A non-contact material surface detection device

Abstract

A non-contact material surface detection device comprises a remote control component, an auxiliary adjustment component, and a mounting frame component, a guide rail component and a sensor component arranged on a material furnace. The present invention reasonably designs the structure and can adjust the sensor unit to be perpendicular to the ideal material surface state through the auxiliary adjustment component for signal collection, so as to improve the collection accuracy of the material surface and the material level; the whole sensor component is driven to move by a slider, so that a single fixed point signal collected by a single sensor can be converted into a curved surface signal of the whole material surface collected by multiple sensors, thereby greatly improving the accuracy and collection efficiency of material surface detection, and at the same time, the number of sensor units can be arbitrarily expanded according to the actual detection surface requirements. At the same time, the device adopts a non-contact detection method, which can realize the detection of material surfaces in harsh conditions such as high positions and oil stains, and has significant advantages such as safety, high efficiency and high detection accuracy.

Description

Technical Field

[0001] The invention relates to the technical field of material surface detection, in particular to a non-contact material surface detection device. Background Art

[0002] With the development of industrial technology, many factories will detect the process of material level descent during material unloading. However, during the mineral unloading process, due to equipment installation and dust and other reasons, it is impossible to detect the change of material level in the furnace and the height of the dropped material level in real time. It can only be observed visually, and relevant test data cannot be accurately obtained, which brings difficulties to the design and production guidance.

[0003] The process of many materials falling is accompanied by harsh environments such as high temperature, high pressure, and oil pollution. At present, the methods of material surface detection can be mainly divided into contact detection and non-contact detection. Among them, contact detection can be divided into mechanical probe measurement and industrial endoscope detection. The mechanical probe measurement method has the characteristics of simple operation and high detection accuracy, but the probe needs to contact the material surface during measurement, and can only obtain the material surface height of a single point, and the information of the entire material surface is very limited. Industrial endoscope detection can obtain image information of the entire material surface, but it is greatly affected by the detection environment. At the same time, various endoscope detections cannot detect the material level height of the material surface in real time, and can only capture the outline of the material surface. LiDAR has high measurement accuracy, can realize non-contact measurement, and has high stability and strong anti-interference ability, but can only obtain the material surface height of a single point, and cannot ensure that the LiDAR sensor is parallel when installed, which affects the verticality of the contact between the laser and the material surface, causing measurement errors.

[0004] Therefore, the traditional measurement method has low efficiency in measuring the material surface shape and material surface height and cannot measure in real time. Therefore, it is necessary to provide a new technical solution to improve the accuracy of detection. Invention Technology

[0005] The technical purpose of the present invention is to provide a non-contact material surface detection device with a simple structure and easy use. The device can reasonably design the structure and adjust the sensor unit to be perpendicular to the ideal material surface state for signal collection through an auxiliary adjustment component to improve the collection accuracy of the material surface and the material level; the slider drives the entire sensor assembly to move, so that the single fixed point signal collected by a single sensor can be converted into a curved surface signal of the entire material surface collected by multiple sensors, thereby greatly improving the accuracy and collection efficiency of material surface detection. At the same time, the number of sensor units can be arbitrarily expanded according to the actual detection surface requirements. At the same time, the device adopts a non-contact detection method, which can realize the detection of material surfaces in harsh conditions such as high positions and oil stains, and has significant advantages such as safety, high efficiency, and high detection accuracy.

[0006] In order to solve the above technical problems, the technical solution adopted by the present invention is: a non-contact material surface detection device, including a remote control component, an auxiliary adjustment component, and a mounting frame component, a guide rail component and a sensor component arranged on the material furnace. The mounting frame component is horizontally fixed on the top of the material furnace and is used to fix and support the guide rail component and the sensor component. The guide rail component includes a linear guide rail, a motor and a slider. The linear guide rail is horizontally erected directly above the material furnace through the mounting frame component, and the slider can move back and forth along the linear guide rail under the drive of the motor;

[0007] The sensor assembly is composed of a sensor bracket, a support wheel unit and a plurality of sensor units. The sensor bracket is in the form of an elongated structure. The elongated sensor bracket is fixed on the slider of the guide rail assembly and is arranged perpendicular to the linear guide rail. The plurality of sensor units are distributed along the length direction of the sensor bracket and can be detachably installed on the sensor bracket. Each sensor unit includes a laser radar sensor, a signal converter, an angle adjuster and a sensor fixing plate. The sensor fixing plate is in the form of an L-shaped structure. The top of the L-shaped structure is fixed to the sensor bracket through a fixing plate connector and a positioning screw. The upper plane of the L-shaped structure is used to install the laser radar sensor. The signal converter is fixed on the back side of the laser radar sensor. An angle adjuster for adjusting the horizontality of the laser radar sensor is also provided at the bottom of the laser radar sensor. The two ends of the sensor bracket in the length direction are respectively slidably arranged in a preset horizontal slot on the mounting frame assembly through a support wheel unit, so that the slider can drive the entire sensor assembly to move back and forth in the linear guide rail and the horizontal slot, so as to realize the continuous signal collection of the material surface in the furnace by the sensor assembly.

