Monitoring and early warning method and system for conditions in semi-closed submerged arc furnace

Abstract

The invention provides a method and a system for monitoring and early warning conditions in a semi-closed submerged arc furnace. According to the in-furnace condition monitoring system for the semi-closed submerged arc furnace, early warning of soft and hard breakage and material collapse of the electrode of the submerged arc furnace is achieved, reliable and effective data support is provided for production of the submerged arc furnace, the in-furnace condition monitoring system can be used for early warning of soft and hard breakage and material collapse of the electrode of the submerged arc furnace, and the overall intelligent level of the submerged arc furnace is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of monitoring and early warning systems, and in particular to a method and system for monitoring and early warning of furnace conditions in a semi-closed ore-fired furnace. Background Art

[0002] Semi-closed submerged arc furnaces are mostly used for smelting silicon alloy products. The reason is that industrial silicon, ferrosilicon, etc. are easily sintered into blocks during the smelting process, and the melting effect between the molten pools inside the furnace is not good. Therefore, the submerged arc furnaces for the corresponding smelting products are mostly designed to be semi-closed, mainly with the furnace cover designed to be hexagonal, of which four sides are designed to have lifting furnace doors, which can be lifted and opened when the furnace surface needs to be tamped, so that the tamping machine arm can be extended to start the tamping work, and the other two sides are designed to be fixed with an exhaust hood on the top. The CO generated during the smelting process reacts with the O2 in the air to generate CO2, which is discharged through the chimney connected to the exhaust hood; in view of the poor melting effect between the molten pools at the bottom of the furnace surface inside the furnace, a rotatable furnace body is designed to run slowly by a single-point drive of a three-in-one reducer.

[0003] The smelting of the submerged arc furnace is a complex chemical reduction reaction in the furnace. At the same time, the intermittent charging of the semi-closed submerged arc furnace causes dust on the upper part of the furnace surface, which makes the furnace condition even more difficult to grasp. The process is hidden and difficult to measure. There is a large amount of ambiguity, randomness and uncertainty. If the operation is improper, material collapse and electrode soft and hard break accidents often occur. These two abnormal events are the most common accidents in the submerged arc furnace, which seriously affect the normal production of the submerged arc furnace. Once an accident occurs, the light one will consume a lot of manpower, financial resources and time; the serious one will damage some equipment of the submerged arc furnace body, and even produce high-temperature flue gas or hot melt spraying out of the furnace, causing burns and scalds to the workers in the dangerous area, the furnace body explosion, etc., with very serious consequences. The submerged arc furnace equipment is expensive, the maintenance work is large, and the economic losses after shutdown are huge. With the evolution of science and technology, equipment maintenance methods have also gradually developed, from passive maintenance to intelligent predictive maintenance, reducing production losses and equipment maintenance costs caused by unplanned downtime. Summary of the invention

[0004] According to the technical problem that the internal production furnace conditions of the ore-heating furnace cannot be accurately grasped, a method and system for monitoring and warning the internal conditions of a semi-closed ore-heating furnace is provided. The present invention proposes a monitoring system for the internal conditions of a semi-closed ore-heating furnace, which realizes the early warning of soft and hard fractures and material collapse of ore-heating furnace electrodes, provides reliable and effective data support for ore-heating furnace production, can be used for early warning of soft and hard fractures and material collapse of ore-heating furnace electrodes, and improves the overall intelligence level of ore-heating furnaces.

[0005] The technical means adopted by the present invention are as follows:

[0006] A method for monitoring and warning the internal condition of a semi-closed ore-fired furnace comprises the following steps:

[0007] S201, after the closed sliding mechanism moves forward and extends, the images of the three electrodes and the material surface in the ore-fired furnace are transmitted from the furnace to the outside of the furnace through the cylindrical lens of the camera, and are gathered on the target surface of the CMOS of the camera;

[0008] S202, the camera uses the DSP double-speed exposure image processing algorithm to perform dynamic range shooting on the target surface of the CMOS, selects clear and normal bright image and dark image to superimpose and synthesize, and outputs an image in which both the bright and dark areas are clearly visible; then the camera converts the color image into a video signal and transmits the video signal to the hard disk recorder through the Ethernet optical fiber and network cable via the network switch;

[0009] S203, the industrial computer reads the color image of the hard disk video recorder in real time via the network switch, and outputs the color image in real time via the HDMI line to display on the liquid crystal display;

[0010] S204, performing feature value extraction and early warning calculation in the industrial computer according to the video signal read in real time;

[0011] S205, using an aperture correction technology on the video signal read in real time to obtain an image with clear edges;

[0012] S206, smoothing the image with clear edges using a 3x3 discrete Gaussian filter to obtain a smoothed filtered image;

[0013] S207, reading the three primary colors R, G, B values ​​of each pixel on the smoothed filtered image;

[0014] S208. Since the semi-enclosed ore-fired furnace contains mostly iron and flame-related materials and uses an infrared camera, the color of the image captured by the video is a red threshold series. The RGB model is used to extract the red component R value, so that the image is changed from a color image to a grayscale image.

