Composite detection system and detection method for furnace wall temperature of electric furnace

Abstract

The invention discloses an electric furnace wall temperature composite detection system and detection method, and relates to the technical field of electric furnace wall temperature measurement, the electric furnace wall temperature composite detection system comprises an electric furnace, thermocouples, a high temperature camera and an infrared thermal imager, the multiple thermocouples are uniformly arranged on the inner side of the electric furnace wall, and the thermocouples are connected with a PLC; the high-temperature camera is arranged on the furnace wall of the electric furnace and extends into the furnace wall from the outer side of the furnace wall to shoot; the plurality of infrared thermal imagers are uniformly arranged on the outer side of the electric furnace and are used for detecting the furnace wall temperature of each area of the electric furnace; composite detection of the temperature of the furnace wall of the electric furnace is achieved through multiple detection means such as the external thermal imager, the camera in the furnace and the furnace wall thermal resistor, so that measurement errors caused by a single temperature measurement mode are avoided, the detection precision and monitoring and alarming accuracy of the temperature of the furnace wall are effectively improved, and frequent shutdown is avoided.

Description

Technical Field

[0001] The invention relates to the technical field of electric furnace wall temperature measurement, and in particular to a composite detection system and a detection method for an electric furnace wall temperature. Background Art

[0002] Rock wool is made of high-quality basalt, dolomite and other raw materials. After being melted at a high temperature of more than 1450℃, it is centrifuged into fibers at high speed using an internationally advanced four-axis centrifuge. At the same time, a certain amount of adhesive, dust-proof oil and water-repellent agent are sprayed into it, and then collected by a cotton collector, processed by the pendulum method, and spread using the three-dimensional method, and then cured and cut to form rock wool products of different specifications and uses.

[0003] There are two main technologies for producing rock wool: cupola smelting technology and electric furnace smelting technology. Among them, rock wool produced by electric furnace has the advantages of high production efficiency, low pollution and stable melt quality.

[0004] During the rock wool production process, the furnace wall usually withstands a high temperature of thousands of degrees. Although the furnace wall can be protected by increasing the thickness of the furnace wall steel plate, laying refractory bricks, adding insulation materials, water cooling and air cooling, etc., reliable furnace wall detection methods are still the most stable means to ensure the safe operation of the electric furnace. The existing technology generally uses thermal resistors to measure the furnace wall temperature, but there is a lack of effective monitoring of the actual temperature in the furnace, melt problems, and especially the furnace outlet temperature; because the temperature of the electric furnace exceeds thousands of degrees, and high voltage discharge is carried out around the electric furnace, it is strictly forbidden for people to enter and exit at will. Therefore, the limitations of the existing detection methods cannot achieve timely and accurate grasp of the temperature of the electric furnace, which has caused serious restrictions on the development of the electric furnace production process. Summary of the invention

[0005] In view of the deficiencies in the above-mentioned prior art, the present invention provides a composite detection system and method for the temperature of an electric furnace wall, which can perform composite temperature detection on the electric furnace wall, effectively improve the accuracy and reliability of temperature detection, and ensure the safe operation of the electric furnace.

[0006] In order to achieve the above object, the present invention adopts the following technical solution:

[0007] A composite detection system for the temperature of an electric furnace wall comprises an electric furnace, a thermocouple, a high-temperature camera and an infrared thermal imager, wherein a plurality of the thermocouples are evenly arranged on the inner side of the electric furnace wall, and the thermocouples are connected to a PLC controller; the high-temperature camera is arranged on the electric furnace wall and extends from the outer side of the furnace wall to the inner side for shooting; and the plurality of the infrared thermal imagers are evenly arranged on the outer side of the electric furnace for detecting the temperature of the furnace wall in each area of ​​the electric furnace.

[0008] Preferably, the high-temperature camera is connected to the cooling pipeline of the electric furnace to cool the high-temperature camera to avoid damage.

[0009] Preferably, the high-temperature camera comprises a plurality of cameras, which are arranged at the upper part of the electric furnace, extending into the furnace, and are evenly distributed along the circumference of the furnace wall.

[0010] Preferably, the electric furnace is formed by splicing steel plates, and the side walls of the electric furnace are processed with mounting holes for installing thermocouples and high-temperature cameras.

[0011] Preferably, a PLC controller is also included, and the thermocouple, high-temperature camera and infrared thermal imager are all connected to the PLC controller.

[0012] Preferably, the PLC controller is connected to a monitoring system and an alarm device.