[0008] The auxiliary adjustment component is detachably arranged on the outside of the sensor unit to assist in adjusting the horizontality of the sensor unit. The auxiliary adjustment component includes a vertically arranged adjustment bracket plate, a horizontally arranged adjustment positioning plate, a left wing, a right wing, a spring unit, a level bubble and two spirit levels. The adjustment bracket plate and the adjustment positioning plate are connected at the ends to jointly form an L-shaped structure with an opening downward. The level bubble is installed at the center of the upper surface of the adjustment positioning plate. The two spirit levels are fixed on two adjacent sides of the adjustment positioning plate. The left wing and the right wing are symmetrically arranged on both sides of the adjustment bracket plate, and the left wing and the right wing are connected by a spring unit installed inside the adjustment bracket plate. After the lower surface of the adjustment positioning plate is in contact with the upper surface of the laser radar sensor, the left wing, the right wing and the adjustment bracket plate can be clamped and fitted on the three side walls of the laser radar sensor to assist in adjusting the horizontality of the sensor unit through the level bubble and the two spirit levels.

[0009] The remote control component is electrically connected to the signal converter and is used for modeling and processing data to detect the material surface condition.

[0010] Furthermore, the mounting frame assembly consists of a fixed bracket and two slot plates. The fixed bracket includes a rectangular support frame horizontally fixed on the top of the furnace and bracket side panels surrounding the rectangular support frame. A guide rail positioning groove for fixing the linear guide rail is provided at the top center of the bracket side panel, and a slot plate for vertically limiting the two ends of the sensor bracket is installed on the inner side wall of the bracket side panel.

[0011] Furthermore, the support wheel unit includes a connecting plate, a connecting shaft, a bearing and a support wheel. The connecting plate is fixed to the end of the sensor bracket, the connecting shaft is vertically fixed to the connecting plate, the bearing and the support wheel are sequentially mounted on the connecting shaft from the inside to the outside, and the support wheel is clamped in the horizontal slot in the slot plate.

[0012] Furthermore, the guide rail assembly also includes two limit units installed on the linear guide rail, and the two limit units are respectively installed at both ends of the linear guide rail in the length direction, and are used to limit the stroke of the slider to the left and right.

[0013] Furthermore, the sensor bracket includes a bracket body, a sensor positioning groove and a bracket fixing plate. The bracket body is a long strip structure. The sensor positioning groove is opened along the length direction of the bracket body. The sensor positioning groove can cooperate with the fixing plate connecting piece at the top of the sensor fixing plate, so that the sensor fixing plate can be fixed on the bracket body by positioning screws. The bracket fixing plate is arranged in the middle part of the bracket body, and the upper part of the bracket fixing plate is used to connect the slider.

[0014] Furthermore, the sensor positioning groove is provided on the upper surface of the bracket body, and the fixing plate connecting piece is in an inverted T-shaped structure.

[0015] Furthermore, a fixing hole is vertically opened on the fixing plate connecting member, and the cooperation between the fixing hole and the positioning screw can realize the fixation of the sensor unit on the sensor bracket.

[0016] Furthermore, the angle adjuster includes a mounting plate and at least three angle adjustment units evenly arranged along the circumference of the mounting plate. The mounting plate is horizontally arranged on the sensor fixing plate, and the laser radar sensor is fixed on the upper surface of the mounting plate. Each angle adjustment unit includes an adjustment screw and three regulating nuts. The adjustment screw is vertically passed through the mounting plate, and its lower end is fixed to the sensor fixing plate through an regulating nut. The other two regulating nuts are both sleeved on the adjustment screw and are respectively located on the upper surface and lower surface of the mounting plate, and are used to adjust the verticality of the laser emitted by the laser radar sensor.

[0017] Furthermore, the laser radar sensor and signal converter are both connected to an external power supply battery, and the motor is connected to a remote control component.

[0018] Furthermore, the remote control component includes a computer and a data receiver. The data receiver is set on the computer and is communicatively connected to the signal converter. The computer models the data through the NURBS surface algorithm to form a 3D material surface to reflect the material surface condition. Beneficial effects:

[0019] 1. The non-contact material surface detection device of the present invention has a simple structure, reasonable design and is easy to use. The device can reasonably design the structure, and can adjust the sensor unit to be perpendicular to the ideal material surface state through the auxiliary adjustment component to collect signals, so as to improve the collection accuracy of the material surface and material level; the slider drives the entire sensor component to move, so that the single fixed point signal collected by a single sensor can be converted into a curved surface signal collected by multiple sensors on the entire material surface, thereby greatly improving the accuracy and collection efficiency of material surface detection.

[0020] 2. A non-contact material surface detection device of the present invention can arbitrarily expand the number of sensor units in the sensor assembly according to actual production conditions and detection requirements. At the same time, the device adopts a non-contact detection method, which can realize the detection of material surfaces in harsh conditions such as high positions, oily pollution, and toxicity. It has significant advantages such as safety, high efficiency, and high detection accuracy.

[0021] 3. A non-contact material surface detection device of the present invention can adjust the acquisition frequency of each sensor unit, cooperate with the slider to drive the entire sensor assembly to move, a single sensor unit can collect N data in one acquisition cycle, and the N data can be fitted into a curve using a curve fitting algorithm, and then the data collected by multiple sensor units are fitted into multiple curves through a surface fitting algorithm, and finally multiple curves are generated into a surface through a surface fitting algorithm, and the material level height of the material surface can also be displayed. The detection device can set the acquisition cycle, number of sensor units, sensor unit position, and slider movement speed of different sensor units according to the working conditions to generate material surface shapes with different accuracies.