[0015] S209, because the grayscale of the electrode and material surface images and the background varies greatly, 8-neighborhood adaptive threshold segmentation is adopted, that is, an 8-neighborhood window centered on each pixel is determined, totaling 9 pixels, and the average value of all pixels in the window is used as the threshold to convert the image into a 0 / 1 binary image with obvious contrast;

[0016] S210, extracting edges of the binary image to obtain characteristic elements related to material collapse and soft or hard fracture of the electrode;

[0017] S211. The characteristic elements corresponding to the abnormal events that have occurred in the production process are stored as historical sample characteristic elements, or the real-time edge characteristic elements extracted by real-time online calculation are compared with the stored historical sample characteristic elements, and the similarity is calculated using the cosine similarity method. When the similarity is ≥0.85, it is determined that an abnormal event is about to occur, and the industrial computer outputs the video information to the LCD display via the network switch for early warning.

[0018] The present invention also includes a semi-closed ore-fired furnace internal condition monitoring and early warning system, comprising:

[0019] Camera barrel lens, camera, closed sliding mechanism, sliding drive air pipe, lens purge cooling air pipe, lens barrel cooling water inlet pipe, lens barrel cooling water return pipe, cooling air control valve group, cooling water control valve group, filter, air pressure transmitter, water pressure transmitter, power module, PLC controller, network switch, hard disk recorder, industrial computer and liquid crystal display; the power module provides power for the camera, the touch screen and the PLC controller;

[0020] After the closed sliding mechanism moves forward and extends, the image inside the ore-heating furnace is transmitted from the furnace to the outside of the furnace through the cylindrical lens of the camera, and is gathered on the target surface of the CMOS of the camera; the color image is collected by the camera and then converted into a video signal by the camera, and the video signal is transmitted to the hard disk recorder through the Ethernet optical fiber and the network cable through the network switch; the industrial computer reads the color image of the hard disk recorder in real time through the network switch, and outputs the color image in real time through the HDMI line to display on the liquid crystal display, and extracts feature values ​​and calculates early warnings based on the video signal read in real time in the industrial computer; the feature elements corresponding to the abnormal events that have occurred in the production process are stored as historical sample feature elements, or the real-time edge feature elements extracted by real-time online calculation are compared with the stored historical sample feature elements. When the correlation is ≥0.85, it is determined that the abnormal event is about to occur, and the industrial computer outputs the video information to the liquid crystal display through the network switch for early warning.

[0021] Furthermore, the camera barrel lens is a sapphire high temperature resistant extended zoom 1.0mm pinhole lens; the observation angle of the camera barrel lens is 100° horizontally and 70° vertically, and it is a wind curtain blowing mode, forming a rotating wind curtain in front of the lens to increase the strength and blowing area of ​​the wind curtain;

[0022] The purge cooling air inlet of the camera barrel lens is connected to a lens purge cooling air pipe; cooling air is connected through the lens purge cooling air pipe to achieve cooling of the camera barrel lens; the other end of the lens purge cooling air pipe is connected to a cooling air control valve group;

[0023] The barrel cooling water inlet of the camera barrel lens is connected to the lens barrel cooling water inlet pipe; the other end of the lens barrel cooling water inlet pipe is connected to the cooling water control valve group; the barrel cooling water outlet of the camera barrel lens is connected to the lens barrel cooling water return pipe; the other end of the lens barrel cooling water return pipe is connected to the cooling water control valve group.

[0024] Furthermore, the lens purge cooling air pipe, the lens barrel cooling water inlet pipe and the lens barrel cooling water return pipe are all made of soft flexible pipes, which do not hinder the forward and backward movement of the camera barrel lens and the camera.

[0025] Furthermore, the camera and the camera barrel lens adopt a flange plus sealing gasket method, and are mechanically hard-connected with the piston-type sliding mechanism in the closed sliding mechanism, and the three can move forward and backward at the same time.

[0026] Furthermore, the closed sliding mechanism is connected to a sliding drive air pipe at the end away from the furnace body, and the closed sliding mechanism is also provided with a forward limit switch, a return limit switch, an air locking and exhaust device, and a counterweight block;

[0027] After the input gas source reaches the set pressure, the internal piston sliding mechanism overcomes the pulling force of the counterweight block and moves forward under the action of pressure; when the cooling gas control valve group switches the gas circuit or there is a gas failure, the counterweight block pulls the internal piston sliding mechanism back to its original position, and the gas in the mechanism is discharged through the cooling gas control valve group or through a pressure-adjustable gas lock and exhaust device to achieve gas discharge, so that the camera cylindrical lens automatically returns to its original position when the system is powered off and the gas is cut off to avoid high-temperature burning.