[0013] Preferably, it also includes a stream thermal camera, which is arranged at the outlet of the electric furnace and is used to detect the temperature of the outflowing melt.

[0014] Preferably, the stream thermal camera is connected to a PLC controller.

[0015] Preferably, the high temperature camera communicates with the industrial computer decoding software via TCPIP, and is connected to the monitoring system, and the monitoring system is connected to the alarm device.

[0016] Preferably, a plurality of infrared thermal imagers are installed at the same height to measure the temperature at the same height in different areas for comparison; and a plurality of infrared thermal imagers are installed at half the height of the electric furnace.

[0017] On the other hand, a composite detection method for the temperature of an electric furnace wall is provided, comprising the following steps:

[0018] The furnace temperature, high temperature image, temperature outside the furnace wall in each area of ​​the electric furnace and melt temperature at the furnace outlet are collected respectively, and the sampled temperatures are sent to the PLC controller;

[0019] When the sampled temperature exceeds the set temperature threshold, the display will trigger a local alarm signal and the abnormal temperature information will be fed back to the PLC controller;

[0020] When the temperature feedback from one detection state is abnormal, the PLC controller automatically matches other temperature information collected at the same location and displays it on the monitoring system; if the temperature feedback from two or more detection states is abnormal, the electric furnace alarm device will be immediately triggered.

[0021] By adopting the above technical solution, the beneficial effects of the present invention are as follows:

[0022] 1. The present invention realizes composite detection of the temperature of the electric furnace wall through multiple detection means such as external thermal imager, in-furnace camera and furnace wall thermal resistor, and can perform composite detection from multiple positions such as inside the wall, outside the wall, melt outlet, etc., thereby avoiding the measurement error of a single temperature measurement method, effectively improving the detection accuracy of the furnace wall temperature and the accuracy of monitoring and alarming, and avoiding frequent shutdowns.

[0023] 2. The present invention can be connected to the PLC control system and the monitoring system of the entire factory to provide real-time feedback on the actual situation of the electric furnace. The automatic control of the PLC system can reduce the repetitive operation procedures of the operators, and can also help the workers to accurately control the furnace through monitoring and temperature feedback.

[0024] 2. The present invention can also reserve sufficient redundant points to facilitate the subsequent transformation and upgrading of the entire system. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The accompanying drawings in the specification, which constitute a part of the present invention, are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute improper limitations on the present invention.

[0026] Figure 1 It is a schematic diagram of the structural arrangement of the present invention;

[0027] Figure 2 It is a top view of the structural arrangement of the present invention.

[0028] In the figure: 1. furnace body; 2. thermocouple; 3. infrared thermal imager; 4. high temperature camera; 5. stream thermal camera. DETAILED DESCRIPTION

[0029] The technical solutions 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. It should be noted that the following detailed descriptions are illustrative and are intended to provide further explanation of the present invention. Unless otherwise specified, all technical and scientific terms used in the present invention have the same meanings as those commonly understood by ordinary technicians in the technical field to which the present invention belongs. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0030] Embodiment 1:

[0031] In a typical embodiment of the present application, a composite detection system for the temperature of an electric furnace wall is provided, such as Figure 1 , 2As shown, it includes a furnace body 1, a thermocouple 2 installed on the furnace wall, an infrared thermal imager 3, a high-temperature camera 4 extending into the furnace, and a stream thermal camera 5. The outer wall of the furnace body 1 is spliced ​​by a plurality of arc-shaped thickened steel plates. A plurality of thermocouples 2 are evenly arranged inside the electric furnace body, and the thermocouples are connected to a PLC controller; the high-temperature camera 4 is arranged on the furnace wall of the furnace body and extends from the outside of the furnace body to the inside for shooting; a plurality of infrared thermal imagers 3 are evenly arranged on the outside of the furnace body for detecting the furnace wall temperature of each area of ​​the electric furnace.

[0032] Specifically, 6-8 thermocouples are installed on each steel plate on the outer wall of the furnace body for temperature detection. These thermocouples are evenly distributed on the upper, middle and lower layers of the furnace wall so that the detection range can cover the entire furnace wall surface of the furnace body. The thermocouples are connected to the PLC controller, and all the collected furnace wall temperature information is transmitted to the PLC controller in the control center, and the temperature of each detection point is displayed in digital form through the PLC controller.