[0022] 4. A non-contact material surface detection device of the present invention can present important information such as material surface shape, material level height difference, average flow rate, material surface changes in each stage, etc. on the computer in real time, which can guide actual production and design and improve the structure of the material furnace. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is a structural schematic diagram of the present invention; Figure 2 It is a schematic diagram of the structure of the installation frame assembly; Figure 3 is a schematic diagram of the structure of the guide rail assembly; Figure 4 It is a structural schematic diagram of the support wheel unit; Figure 5 It is a structural schematic diagram of the sensor bracket; Figure 6 is a schematic diagram of the structure of the sensor unit; Figure 7 A schematic diagram of the structure of the auxiliary adjustment component; Figure 8 It is a NURBS surface fitting flow chart; 1. Material furnace, 2. Fixed bracket, 21. Rectangular support frame, 22. Bracket side plate, 23. Guide rail positioning groove, 3. Slot plate, 4. Guide rail assembly, 41. Motor, 42. Limit unit, 43. Linear guide, 44. Slider, 5. Support wheel unit, 51. Connecting plate, 52. Connecting shaft, 53. Bearing, 54. Support wheel, 6. Sensor bracket, 61. Sensor positioning groove, 62. Positioning screw, 63. Bracket fixing plate, 64. Bracket body, 7. Sensor unit, 71. LiDAR sensor, 72. Signal converter, 73. Angle adjuster, 74. Sensor fixing plate, 75. Fixing plate connector, 76. Fixing hole, 8. Auxiliary adjustment assembly, 81. Left wing, 82. Adjust bracket plate, 83. Spring unit, 84. Right wing, 85. Adjust positioning plate, 86. Level bubble, 87. Level, 9. Data receiver, 10. Computer, 11. Power supply battery. DETAILED DESCRIPTION

[0024] In order to enable those skilled in the art to better understand the scheme of the present invention, the technical scheme in the embodiments of the present invention is clearly and completely described below in conjunction with the accompanying drawings and specific implementation methods. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments in the 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.

[0025] It should be noted that, unless otherwise defined, the technical terms or scientific terms used herein shall have the usual meanings understood by persons with ordinary skills in the field to which the invention belongs. The words "one", "an" or "the" and the like used in the patent application specification and claims of the present invention do not express quantitative limitations, but indicate the existence of at least one. Words such as "include" or "comprise" indicate that the elements or objects appearing before "include" or "comprises" include the elements or objects listed after "include" or "comprises" and their equivalents, but do not exclude other elements or objects with the same function.

[0026] like Figure 1As shown, a non-contact material surface detection device of the present invention includes a remote control component, an auxiliary adjustment component 8, and a mounting frame component, a guide rail component 4 and a sensor component arranged on the material furnace 1.

[0027] The mounting frame assembly is fixed horizontally on the top of the furnace 1, and is used to fix and support the guide rail assembly 4 and the sensor assembly. The mounting frame assembly is composed of a fixed bracket 2 and two slot plates 3. The fixed bracket 2 includes a rectangular support frame 21 fixed horizontally on the top of the furnace 1 and a bracket side plate 22 arranged around the rectangular support frame 21. A guide rail positioning groove 23 for fixing the linear guide rail 43 is set at the top center of the bracket side plate 22, and a slot plate 3 for vertically limiting the two ends of the sensor bracket 6 is installed on the inner side wall of the bracket side plate 22. That is, the rectangular support frame 21 is fixed on the furnace 1 to support the entire set of detection devices, the bracket side plate 22 is used to fix the slot plate 3 to ensure the flatness of the sensor assembly during the detection process, and the guide rail positioning groove 23 is used to accurately position the linear guide rail 4.

[0028] The guide rail assembly 4 includes a linear guide rail 43, a motor 41, a slider 44 and two limit units 42 installed on the linear guide rail 43. The linear guide rail 43 is horizontally mounted directly above the furnace 1 through the guide rail positioning groove 23 in the mounting frame assembly. The slider 44 can move back and forth along the linear guide rail 43 driven by the motor 41. The two limit units 42 are respectively installed at both ends of the linear guide rail 43 in the length direction, and are used to limit the stroke of the slider 44 to the left and right to ensure that the detection area is consistent during the entire detection process.

[0029] The sensor assembly is composed of a sensor bracket 6, a support wheel unit 5 and a plurality of sensor units 7. The sensor bracket 6 is in a long strip structure, which is fixed on the slider 44 of the guide rail assembly 4 and is arranged perpendicular to the linear guide rail 43. The sensor bracket 6 includes a bracket body 64, a sensor positioning groove 61 and a bracket fixing plate 63. The bracket body 64 is in a long strip structure, and the sensor positioning groove 61 is opened along the length direction of the bracket body 64. The sensor positioning groove 61 can cooperate with the fixing plate connector 75 at the top of the sensor fixing plate 74, so that the sensor fixing plate 74 can be fixed on the bracket body 64 through the positioning screw 62. The bracket fixing plate 63 is arranged in the middle of the bracket body 64, and the upper part of the bracket fixing plate 63 is used to connect the slider 44. The sensor positioning groove 61 is opened on the upper surface of the bracket body 64, and the fixing plate connector 75 is in an inverted T-shaped structure. The fixing plate connector 75 on the sensor unit 7 is fixed in the sensor positioning slot 61 on the sensor bracket 6, so that the position of the sensor can be accurately adjusted and the sensor unit 7 can be quickly disassembled and assembled. The number of sensor units can also be quickly adjusted. The relative positions of multiple sensor units 7 on the sensor bracket 6 are fixed by fixing holes 76 and positioning screws 62, so that the distance between any two sensor units 7 can be changed at will, and the number of sensors can also be changed at will.