[0028] Furthermore, the cooling air control valve group is arranged in the lower compartment of the field control cabinet, connected to the camera barrel lens through the lens purge cooling air pipe, connected to the closed sliding mechanism through the sliding drive air pipe, and the signal line is connected to the PLC controller; the cooling air control valve group is controlled by the PLC controller to respectively deliver the gas output by the filter to the camera barrel lens and the closed sliding mechanism;

[0029] Clean, dry compressed air is input from the air compressor station, sent to the control system through the filter, and then finely filtered and decompressed before being distributed to the inner cavity of the camera barrel lens cover and the interlayer of the probe cover to cool the camera and the barrel lens of the camera;

[0030] When the compressed air pressure delivered by the air compressor station is lower than the specified value of 0.35Mpa, the pressure switch on the air line in the control system will reflect the information of insufficient pressure to the PLC controller to control the probe to withdraw outside the furnace and return to its original position.

[0031] The air pressure transmitter is arranged in the upper compartment of the field control cabinet, and the sampling point is arranged at the cooling air control valve group, which is used to measure the air pressure of the air source, and the air pressure signal is connected to the PLC controller;

[0032] The water pressure transmitter is arranged in the upper compartment of the field control cabinet, and the sampling point is arranged at the cooling water control valve group for measuring the cooling water pressure, and the air pressure signal is connected to the PLC controller.

[0033] Compared with the prior art, the present invention has the following advantages:

[0034] The method and system of the present invention realizes early warning of abnormal events in a semi-closed ore-fired furnace through clear in-furnace video images of real-time human-machine interaction, improves efficiency, reduces costs, and ensures safe and continuous production; it can effectively avoid "excessive maintenance", while reducing maintenance time and reducing labor intensity of personnel; BRIEF DESCRIPTION OF THE DRAWINGS

[0035] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.

[0036] Figure 1 It is a schematic diagram of the system structure of the present invention.

[0037] Figure 2 It is a schematic diagram of the process of the present invention.

[0038] In the figure: 101, camera barrel lens; 102, camera; 103, positioning guide substrate; 104, closed sliding mechanism; 105, forward limit switch; 106, return limit switch; 107, air lock exhaust device; 108, counterweight; 109, sliding drive air pipe; 110, lens purge cooling air pipe; 111, lens barrel cooling water inlet pipe; 112, lens barrel cooling return pipe; 113, cooling air control valve group; 114, cooling water control valve group; 115, filter; 116, air pressure transmitter; 117, water pressure transmitter; 118, touch screen; 119, fiber optic transceiver; 120, power module; 121, PLC controller; 122, digital display temperature controller; 123, network switch; 124, hard disk recorder; 125, industrial computer; 126, liquid crystal display. DETAILED DESCRIPTION

[0039] 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 will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work should fall within the scope of protection of the present invention.

[0040] It should be noted that the terms "first", "second", etc. in the specification and claims of the present invention and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence. It should be understood that the data used in this way can be interchanged where appropriate, so that the embodiments of the present invention described herein can be implemented in an order other than those illustrated or described herein. In addition, the terms "including" and "having" and any variations thereof are intended to cover non-exclusive inclusions, for example, a process, method, system, product or device that includes a series of steps or units is not necessarily limited to those steps or units that are clearly listed, but may include other steps or units that are not clearly listed or inherent to these processes, methods, products or devices.

[0041] like Figure 1 As shown, the present invention provides a method for monitoring and warning the internal conditions of a semi-closed ore-heating furnace. In the historical video data of the semi-closed ore-heating furnace, historical video data segments with a fixed time length before the occurrence of typical abnormal events such as material collapse, electrode soft or hard breakage, etc. are intercepted multiple times. This data segment corresponds to the typical abnormal events such as material collapse, electrode soft or hard breakage, etc., and is used as a typical historical sample feature element of the abnormal event. The new feature element calculated in real time is compared with it. When the similarity is high, it is determined that the abnormal event is about to occur and outputs a warning message to remind the process personnel to change the operation strategy. The sample feature element extraction of the historical video data is the same as the feature element extraction algorithm of the real-time online video data. The video signal is processed in the industrial computer 125, and the internal conditions of the semi-closed ore-heating furnace are monitored by reading the signal of the hard disk recorder 124. On this basis, the warning of the material collapse and electrode soft or hard breakage of the ore-heating furnace is realized, such as Figure 2 As shown, the specific steps are as follows:

