this embodiment refers to Figure 1 shown in the following to further specifically describe a heat control system for a mesh - belt furnace used for ceramic sintering in Embodiment 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, further using the local mesh - belt furnace sintered ceramic image data as the capture area, the burners distributed in the capture area are picked up in combination with the coordinate axis grid;

[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 grid, so as to facilitate the system to immediately determine the corresponding targets based on the correlation between the sintered ceramic image and the burners.

[0103] The segmented mesh - belt furnace sintered ceramic image data, that is, the 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 runs to receive a set of segmented mesh - belt furnace sintered ceramic image data each time. Further, the coordinates of the burners distributed in the capture area under the top - view perspective in the coordinate axis grid are mapped into the segmented mesh - belt furnace sintered ceramic image data. The heat dispersion radius of the burner is set, and circles are drawn with each group of mapped coordinates as the center and the burner heat dispersion radius as the circular drawing radius. The area in the corresponding segmented mesh - belt furnace sintered ceramic image data of the circle is the target area for performing the heat distribution state analysis of the sintered ceramics. The heat distribution state analysis of the target area is carried out based on the analysis logic.

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

[0106] Embodiment 3:

[0107] At the specific implementation level, based on Example 1, this example refers to Figure 2 as shown to further specifically illustrate a heat control method for a mesh belt furnace used in ceramic sintering in Example 1:

[0108] A heat control method for a mesh belt furnace used in ceramic sintering includes the following steps:

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

[0110] Taking the contour image of the sintered ceramics as the segmentation path, segment and obtain the local image data of the sintered ceramics in the mesh belt furnace from the image data of the sintered ceramics in the mesh belt furnace, and save it;

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

[0112] Configure axis network coordinates for the image data of the sintered ceramics in the mesh belt furnace, determine the burners corresponding to each group of sintered ceramics based on the axis network coordinates, and match the burner group to be regulated in combination with 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 image data of the sintered ceramics in the mesh belt furnace, and analyze whether the temperature of the selected area in each group meets the standard temperature for ceramic sintering;

[0114] Capture the burners corresponding to the areas that do not meet the standard temperature for ceramic sintering in the burner cloud to be regulated, set a regulation logic, and regulate the captured burners based on the regulation logic.

[0115] In summary, the image data of the sintered ceramics in the mesh belt furnace collected during the operation of the system in the above embodiments, extract the contour image of the sintered ceramics, segment the image data of the sintered ceramics in the mesh belt furnace with the extracted contour image of the sintered ceramics, further configure it in the form of an axis network, determine the burners in the mesh belt furnace corresponding to the segmented images one by one, further analyze the areas corresponding to the burners one by one in the segmented images, to finally determine the burners that need to be independently controlled, and further use the determined burners as the control targets to independently control the burners, so as to improve the yield rate and cost control of the sintered ceramics in the mesh belt furnace, and control the mesh belt furnace in this way, effectively improving the intelligence during the execution of the task of sintering ceramics in the mesh belt furnace. At the same time, during the execution of this method, it provides further operation logic support for the above system, ensures the stable operation of the system, and brings effective and real-time intelligent control for the sintering of ceramics in the mesh belt furnace.

[0116] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it; although the present invention has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that: they can still modify the technical solutions recorded in the foregoing embodiments, or perform equivalent replacements on some of the technical features; and these 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 various 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 sintered ceramics in the mesh belt furnace is collected through the monitoring layer. The monitoring layer simultaneously extracts the sintered ceramic contour image from the collected mesh belt furnace sintered ceramic image data, and segments and stores the mesh belt furnace sintered ceramic image data 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, analyzes the sintering heat distribution of the sintered ceramics based on the segmented mesh belt furnace sintered ceramic image data, and matches the corresponding burner to be regulated 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 according to the analysis result. The heat distribution state analysis logic of sintered ceramics in the analysis module is expressed as: ； Where: is the surface heat of sintered ceramics; is the thermal conductivity of the sintered ceramic raw material; is the total surface area of sintered ceramic; is the average surface temperature of sintered ceramics; is the reference ambient temperature; is the thermal diffusivity of the sintered ceramic; To calculate the surface heat of sintered ceramics The acquisition time of the source image data; is the maximum diameter of the top surface of the sintered ceramic; Among them, the surface heat of sintered ceramics is calculated Acquisition time of source image data The value is 1, referring to the ambient temperature Take the current ambient temperature in the mesh belt furnace and the average surface temperature of the sintered ceramics 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, 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 a 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 by the extraction module, apply the sintered ceramic contour in the sintered ceramic contour image as a segmentation path, perform segmentation processing on the image data of ceramics sintered in the mesh belt furnace, so as to obtain 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 the sintered ceramics 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 top-down perspective are all known. When the camera module collects the image data of the sintered ceramics in the mesh belt furnace, the collection perspective is a top-down perspective.