[0030] A plurality of sensor units 7 are distributed along the length direction of the sensor bracket 6 and can be detachably mounted on the sensor bracket 6. Each sensor unit 7 includes a laser radar sensor 71, a signal converter 72, an angle adjuster 73 and a sensor fixing plate 74. The sensor fixing plate 74 is an L-shaped structure. The top of the L-shaped structure is fixed to the sensor bracket 6 through a fixing plate connector 75 and a positioning screw 62. The upper plane of the L-shaped structure is used to install the laser radar sensor 71. The signal converter 72 is fixed to the back side of the laser radar sensor 71. An angle adjuster 73 for adjusting the horizontality of the laser radar sensor 71 is also provided at the bottom of the laser radar sensor 71. The two ends of the frame 6 in the length direction are respectively slidably arranged in the preset horizontal slots on the mounting frame assembly through a support wheel unit 5, so that the slider 44 can drive the entire sensor assembly to move back and forth in the linear guide 43 and the horizontal slot, so as to realize the continuous signal collection of the material surface in the material furnace 1 by the sensor assembly; the support wheel unit 5 includes a connecting plate 51, a connecting shaft 52, a bearing 53 and a support wheel 54, the connecting plate 51 is fixed to the end of the sensor bracket 6, the connecting shaft 52 is vertically fixed on the connecting plate 51, the bearing 53 and the support wheel 54 are sequentially sleeved on the connecting shaft 52 from the inside to the outside, and the support wheel 54 is clamped in the horizontal slot in the slot plate 3, and the bearing 53 is a deep groove ball bearing. In the support wheel unit 5, a bearing 53 is sleeved on the connecting shaft 52, and a support wheel 54 is sleeved on the bearing 53, which can reduce the rotation resistance of the support wheel 54, and the support wheel 54 is installed on the slot plate 3, which can limit the movement trajectory of the support wheel 54, so as to ensure that the sensor bracket 6 does not deform during detection, thereby ensuring the detection accuracy.

[0031] The fixing plate connector 75 is vertically provided with a fixing hole 76, and the fixing hole 76 cooperates with the positioning screw 62 to realize the fixation of the sensor unit 7 on the sensor bracket 6. The angle adjuster 73 includes a mounting plate and at least three angle adjustment units evenly arranged along the circumference of the mounting plate. The mounting plate is horizontally arranged on the sensor fixing plate 74, and the laser radar sensor 71 is fixed on the upper surface of the mounting plate. Each angle adjustment unit includes an adjustment screw and three regulating nuts. The adjustment screw is vertically penetrated on the mounting plate, and its lower end is fixed on the sensor fixing plate 74 through an adjusting nut. The other two regulating nuts are both sleeved on the adjustment screw and are respectively located on the upper and lower surfaces of the mounting plate, and are used to adjust the verticality of the laser emitted by the laser radar sensor 71. The laser radar sensor 71 and the signal converter 72 are both connected to the external power supply battery 11, and the motor 41 is connected to the remote control component. The laser radar sensor 71 can be accurately positioned through the angle adjuster 73 at its bottom to improve the detection accuracy. The signal converter 72 is fixed on the back of the laser radar sensor 71, which can realize the conversion of the collected signal and ensure that the collected data is not lost.

[0032] The auxiliary adjustment component 8 is detachably arranged on the outside of the sensor unit 7, and is used to assist in adjusting the horizontality of the sensor unit 7. The auxiliary adjustment component 8 includes a vertically arranged adjustment bracket plate 82, a horizontally arranged adjustment positioning plate 85, a left wing 81, a right wing 84, a spring unit 83, a level bubble 86 and two spirit levels 87. The adjustment bracket plate 82 and the adjustment positioning plate 85 are connected at the ends to jointly form an L-shaped structure with an opening downward, that is, the adjustment bracket plate 82 is vertically connected to the positioning plate 85, the level bubble 86 is installed at the center of the upper surface of the adjustment positioning plate 85, and is used to coarsely adjust the position accuracy of the sensor unit 7. The two spirit levels 87 are fixed on two adjacent sides of the adjustment positioning plate 85, and are used to fine-tune the position accuracy of the sensor unit 7. The left wing 81 and the right wing 84 are symmetrically arranged on both sides of the adjustment bracket plate 82, and the left wing 81 and the right wing 84 are connected by a spring unit 83 installed inside the adjustment bracket plate 82, so that the lower surface of the adjustment positioning plate 85 is in contact with the upper surface of the laser radar sensor 71, and the left wing 81, the right wing 84 and the adjustment bracket plate 82 can be clamped and fitted on the three side walls of the laser radar sensor 71, so as to assist in adjusting the horizontality of the sensor unit 7 through the level bubble 86 and the two level gauges 87. That is, the left wing 81 and the right wing 84 are fixed on both sides of the adjustment bracket plate 82, and the left and right sides of the sensor unit 7 can be clamped in cooperation with the spring unit 83, and the positioning plate 85 can be tightly fitted on the upper surface of the sensor unit 7 to maintain the position accuracy of the sensor.