[0042] S201, after the closed sliding mechanism 104 is extended forward, the images of the three electrodes and the material surface in the ore-forming furnace are transmitted from the furnace to the outside of the furnace through the camera barrel lens 101, and are focused on the target surface of the CMOS of the camera 102;

[0043] S202, the camera 102 uses the DSP double-speed exposure image processing algorithm to perform dynamic range shooting on the target surface of the CMOS, selects clear and normal bright image and dark image to superimpose and synthesize, and outputs an image in which both the bright and dark areas are clearly visible; the camera 102 then converts the color image into a video signal and transmits the video signal to the hard disk recorder 124 through the Ethernet optical fiber and network cable via the network switch 123;

[0044] S203, the industrial computer 125 reads the color image of the hard disk video recorder 124 in real time via the network switch 123, and outputs the color image in real time via the HDMI line to display on the LCD display 126;

[0045] S204, extracting characteristic values ​​and performing early warning calculations in the industrial computer 125 according to the video signal read in real time;

[0046] S205, using an aperture correction technology on the video signal read in real time to obtain an image with clear edges;

[0047] S206, smoothing the image with clear edges using a 3x3 discrete Gaussian filter to obtain a smoothed filtered image;

[0048] S207, reading the three primary colors R, G, B values ​​of each pixel on the smoothed filtered image;

[0049] S208. Since the semi-enclosed ore-fired furnace contains mostly iron and flame-related materials and uses an infrared camera, the color of the image captured by the video is a red threshold series. The RGB model is used to extract the red component R value, so that the image is changed from a color image to a grayscale image.

[0050] S209, because the grayscale of the electrode and material surface images and the background varies greatly, 8-neighborhood adaptive threshold segmentation is adopted, that is, an 8-neighborhood window centered on each pixel is determined, totaling 9 pixels, and the average value of all pixels in the window is used as the threshold to convert the image into a 0 / 1 binary image with obvious contrast;

[0051] S210, extracting edges of the binary image to obtain characteristic elements related to material collapse and soft or hard fracture of the electrode;

[0052] S211. The characteristic elements corresponding to the abnormal events that have occurred in the production process are stored as historical sample characteristic elements, or the real-time edge characteristic elements extracted by real-time online calculation are compared with the stored historical sample characteristic elements, and the similarity is calculated using the cosine similarity method. When the similarity is ≥0.85, it is determined that an abnormal event is about to occur, and the industrial computer 125 outputs the video information to the LCD display 126 via the network switch 123 for early warning.

[0053] Predictive maintenance tests the condition of equipment to determine if failure is likely in the foreseeable future so that changes can be made to the relevant process at the most appropriate time. Although monitoring equipment alone cannot prevent component failures, plant maintenance personnel can extend the life of assets at the lowest cost by more accurately predicting potential failures and replacing components before they fail. The benefits of predictive maintenance include reduced downtime, lower repair and spare parts inventory costs, and avoidance of secondary damage. This strategy is particularly effective for critical assets with high downtime costs, assets with a history of failures, or those that are difficult to reach for routine inspections that are difficult or dangerous.

[0054] like Figure 2 As shown, the present invention provides a semi-enclosed ore-heating furnace internal condition monitoring and early warning system, comprising: a camera barrel lens 101, a camera 102, a positioning guide substrate 103, a closed sliding mechanism 104, a forward limit switch 105, a return limit switch 106, an air lock exhaust device 107, a counterweight 10, a sliding drive air pipe 109, a lens purge cooling air pipe 110, a lens barrel cooling water inlet pipe 111, a lens barrel cooling water return pipe 112, a cooling air control valve group 113, a cooling water control valve group 114, a filter 115, an air pressure transmitter 116, a water pressure transmitter 117, a touch screen 11, an optical fiber transceiver 119, a power module 120, a PLC controller 121, a digital display temperature controller 122, a network switch 123, a hard disk recorder 124, an industrial computer 125 and a liquid crystal display 126.