[0033] At the same time, if Figure 1 , 2 As shown, a plurality of high-temperature cameras are provided on the furnace wall of the furnace body through reserved installation holes, and the high-temperature cameras 4 are installed on the upper part of the furnace body 1. Specifically, the high-temperature camera is installed above the highest point of the liquid level, and a mounting hole is reserved on the steel plate of the furnace wall of the electric furnace. The high-temperature camera extends from the outside of the furnace wall into the furnace body through the mounting hole to collect high-temperature images in the electric furnace, so as to obtain more comprehensive information for temperature detection. Since the actual detection range of the high-temperature camera is about 90°, the number of high-temperature cameras should be no less than four. Considering the cost of the high-temperature camera and the environmental difficulty of the installation in the furnace, in this embodiment, the high-temperature camera is set to 5, and the 5 high-temperature cameras are evenly distributed along the circumference of the furnace wall to ensure that the entire area of ​​the furnace can be covered for detection.

[0034] Considering that the high temperature in the electric furnace can easily damage the high-temperature camera, the high-temperature camera is connected to the cooling pipeline of the electric furnace itself, and the camera is cooled by water-cooling or air-cooling pipelines during the operation of the electric furnace to protect the temperature detection device. The high-temperature camera uses an endoscopic furnace high-temperature infrared thermal imager, such as the RB-TV series produced by Changzhou Rongbang Automation Equipment Co., Ltd. The camera extends into the furnace through the detection port reserved in the furnace wall, directly captures the temperature in the electric furnace, and transmits the image information and temperature information in the furnace to the PLC controller, which can most realistically reflect the temperature distribution in the furnace rather than just the furnace wall range. At the same time, the image information captured in the furnace can be transmitted to the monitoring system of the entire factory, and the real scene in the furnace can be called up at any time to facilitate abnormal monitoring and alarm.

[0035] The composite detection means of the present application also includes a plurality of infrared thermal imagers 3 installed on the outside of the furnace wall, and the plurality of infrared thermal imagers 3 are evenly arranged circumferentially outside the furnace body to detect the temperature of the furnace wall of each part of the furnace body separately so as to determine whether the temperature of each area is uniform. Specifically, the furnace body of the electric furnace is evenly divided into several areas along the circumferential direction, and each area detects the temperature of the furnace wall of the area from the outside through an infrared thermal imager. Since the detection range of each thermal imager does not exceed 120°, it is best to control the thermal imaging detection range to not exceed 90° during the actual installation process. Therefore, the number of infrared thermal imagers is at least four. In this embodiment, the infrared thermal imager is set at about 2 meters away from the outer wall of the electric furnace, and 8 infrared thermal imagers are evenly set to ensure that each area of ​​the furnace wall can be fully covered for temperature measurement. At the same time, the overlapping area of ​​adjacent infrared thermal imagers can be controlled. When the temperature of the overlapping area is abnormal, the infrared thermal imagers including the area will alarm, which can more accurately locate the abnormal temperature part, which is convenient for the staff to adjust in time. From the height, the 8 infrared thermal imagers are installed at the same height to measure the temperature of the same height in different areas for comparison. The eight infrared thermal imagers are all set at half the height of the electric furnace, which can ensure that the temperature distribution in each detection area is relatively uniform in the vertical direction. The temperature at this height is used to judge whether the temperature of each area is uniform, which is conducive to the accuracy of detection and judgment. The infrared thermal imager uses Optris' XI80, and its camera comes with a junction box. The processor in the box can be programmed to set 3 high temperature alarms and 3 low temperature alarms, and the temperature abnormality is divided into three levels. It can achieve different levels of early warning, which is more helpful for the staff to accurately judge the abnormal situation. In addition, each alarm can output a digital signal, and the temperature analog signal of the thermal imager and the digital signal of the alarm can be fed back to the PLC controller.

[0036] It should be noted that the furnace wall temperature of each area detected by the infrared thermal imager can be correlated and corroborated with the temperature information collected by the thermocouple and high-temperature camera. Multiple detected temperatures at the same time can be compared horizontally in the PLC controller. To facilitate the operator's operation, the PLC controller can generate a real-time curve chart on the control industrial computer for comparison, thereby improving the accuracy of judging abnormal furnace temperature through a composite detection method.

[0037] The detection method of the present application also includes setting a stream thermal camera 5 at the melt outlet of the furnace body 1 to detect the temperature of the melt when it flows out. Once the stream temperature exceeds the set standard temperature range, it means that the melt temperature is unqualified, and an alarm signal is triggered to remind the staff to adjust the temperature in the electric furnace, thereby effectively ensuring the quality of the melt. In this embodiment, the stream thermal camera uses a Fluke temperature measuring instrument that irradiates the melt.