[0033] The remote control component includes a computer 10 and a data receiver 9. The data receiver 9 is arranged on the computer 10 and is in communication connection with the signal converter 72. The computer 10 models the data through the NURBS surface algorithm to form a 3D material surface to reflect the material surface condition. The data receiver 9 is used to receive the data collected by the sensor unit 7. The computer 10 converts the material surface height data of each point into the control point data of the NURBS surface through marking and feature setting, and reconstructs the material surface shape grid model by combining the three-dimensional visualization modeling technology of the interpolation NURBS surface. The morphological structure of the material surface shape model finally constructed has high precision and strong sense of reality. The power supply battery 11 is mainly used to power the sensor unit 7. Example 1

[0034] A non-contact material surface detection device of this embodiment includes a guide rail assembly 4, a support wheel unit 5, a sensor unit 7, an auxiliary adjustment assembly 8, etc. installed on the material furnace 1. The guide rail assembly 4 is fixed to the guide rail positioning groove 23 on the fixed bracket 2 and driven by the motor 41. It can drive the sensor bracket 6 to make linear motion, and can accurately measure the measurement range of the sensor unit 7. The support wheel unit 5 is fixed at both ends of the sensor bracket 6 and installed on the card slot plate 3, which can ensure that the sensor bracket 6 is not deformed by the gravity of multiple sensor units 7, so as to improve the acquisition accuracy of the laser radar sensor 71. The sensor bracket 6 can arbitrarily expand the number of sensor units 7 installed thereon according to the detection working conditions to achieve accurate detection.

[0035] The auxiliary adjustment component 8 can be used to adjust the vertical accuracy of the sensor unit 7 relative to the material surface, ensuring that the data collected by the sensor unit 7 is more accurate. The computer 10 processes the collected data in real time, and presents important information such as the material surface shape, material level difference, average flow rate, and material surface changes in each stage in real time. It can also perform post-processing analysis on the collected data, view the entire video of the material surface shape changes, and guide actual production as well as design and improve the structure of the material furnace.

[0036] In the specific structure of the detection device of this embodiment, the fixed bracket 2 includes a rectangular support frame 21, a bracket side plate 22 and a guide rail positioning groove 23. The guide rail positioning groove 23 is located at the center position directly above the fixed bracket 2. The guide rail assembly 4 is installed in the guide rail positioning groove 23 on the fixed bracket 2, which can realize precise positioning of the guide rail assembly 4 and ensure the stability of the sensor unit 7 during the collection process. The rectangular support frame 21 is fixed on the material furnace 1 to support the entire detection device. During inspection, it is only necessary to fix the entire non-contact material surface detection system directly above the material furnace 1.

[0037] In the specific structure of the detection device of this embodiment, the guide rail assembly 4 includes a motor 41, a limit unit 42, a linear guide 43 and a slider 44. The two limit units 42 are used to limit the position of the slider 44 to ensure that the detection area is consistent during the entire detection process. When detecting material surfaces under different working conditions, the area of ​​the detection area can be changed by adjusting the positions of the two limit units 42. The motor 41 is a servo motor with high control accuracy. By changing the speed of the motor 41, the moving speed of the sensor unit 7 can be changed, thereby changing the acquisition frequency of the laser radar sensor 71.

[0038] In the specific structure of the detection device of this embodiment, the support wheel unit 5 includes a connecting plate 51, a connecting shaft 52, a bearing 53 and a support wheel 54. The support wheel unit 5 is fixed to both sides of the sensor bracket 6 by screws, which can be quickly disassembled and assembled, and is convenient for any expansion of the sensor unit 7. The connecting plate 51 is fixed to the end of the sensor bracket 6 and is connected to the connecting shaft 52. The connecting shaft 52 is sleeved with a bearing 53, and the bearing 53 is sleeved with a support wheel 54 to reduce the rotation resistance of the support wheel 54. The support wheel 54 is installed on the card slot plate 3 to limit the movement trajectory of the support wheel 54, to ensure that the sensor bracket 6 does not deform during detection, thereby ensuring the detection accuracy.

[0039] In the specific structure of the detection device of this embodiment, the sensor unit 7 includes a laser radar sensor 71, a signal converter 72, an angle adjuster 73, a sensor fixing plate 74, a fixing plate connector 75 and a fixing hole 76. The laser radar sensor 71 can be accurately positioned on the sensor fixing plate 74 through the angle adjuster 73 to improve the detection accuracy. The laser radar sensor 71 has an accuracy of 2mm, an applicable temperature of -30℃~70℃, a power supply voltage of 3.7V, a power consumption of less than 0.6w, a weight of only 10g, and outputs a TTL signal. The signal converter 72 is fixed on the back of the laser radar sensor 71, and can convert the TTL signal output by the laser radar sensor 71 into an RS485 signal, thereby enhancing the transmission capability and stability of the signal and ensuring that the collected data is not lost.

[0040] In the specific structure of the detection device of this embodiment, the fixing plate connecting member 75 is fixed in the sensor bracket 6, so that the sensor unit 7 can be freely moved and adjusted and quickly disassembled and assembled on the sensor bracket 6, and the number of sensor units 7 can be quickly expanded and the distance between any two sensor units 7 can be freely changed. The relative position of the sensor unit 7 on the sensor bracket 6 is fixed by the fixing hole 76 and the positioning screw 62. The sensor bracket 6 is fixed on the slider 44 through the bracket fixing plate 63. The two sides of the sensor bracket 6 are connected to the supporting wheel unit 5, and the supporting wheel unit 5 is installed in the card slot plate 3 to ensure that the sensor bracket 6 does not deform during the detection process. At the same time, the linear motion of the sensor unit 7 can be realized under the drive of the guide rail assembly 4, and the supporting wheel unit 5 can greatly reduce the resistance and deformation of the movement of the sensor bracket 6.