[0055] Camera barrel lens 101: It uses a sapphire high-temperature resistant extended zoom 1.0mm pinhole lens with high optical design indicators, high-quality optical components, a wide field of view (100° diagonal) and a large depth of field range, high clarity, stable performance, which greatly reduces the size of the furnace wall opening, reduces energy consumption, and avoids the safety hazards caused by the passive front placement of early endoscopic cameras. While ensuring the necessary observation angle, avoid excessive exposure of the front end of the probe cover, extend the service life of the equipment, and ensure safe and stable operation. Because the high temperature resistance value of the lens is higher than that of camera 102, it is more conducive to cooling if only the lens is extended into the furnace; the end face of the lens is made of sapphire and can withstand high temperatures below 2000℃. Even in unexpected circumstances, the lens will not be burned. The length of the lens can be selected according to the thickness of the furnace wall on site. The angle of the opening horn of the furnace wall of the submerged arc furnace is 120°, which meets the requirements of the design lens observation angle of 100° horizontally and 70° vertically. It is designed as a wind curtain purge mode, forming a rotating wind curtain in front of the lens, increasing the strength and purge area of ​​the wind curtain, effectively preventing the dust in the furnace from contacting the lens objective lens, and achieving a good anti-dust and dustproof effect. For cooling the front-end lens, the cooling air is connected through the lens purge cooling air pipe 110; it is designed as an intermediate barrel water cooling mode, and the cooling water is connected through the lens barrel cooling water inlet pipe 111, and the cooling water is discharged through the lens barrel cooling return water pipe 112. Water circulation cooling is adopted, and the cold water enters the shield interlayer through the water inlet to circulate and push the hot water to be discharged through the water outlet to take away the heat to achieve the cooling effect, and the cooling effect on the barrel is significant. . The system equipment can operate continuously and stably for a long time with basically maintenance-free.

[0056] Camera 102: The flange plus gasket method is used with the camera barrel lens 101, and the piston sliding mechanism in the closed sliding mechanism 104 is mechanically hard-connected. The three can move forward and backward at the same time. A 4-megapixel full HD real-time infrared camera is selected, which has high permeability to the dust generated by the semi-enclosed furnace charging, reducing the interference of dust on the captured image. The image is output in real time at up to 60fps. The strong light suppression low-illumination DSP color camera is used in conjunction with a high-temperature lens, enhanced super dynamic technology and ABS (automatic dark area compensation) technology, and a high-sensitivity MOS sensor to create full HD ultra-high resolution images to ensure the clarity and accuracy of every detail on the scene. The camera electronic shutter and white balance are set and adjusted according to the brightness of the monitor and the imaging of the monitored object to achieve the best monitoring effect. The video compression algorithms such as H.265 / H.264 / MJPEG are used to make the code stream smoothly transmitted to meet the different requirements for image quality and fluency in different scenarios. Compared with traditional wide dynamic, this system adopts double-speed exposure to achieve wide dynamic, and the unique DSP algorithm of high-definition network camera to achieve higher dynamic range shooting, and its dynamic range can reach 120dB. The core of ultra-wide dynamic technology is to use multiple uninterrupted exposure technology for scenes with large light-dark contrast, plus DSP-specific image processing algorithm, select clear and normal bright image and dark image for superposition synthesis and output an image with clear light and dark areas. In this way, the problem of overexposure of bright parts and underexposure of dark parts can be avoided, so that the whole picture can be clearly seen to achieve wide dynamic processing effect. The practical application of such high wide dynamic technology enables us to see colorful, clear and stable furnace images on the monitoring display in the case of two situations with large light-dark contrast, such as the very dazzling flame light in the furnace and the dark light in the furnace, and can cover every corner of the high-temperature furnace. The camera barrel lens 101 transmits the image in the ore heating furnace from the furnace to the outside of the furnace, and gathers it on the target surface of the camera 102 CMOS. The camera 102 is used to convert the color image into a video signal and send the video signal through the Ethernet optical fiber.

[0057] Positioning guide base plate 103: It is fixed on the furnace body by welding, with a hole at the bottom for positioning the camera barrel lens 101, and a bolt interface at the top for fixing the closed sliding mechanism 104 and providing corresponding bearing capacity.

[0058] Closed sliding mechanism 104: It is fixed on the positioning guide base plate 103 by bolt connection. The whole mechanism adopts a closed structure. The sliding drive air pipe 109 is connected at the end far away from the furnace body. The mechanism is provided with a forward limit switch 105, a return limit switch 106, a gas lock exhaust device 107, and a counterweight 108. After the input gas source reaches the set pressure, the internal piston sliding mechanism overcomes the pulling force of the counterweight 108 under the action of pressure and moves forward; when the cooling gas control valve group 113 switches the gas path or the gas is cut off, the counterweight 108 pulls the internal piston sliding mechanism back to the original position, and the gas in the mechanism is discharged through the cooling gas control valve group 113 or the pressure-adjustable gas lock exhaust device 107 to achieve gas discharge, which is used for the camera barrel lens 101 to automatically return to the original position when the system is powered off and the gas is cut off to avoid high temperature burns.

[0059] Forward limit switch 105: installed at the front end of the closed sliding mechanism 104, the signal line is connected to the PLC controller 121, when the internal piston sliding mechanism in the closed sliding mechanism 104 moves to the front end, a detection signal is sent out to start the normal furnace condition monitoring.