[0038] Embodiment 2

[0039] In another typical embodiment of the present application, a composite detection method for the temperature of an electric furnace wall is provided. The composite detection system for the temperature of an electric furnace wall of the present application includes the following steps:

[0040] The furnace temperature, high temperature image, temperature outside the furnace wall in each area of ​​the electric furnace and melt temperature at the furnace outlet are collected respectively, and the sampled temperatures are sent to the PLC controller;

[0041] When the sampled temperature exceeds the set temperature threshold, the display will trigger a local alarm signal and the abnormal temperature information will be fed back to the PLC controller;

[0042] When the temperature feedback from one detection state is abnormal, the PLC controller automatically matches other temperature information collected at the same location and displays it on the monitoring system; if the temperature feedback from two or more detection states is abnormal, the electric furnace alarm device will be immediately triggered.

[0043] Specifically, in the background program of the PLC controller, the temperature signals obtained by multiple detection devices are distributed, and the video image signals are connected to the production monitoring system. The real video images inside the furnace can be retrieved in real time, thereby guiding the temperature control of the electric furnace.

[0044] All sampling temperatures have preset upper and lower limits. Once the upper limit is exceeded or the lower limit is lower than, an alarm signal will be triggered and the abnormal status will be fed back to the operator via text information.

[0045] The alarm device can be an alarm light to remind everyone to pay attention to the abnormality of a certain location. At the same time, the real-time monitoring screen in the production monitoring system will give priority to the abnormal location to facilitate the operation of the operator. The alarm cannot be eliminated manually. The temperature must be controlled within the preset range, and all alarms can be eliminated.

[0046] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A composite detection system for the temperature of an electric furnace wall, characterized in that: It includes an electric furnace, a thermocouple, a high-temperature camera and an infrared thermal imager. A plurality of the thermocouples are evenly arranged on the inner side of the furnace wall of the electric furnace, and the thermocouples are connected to a PLC controller; the high-temperature camera is arranged on the furnace wall of the electric furnace, and extends from the outer side of the furnace wall to the inner side for shooting; a plurality of the infrared thermal imagers are evenly arranged on the outer side of the electric furnace along the circumferential direction of the electric furnace, and are used to detect the furnace wall temperature of each area of ​​the electric furnace.

2. A composite detection system for the temperature of an electric furnace wall as claimed in claim 1, characterized in that: The high temperature camera is connected to the cooling pipeline of the electric furnace.

3. A composite detection system for the temperature of an electric furnace wall as claimed in claim 1, characterized in that: The high-temperature cameras include a plurality of cameras, which are arranged at the upper part of the electric furnace, extend into the furnace, and are evenly distributed along the circumference of the furnace wall.

4. A composite detection system for the temperature of an electric furnace wall as claimed in claim 1, characterized in that: The electric furnace is formed by splicing steel plates, and the side walls of the electric furnace are processed with mounting holes for mounting thermocouples and high-temperature cameras.

5. The composite detection system for the temperature of an electric furnace wall according to claim 1, characterized in that: It also includes a PLC controller, and the thermocouple, high-temperature camera and infrared thermal imager are all connected to the PLC controller.

6. A composite detection system for the temperature of an electric furnace wall as claimed in claim 5, characterized in that: The PLC controller is connected to the monitoring system and the alarm device.

7. A composite detection system for the temperature of an electric furnace wall as claimed in claim 1, characterized in that: Multiple infrared thermal imagers are installed at the same height, and the infrared thermal imager is installed at half the height of the electric furnace.

8. The composite detection system for the temperature of an electric furnace wall according to claim 1, characterized in that: It also includes a stream thermal camera, which is arranged at the outlet of the electric furnace.

9. A composite detection system for the temperature of an electric furnace wall as claimed in claim 1, characterized in that: The stream thermal camera is connected to the PLC controller.

10. A composite detection method for the temperature of an electric furnace wall, based on a composite detection system for the temperature of an electric furnace wall as claimed in any one of claims 1 to 9, characterized in that: The steps include: The furnace temperature, high temperature image, temperature outside the furnace wall in each area of ​​the electric furnace and melt temperature at the furnace outlet are collected respectively, and the sampled temperatures are sent to the PLC controller; When the sampled temperature exceeds the set temperature threshold, the display will trigger a local alarm signal and the abnormal temperature information will be fed back to the PLC controller; When the temperature feedback from one detection state is abnormal, the PLC controller automatically matches other temperature information collected at the same location and displays it on the monitoring system; if the temperature feedback from two or more detection states is abnormal, the electric furnace alarm device will be immediately triggered.

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