[0041] In the specific structure of the detection device of this embodiment, the auxiliary adjustment component 8 includes a left wing 81, an adjustment bracket plate 82, a spring unit 83, a right wing 84, an adjustment positioning plate 85, a level bubble 86, and a level 87. The left wing 81 and the right wing 84 are fixed on both sides of the adjustment bracket plate 82 to cooperate with the spring unit 83. When installing the sensor unit 7, it is necessary to pull the left wing 81 and the right wing 84 of the auxiliary adjustment component 8 apart, clamp the left and right sides of the sensor unit 7, and fit the top of the laser radar sensor 71 tightly with the adjustment positioning plate 85. The adjustment bracket plate 82 is vertically connected to the positioning plate 85 to ensure the position accuracy of the sensor. The angle adjuster set at the bottom of the rotating sensor unit 7, the angle adjuster 73 includes a mounting plate and at least three angle adjustment units evenly arranged along the circumference of the mounting plate, the mounting plate is horizontally arranged on the sensor fixing plate 74, and each angle adjustment unit is composed of an adjustment screw and 3 regulating nuts. The bottom regulating nut is used to connect the sensor fixing plate 74 with the sensor unit 7, and the two upper regulating nuts are used to adjust the verticality between the laser emitted by the laser radar sensor 71 and the material surface.

[0042] In the specific structure of the detection device of this embodiment, the level bubble 86 is installed directly above the adjustment positioning plate 85 for coarsely adjusting the position accuracy of the sensor unit 7, and the level 87 is fixed on the edges of both sides of the adjustment positioning plate 85 for finely adjusting the position accuracy of the sensor unit 7.

[0043] The adjustment process of the sensor unit 7 is as follows: first install the sensor unit 7 on the sensor bracket 6, and when it is adjusted to the appropriate position on the sensor positioning groove 61, lock the fixing hole 76 by the positioning screw 62 to complete the position fixation of each sensor unit 7, pull the left and right wings 81 and 84 of the auxiliary adjustment assembly 8 apart to clamp the left and right sides of the sensor unit 7, and fit the top of the lidar sensor 71 tightly against the adjustment positioning plate 85, rotate the top two adjustment nuts of the three angle adjustment units to move the bubble in the level bubble 86 to the relative middle position of the level bubble 86, and complete the coarse adjustment of the position accuracy of the sensor unit 7, continue to rotate the top two adjustment nuts of the three angle adjustment units, observe the bubbles in the two spirit levels 87, and adjust the bubbles in the two spirit levels 87 to between the two scale lines on the spirit level 87 to complete the fine adjustment of the position of the sensor unit 7. After the adjustment is completed, lock the angle adjuster 73, remove the auxiliary adjustment assembly 8, and install it on another sensor unit 7 for adjustment. Repeat this process to complete the position accuracy adjustment of all sensor units 7.

[0044] In the specific structure of the detection device of this embodiment, the data receiver 9 transmits the received RS485 to the software written in LabVIEW in the laptop computer. The software can perform mathematical modeling on the input signal, apply the curve fitting algorithm to the point signal obtained by each laser radar sensor 71 to generate a curve, and then apply the surface fitting algorithm to the curve generated by each laser radar sensor 71 to generate a surface.

[0045] The surface fitting process is as follows: (1) 1NURBS surface model construction NURBS surface can be considered as a control mesh constructed by multiple NURBS curves in u and v directions. The control mesh is built by (m+1)(n+1) control points. Therefore, the material surface shape model can be accurately constructed. NURBS surface of r order in u direction and s order in v direction (rs order) can be expressed as follows: From the above formula, we can see that q i,j is the control point column of the NURBS surface, forming a topological rectangular array of control vertex grids with n rows and m columns, w i,j is the weight factor corresponding to the control vertex of the NURBS surface, and the four vertices are defined as positive values. u is the u-direction parameter variable, where v is the v-directional parameter variable, where N i,r (u) and N j,s (v) are all basis functions, U = [u0,u1,...,u n+2r ] and V=[v0,v1,...,v n+2s ] are the node vectors in the U and V directions respectively.

[0046] 2. Interpolation NURBS surface reconstruction model The node vector calculation controls the (m+1)(n+1) data points of the grid {S i,j}, where i = 0, 1, ..., m; j = 0, 1, ..., n reconstructs the rs-order interpolation surface as Calculate from the given data points The node vectors U and V in the u and v directions are obtained. The cumulative chord length parameterization method is used to calculate the parameter node vectors in the u direction. for d is the total chord length of each NURBS curve in the u direction. The average value of each node

[0047] 3. Control point back calculation For the unobtained control point q i,j , Formula 2 can be changed to: Use the isoparametric lines in the v direction to control point R i (v j ) replaces the control point in the u direction as: By obtaining the material level information and the entire material surface shape, important information such as material surface shape, material level height difference, average flow rate, material surface changes at each stage, etc. can be presented on the computer in real time, which can guide actual production and design and improve the structure of the material furnace.