[0060] Return limit switch 106: installed at the rear end of the closed sliding mechanism 104, the signal line is connected to the PLC controller 121, when the internal piston sliding mechanism in the closed sliding mechanism 104 returns to the original position, it sends out an original position signal to stop the furnace condition monitoring.

[0061] Air locking and exhaust device 107: installed at the rear end of the closed sliding mechanism 104, adopts a spring top screw adjustable structure, and the top screw pressure is adjusted by rotating the handle. The pressure adjustment enables the gas in the cavity of the closed sliding mechanism 104 to be discharged smoothly when the air source provided by the sliding drive air pipe 109 loses pressure, ensuring that the counterweight block 108 pulls the internal piston sliding mechanism in the closed sliding mechanism 104 back to its original position.

[0062] The counterweight block 108 is installed at the rear end of the closed sliding mechanism 104 and is connected to the center of the internal piston sliding mechanism in the closed sliding mechanism 104 through a fixed pulley guide using a flexible steel wire rope. The counterweight block matches the air source pressure, the sliding mechanism cross-sectional area and the tightening pressure of the air lock exhaust device 107.

[0063] The sliding drive air pipe 109 is connected to the rear end of the closed sliding mechanism 104 to provide a pressure air source for the internal piston sliding mechanism.

[0064] Lens purge cooling air pipe 110: connected to the purge cooling air inlet of the camera barrel lens 101, and the other end is connected to the cooling air control valve group 113. A soft flexible pipe is used, which does not hinder the camera barrel lens 101 and the camera 102 from moving forward and backward.

[0065] The lens barrel cooling water inlet pipe 111 is connected to the cooling water inlet of the barrel of the camera barrel lens 101, and the other end is connected to the cooling water control valve group 114. A soft flexible pipe is used, which does not hinder the camera barrel lens 101 and the camera 102 from moving forward and backward.

[0066] The lens barrel cooling water return pipe 112 is connected to the cooling water outlet of the barrel of the camera barrel lens 101, and the other end is connected to the cooling water control valve group 114. A soft flexible pipe is used, which does not hinder the camera barrel lens 101 and the camera 102 from moving forward and backward.

[0067] Cooling air control valve group 113: It is set in the lower compartment of the field control cabinet, connected to the camera barrel lens 101 through the lens purge cooling air pipe 110, connected to the closed sliding mechanism 104 through the sliding drive air pipe 109, and connected to the PLC controller 121 through the signal line. Under the control of the PLC controller 121, the gas output by the filter 115 is respectively delivered to the camera barrel lens 101 and the closed sliding mechanism 104. Clean and dry compressed air is input from the air compressor station, sent to the control system through the filter cleaning filter 115, and then finely filtered and decompressed. It is distributed to the inner cavity of the camera barrel lens 101 cover and the probe cover interlayer to cool the camera 102 and the camera barrel lens 101. When the pressure of the compressed air sent by the air compressor station is lower than the specified value of 0.35Mpa, the pressure switch on the air path in the control system will reflect the information of insufficient pressure to the PLC controller 121 to control the probe to withdraw to the outside of the furnace and return to its original position.

[0068] Cooling water control valve group 114: It is set in the lower compartment of the field control cabinet, connected to the camera barrel lens 101 through the lens barrel cooling water inlet pipe 111 and the lens barrel cooling water return pipe 112, and the signal line is connected to the PLC controller 121. Under the control of the PLC controller 121, the cooling water is delivered to the camera barrel lens 101 and returned.

[0069] Filter 115: It is installed in the lower compartment of the field control cabinet to remove impurities and moisture from the factory air source. The main structure is equipped with an automatic drain valve, and the output end is connected to the cooling air control valve group 113. The compressed air to be treated enters the filter 115 through the air inlet. When passing through the high-efficiency filter layer, the compressed air is intercepted, inertial, diffused and adsorbed, so that the water, dust and oil in it are blocked and retained and stored at the bottom of the purifier. The pure compressed air is discharged through the exhaust hole. The filter 115 is equipped with a pressure gauge safety valve. When the compressed air pressure in the purifier exceeds 1.06 times the rated pressure, the safety valve automatically opens to exhaust to ensure safe use.

[0070] Air pressure transmitter 116: The meter head is arranged in the upper compartment of the field control cabinet, and the sampling point is arranged around the cooling air control valve group 113, which is used to measure the air pressure of the air source, and the air pressure signal is connected to the PLC controller 121.

[0071] Water pressure transmitter 117: The meter head is set in the upper compartment of the field control cabinet, and the sampling point is set around the cooling water control valve group 114 to measure the cooling water pressure. The air pressure signal is connected to the PLC controller 121.