3. The thermal control system of a mesh belt furnace for ceramic sintering according to claim 2, characterized in that: During the operation phase of the extraction module, after receiving the ceramic image data sintered in the mesh belt furnace, the extraction module identifies the contour pixels in the ceramic image data sintered in the mesh belt furnace based on the contour pixel recognition logic, and constructs the sintered ceramic contour image 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 follows: ； Where: Pixels in the image data of ceramics sintered in a mesh belt furnace Pixel value of Pixels The number of rows and columns; is the contour pixel judgment value; is the pixel value of the contour pixel; Among them, the pixel value of the contour pixel Customized by the system user, When , the pixel value corresponding to the pixel is the contour pixel, When , the pixel corresponding to the pixel value 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, i.e., 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 under the top-down perspective in the coordinate axis network 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 The calculation formula is: ； Where: is the total number of pixels in the segmented mesh belt furnace sintered ceramic image data corresponding to the sintered ceramic; is the gray value of the j-th pixel; is the ratio of temperature to grayscale value; Among them, the ratio of temperature to gray value The matching module is a priori known parameter, and a threshold value for determining the burner to be controlled 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, compares the analysis results with the threshold value for determining the burner to be controlled, and determines the analysis results that meet the threshold value; The target area corresponding to the analysis result meeting the threshold value for performing the sintered ceramic heat distribution state analysis is used as the burner in the target area 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 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 identification 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 operating status of the camera module, the camera module runs continuously based on the operating frequency customized by the system end user, continuously collects the image data of the ceramics sintered in the current mesh belt furnace, and uses the continuously collected image data of the ceramics sintered in the mesh belt furnace to perform a difference comparison with the image data of the ceramics sintered in the mesh belt furnace collected before the burner to be controlled performs the control operation: ； Where: is the difference between the two groups of images; is the value of image a and image b in the R channel; is the value of image a and image b in the G channel; is the value of image a and image b in channel B; is the trigger judgment value; 、 is the weight; Indicates taking the maximum value in the brackets; Among them, the trigger judgment value Customized by the system user, weight 、 、 are all greater than zero and the sum of the three groups of weights is 1, When established, the identification module triggers the system reset operation.

8. The thermal control system of a mesh belt furnace for ceramic sintering according to claim 7, characterized in that: The control logic of the burner to be controlled set in the logic module is: Obtain the segmented mesh belt furnace sintering ceramic image data corresponding to the burner to be controlled The logic module stores the ceramic sintering standard temperature. Comparison, standard temperature is greater than , 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 , 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 performs the regulation operation before the valve. 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 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.

10. A method for controlling heat of a mesh belt furnace for ceramic sintering, the method being an implementation method of the heat control system of a mesh belt furnace for ceramic sintering according to any one of claims 1 to 9, characterized in that: The following steps are involved: Collecting image data of ceramics sintered in the mesh belt furnace, setting contour image extraction logic, and extracting the contour image of the sintered ceramics from the image data of the 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 the data; Obtain stored image data of ceramics sintered in a local mesh belt furnace and analyze the heat distribution of the sintered ceramics in each set of image data; Configure the axis grid coordinates for the image data of ceramics sintered 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 burner corresponding area in the local mesh belt furnace sintering ceramic image data, and analyze whether the regional temperature of each group of selected areas meets the ceramic sintering standard temperature; The burners corresponding to the areas that do not meet the standard temperature of ceramic sintering in the burner group to be regulated are captured, the regulation logic is set, and the captured burners are regulated based on the regulation logic.

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