[0048] The working principle of this scheme is as follows: when using the hardware installation of the material surface detection system, place the entire fixed bracket 2 on the material furnace 1 to be detected, and adjust the fixed bracket 2 to a horizontal state, adjust the position of the two limit units 42 in the guide rail assembly 4 on the linear guide rail 43 to limit the position of the slider 44 to ensure that the detection area is consistent throughout the entire detection process. The fixed plate connector 75 of the sensor unit 7 is fixed in the sensor bracket 6. Different numbers of sensor units 7 can be installed according to the working conditions, and the relative position of the sensor unit 7 on the sensor bracket 6 is fixed by the fixing hole 76 and the positioning screw 62. Pull the left guard 81 and the right guard 84 of the auxiliary adjustment component 8 apart to clamp the left and right sides of the sensor unit 7, fit the top of the lidar sensor 71 tightly against the adjustment positioning plate 85, turn the two top adjustment nuts of the three angle adjustment units to move the bubble in the level bubble 86 to a position relatively to the middle of the level bubble 86, and complete the coarse adjustment of the position accuracy of the sensor unit 7, continue to turn the two top adjustment nuts of the three angle adjustment units, observe the bubbles in the two spirit levels 87, adjust the bubbles in the two spirit levels 87 to between the two scale lines on the spirit level 87, and complete the fine adjustment of the position of the sensor unit 7. After the adjustment is completed, lock the angle adjuster 73, remove the auxiliary adjustment component 8, and install it on another sensor unit 7 for adjustment. Repeat this process to complete the position accuracy adjustment of all sensor units.

[0049] The sensor bracket 6 is fixed on the slider 44 through the bracket fixing plate 63. The two sides of the sensor bracket 6 are connected to the support wheel unit 5. The support wheel unit 5 is installed in the card slot plate 3 to ensure that the sensor bracket 6 does not deform during the detection process. At the same time, the linear motion of the sensor unit 7 can be realized under the drive of the guide rail assembly 4. The support wheel unit 5 can greatly reduce the resistance and deformation of the movement of the sensor bracket 6. After the hardware system is installed, open the software interface to turn on the power supply battery 11 for powering the laser radar sensor 71 and the signal converter 72, and connect the guide rail assembly 4 to the power supply for powering the motor 41. Open the material surface detection software on the computer 10, insert the data receiver 9 into the USB3.0 socket on the computer 10, and observe whether each laser radar sensor 71 communicates normally. After the communication is normal, the detection can be started. The slider 44 completes a stroke, and the computer 10 processes it to form a real-time material surface 3D picture and information on average flow rate, material surface height, material surface height difference and average height difference, and automatically save the data file. The frequency of generating the 3D image of the material surface is related to the moving speed of the guide rail assembly 4. After the material unloading is completed, the collection of the entire material unloading process can be completed. Click the End Collection button, and the 3D image of the entire material descent can be played in the post-processing interface as well as the information showing the average flow rate, material surface height, material surface height difference and average height difference. You can also view the 3D images of the material descent at different time periods as well as the information showing the average flow rate, material surface height, material surface height difference and average height difference.

[0050] Matters not covered by the present invention are known technologies.

[0051] The above embodiments are only for illustrating the technical concept and features of the present invention, and their purpose is to enable people familiar with the technology to understand the content of the present invention and implement it accordingly, and they cannot be used to limit the protection scope of the present invention. Any equivalent changes or modifications made according to the spirit of the present invention should be included in the protection scope of the present invention.

Claims

1. A non-contact material surface detection device, comprising a remote control component, an auxiliary adjustment component (8), and a mounting frame component, a guide rail component (4), and a sensor component arranged on a material furnace (1); the mounting frame component is horizontally fixed to the top of the material furnace (1) and is used to fix and support the guide rail component (4) and the sensor component; the guide rail component (4) comprises a linear guide rail (43), a motor (41), and a slider (44); the linear guide rail (43) is horizontally mounted directly above the material furnace (1) through the mounting frame component; the slider (44) can move back and forth along the linear guide rail (43) under the drive of the motor (41); the device is characterized in that: The sensor assembly is composed of a sensor bracket (6), a support wheel unit (5) and a plurality of sensor units (7); the sensor bracket (6) is in the form of an elongated strip; the elongated strip sensor bracket (6) is fixed on a slider (44) of a guide rail assembly (4) and is arranged perpendicular to a linear guide rail (43); the plurality of sensor units (7) are distributed along the length direction of the sensor bracket (6) and are all detachably mounted on the sensor bracket (6); each sensor unit (7) comprises a laser radar sensor (71), a signal converter (72), an angle adjuster (73) and a sensor fixing plate (74); the sensor fixing plate (74) is in the form of an L-shaped structure; the top end of the L-shaped structure is connected to the sensor bracket by a fixing plate connector. (75) and positioning screws (62) are fixed on the sensor bracket (6); the upper plane of the L-shaped structure is used to install the laser radar sensor (71); the signal converter (72) is fixed on the back side of the laser radar sensor (71); an angle adjuster (73) for adjusting the horizontality of the laser radar sensor (71) is also provided at the bottom of the laser radar sensor (71); the two ends of the sensor bracket (6) in the length direction are respectively slidably arranged in a preset horizontal slot on the mounting frame assembly through a supporting wheel unit (5), so that the slider (44) can drive the entire sensor assembly to move back and forth in the linear guide rail (43) and the horizontal slot, so as to realize the continuous signal collection of the material surface in the material furnace (1) by the sensor assembly; The auxiliary adjustment component (8) is detachably arranged on the outside of the sensor unit (7) and is used to assist in adjusting the horizontality of the sensor unit (7). The auxiliary adjustment component (8) comprises a vertically arranged adjustment bracket plate (82), a horizontally arranged adjustment positioning plate (85), a left wing (81), a right wing (84), a spring unit (83), a level bubble (86) and two level gauges (87). The adjustment bracket plate (82) and the adjustment positioning plate (85) are connected at their ends to form an L-shaped structure with an opening downward. The level bubble (86) is installed at the center of the upper surface of the adjustment positioning plate (85). The two level gauges (87) are fixed on the adjustment positioning plate ( 85), on two adjacent left and right sides, a left wing (81) and a right wing (84) are symmetrically arranged on both sides of the adjustment bracket plate (82), and the left wing (81) and the right wing (84) are connected by a spring unit (83) installed inside the adjustment bracket plate (82), so that after the lower surface of the adjustment positioning plate (85) is in contact with the upper surface of the laser radar sensor (71), the left wing (81), the right wing (84) and the adjustment bracket plate (82) can be clamped and fitted on the three side walls of the laser radar sensor (71), so as to assist in adjusting the horizontality of the sensor unit (7) through a level bubble (86) and two level gauges (87); The remote control component is electrically connected to the signal converter (72) and is used for modeling and processing data to detect material surface conditions.