[0072] Touch screen 118: embedded in the upper compartment panel of the field control cabinet, the signal transmission network cable is connected to the PLC controller 121. Graphic buttons and various state signal displays and historical records are visualized on site, and the information interacts with the PLC controller 121 in real time.

[0073] Fiber optic transceiver 119: The fiber optic transceiver 119 arranged in the field control cabinet is interconnected with the camera 102, and the fiber optic transceiver 119 arranged in the central control room is interconnected with the network switch 123. The video electrical signal is converted into an optical signal for transmission, which increases the signal transmission distance and reduces signal transmission interference. The transmission of the video signal from the four field control cabinets to the central control room is completed.

[0074] Power module 120: is arranged in the upper compartment of the field control cabinet, and provides power for electrical components such as the camera 102, the touch screen 118, and the PLC controller 121.

[0075] PLC controller 121: It is set in the upper compartment of the field control cabinet to realize the logic control of the field equipment such as the cooling gas control valve group 113 and the cooling water control valve group 114, and realize the signal collection of the field forward limit switch 105, the return limit switch 106, the air pressure transmitter 116, the water pressure transmitter 117 and other components. The system adopts PLC control technology to automatically control the extension and return of the camera and lens part. When there are problems such as system power supply and compressed air supply, and the temperature inside the probe cover exceeds the range, the mechanism can be automatically withdrawn from the furnace, which plays an automatic protection role for the equipment. When the compressed air pressure is lower than the set value ≤0.35Mpa, the gas stop alarm automatically exits; when the internal temperature of the camera probe is higher than the set value ≥70℃, the over-temperature alarm automatically exits. After the fault is eliminated, the operator can operate the forward button on the central control room or the on-site touch screen to control the probe to enter the furnace and continue to work.

[0076] Digital temperature controller 122: It is arranged in the upper compartment of the field control cabinet, and displays the temperature signals of multiple key points such as the field water temperature and air temperature in a patrol mode, and the signals are transmitted to the PLC controller 121.

[0077] Network switch 123: connected with the optical fiber transceiver 119, the hard disk recorder 124, and the industrial computer 125 by a network cable to realize real-time information interaction.

[0078] Hard disk video recorder 124: connected to the network switch 123 by a network cable, and used for storing camera video information.

[0079] Industrial computer 125: connected to the network switch 123 with a network cable, used for video information processing.

[0080] Liquid crystal display 126: interconnected with industrial computer 125 via HDMI cable for video information display, network configuration, etc.

[0081] The system adopts pinhole imaging, air curtain and shield interlayer circulation cooling technology, which effectively solves the impact of high-intensity heat radiation, dust and corrosive substances inside the ore-fired furnace on the camera lens, greatly improves the reliability of the system, reduces system maintenance requirements, and basically achieves maintenance-free equipment.

[0082] The system has the function of automatically exiting and returning to its original position when over-temperature, gas outage, power outage, or water outage occurs. The closed sliding mechanism is equipped with a high-temperature resistant slider, track, and external counterweight module. Under the control of the PLC controller, it can drive the high-temperature probe to extend into and out of the furnace.

[0083] The early warning of abnormal events in the production process of semi-closed ore-fired furnaces is mainly aimed at the prediction and early warning of abnormal events such as material collapse and electrode soft and hard fractures that often occur in the production process of semi-closed ore-fired furnaces. Its basic principle is: various accidents that occur in the smelting production process of ore-fired furnaces are generally accompanied by changes in multiple physical phenomena. Find out the main changes in the phenomena of various accidents and other combinations of phenomena that are highly correlated with the phenomena. The characteristic image elements corresponding to the abnormal events can be established as typical data, and the real-time characteristic image elements calculated in real time during the production process can be compared with them, and then the corresponding early warning information will be obtained. For the abnormal event of material collapse, the changes in the material surface and the arrangement of pores are mainly used for prediction and early warning; for the abnormal event of electrode soft and hard fracture, the changes in the electrode surface and the distribution of cracks are mainly used for prediction and early warning.

[0084] The serial numbers of the above embodiments of the present invention are only for description and do not represent the advantages or disadvantages of the embodiments.

[0085] In the above embodiments of the present invention, the description of each embodiment has its own emphasis. For parts that are not described in detail in a certain embodiment, reference can be made to the relevant descriptions of other embodiments.

[0086] In the several embodiments provided in this application, it should be understood that the disclosed technical content can be implemented in other ways. Among them, the device embodiments described above are only schematic. For example, the division of the units can be a logical function division. There may be other division methods in actual implementation. For example, multiple units or components can be combined or integrated into another system, or some features can be ignored or not executed. Another point is that the mutual coupling or direct coupling or communication connection shown or discussed can be through some interfaces, indirect coupling or communication connection of units or modules, which can be electrical or other forms.