2. A non-contact material surface detection device according to claim 1, characterized in that: The mounting frame assembly is composed of a fixed bracket (2) and two slot plates (3), wherein the fixed bracket (2) comprises a rectangular support frame (21) horizontally fixed to the top of the furnace (1) and bracket side plates (22) arranged around the rectangular support frame (21), a guide rail positioning groove (23) for fixing the linear guide rail (43) is arranged at the top center of the bracket side plate (22), and a slot plate (3) for vertically limiting the two ends of the sensor bracket (6) is installed on the inner side wall of the bracket side plate (22).

3. A non-contact material surface detection device according to claim 2, characterized in that: The support wheel unit (5) comprises a connecting plate (51), a connecting shaft (52), a bearing (53) and a support wheel (54); the connecting plate (51) is fixed to the end of the sensor bracket (6); the connecting shaft (52) is vertically fixed to the connecting plate (51); the bearing (53) and the support wheel (54) are sequentially sleeved on the connecting shaft (52) from the inside to the outside; and the support wheel (54) is clamped in a horizontal clamping groove in the clamping groove plate (3).

4. The non-contact material surface detection device according to claim 1, characterized in that: The guide rail assembly (4) further comprises two limit units (42) mounted on the linear guide rail (43), the two limit units (42) being respectively mounted at two ends of the linear guide rail (43) in the length direction and used to limit the travel of the slider (44) to the left and right.

5. The non-contact material surface detection device according to claim 1, characterized in that: The sensor bracket (6) comprises a bracket body (64), a sensor positioning groove (61) and a bracket fixing plate (63); the bracket body (64) is in a long strip structure; the sensor positioning groove (61) is provided along the length direction of the bracket body (64); the sensor positioning groove (61) can cooperate with a fixing plate connecting member (75) at the top end of the sensor fixing plate (74), so that the sensor fixing plate (74) can be fixed on the bracket body (64) by means of positioning screws (62); the bracket fixing plate (63) is arranged in the middle of the bracket body (64); and the upper part of the bracket fixing plate (63) is used for connecting a slider (44).

6. A non-contact material surface detection device according to claim 5, characterized in that: The sensor positioning groove (61) is formed on the upper surface of the bracket body (64), and the fixing plate connecting member (75) is in an inverted T-shaped structure.

7. A non-contact material surface detection device according to claim 1, 5 or 6, characterized in that: The fixing plate connecting member (75) is vertically provided with a fixing hole (76), and the fixing hole (76) cooperates with the positioning screw (62) to achieve the fixation of the sensor unit (7) on the sensor bracket (6).

8. The non-contact material surface detection device according to claim 1, characterized in that: The angle adjuster (73) comprises a mounting plate and at least three angle adjustment units uniformly arranged along the circumference of the mounting plate, the mounting plate being horizontally arranged on a sensor fixing plate (74), the laser radar sensor (71) being fixed on the upper surface of the mounting plate, each angle adjustment unit comprising an adjustment screw and three regulating nuts, the adjustment screw being vertically passed through the mounting plate, and having its lower end being fixed to the sensor fixing plate (74) via an adjusting nut, the other two regulating nuts being sleeved on the adjustment screw and respectively located on the upper surface and the lower surface of the mounting plate, and being used to adjust the verticality of the laser emitted by the laser radar sensor (71).

9. The non-contact material surface detection device according to claim 1, characterized in that: The laser radar sensor (71) and the signal converter (72) are both connected to an external power supply battery (11), and the motor (41) is connected to a remote control component.

10. The non-contact material surface detection device according to claim 1, characterized in that: The remote control component comprises a computer (10) and a data receiver (9). The data receiver (9) is arranged on the computer (10) and is in communication connection with the signal converter (72). The computer (10) performs modeling processing on the data through a NURBS surface algorithm to form a 3D material surface reflecting the material surface condition.

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