[0087] The units described as separate components may or may not be physically separated, and the components shown as units may or may not be physical units, that is, they may be located in one place or distributed on multiple units. Some or all of the units may be selected according to actual needs to achieve the purpose of the present embodiment.

[0088] In addition, each functional unit in each embodiment of the present invention may be integrated into one processing unit, or each unit may exist physically separately, or two or more units may be integrated into one unit. The above-mentioned integrated unit may be implemented in the form of hardware or in the form of software functional units.

[0089] If the integrated unit is implemented in the form of a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art, or all or part of the technical solution can be embodied in the form of a software product, and the computer software product is stored in a storage medium, including a number of instructions for a computer device (which can be a personal computer, a server or a network device, etc.) to perform all or part of the steps of the method described in each embodiment of the present invention. The aforementioned storage medium includes: U disk, read-only memory (ROM, Read-Only Memory), random access memory (RAM, Random Access Memory), mobile hard disk, magnetic disk or optical disk and other media that can store program codes.

[0090] Finally, it should be noted that 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 aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for monitoring and early warning of the condition inside a semi-closed ore-fired furnace, characterized in that: The following steps are involved: S201, after the closed sliding mechanism (104) moves forward and extends, the images of the three electrodes and the material surface in the ore-fired furnace are transmitted from the furnace to the outside of the furnace through the camera barrel lens (101), and are collected on the target surface of the CMOS of the camera (102); S202, the camera (102) performs dynamic range shooting of the image on the target surface of the CMOS through a DSP double-speed exposure image processing algorithm, selects a clear and normal bright image and a dark image, superimposes and synthesizes them, and outputs an image in which both the bright and dark areas are clearly visible; the camera (102) then converts the color image into a video signal and transmits the video signal to a hard disk recorder (124) through an Ethernet optical fiber and a network cable via a network switch (123); S203, the industrial computer (125) reads the color image of the hard disk video recorder (124) in real time via the network switch (123), and outputs the color image in real time via the HDMI line to display on the liquid crystal display (126); S204, performing feature value extraction and early warning calculation in the industrial computer (125) based on the video signal read in real time; S205, using an aperture correction technology on the video signal read in real time to obtain an image with clear edges; S206, smoothing the image with clear edges using a 3x3 discrete Gaussian filter to obtain a smoothed filtered image; S207, reading the three primary colors R, G, B values ​​of each pixel on the smoothed filtered image; S208. Since the semi-enclosed ore-fired furnace contains mostly iron and flame-related materials and uses an infrared camera, the color of the image captured by the video is a red threshold series. The RGB model is used to extract the red component R value, so that the image is changed from a color image to a grayscale image. S209, because the grayscale of the electrode and material surface images and the background varies greatly, 8-neighborhood adaptive threshold segmentation is adopted, that is, an 8-neighborhood window centered on each pixel is determined, totaling 9 pixels, and the average value of all pixels in the window is used as the threshold to convert the image into a 0 / 1 binary image with obvious contrast; S210, extracting edges of the binary image to obtain characteristic elements related to material collapse and soft or hard fracture of the electrode; S211. The characteristic elements corresponding to the abnormal events that have occurred in the production process are stored as historical sample characteristic elements, or the real-time edge characteristic elements extracted by real-time online calculation are compared with the stored historical sample characteristic elements, and the similarity is calculated using the cosine similarity method. When the similarity is ≥ 0.85, it is determined that the abnormal event is about to occur, and the industrial computer (125) outputs the video information to the liquid crystal display (126) via the network switch (123) for early warning.

2. A semi-closed ore-fired furnace internal condition monitoring and early warning system, characterized in that: include: A camera barrel lens (101), a camera (102), a closed sliding mechanism (104), a sliding drive air pipe (109), a lens purge cooling air pipe (110), a lens barrel cooling water inlet pipe (111), a lens barrel cooling water return pipe (112), a cooling air control valve group (113), a cooling water control valve group (114), a filter (115), an air pressure transmitter (116), a water pressure transmitter (117), a power module (120), a PLC controller (121), a network switch (123), a hard disk video recorder (124), an industrial computer (125) and a liquid crystal display (126); the power module (120) provides power for the camera (102), the touch screen (118) and the PLC controller (121); After the closed sliding mechanism (104) moves forward and extends, the image inside the ore-heating furnace is transmitted from inside the furnace to outside the furnace through the camera barrel lens (101), and is gathered on the target surface of the CMOS of the camera (102); the color image is collected by the camera (102), and then converted into a video signal by the camera (102), and the video signal is transmitted to the hard disk video recorder (124) through the Ethernet optical fiber and network cable through the network switch (123); the industrial computer (125) reads the color image of the hard disk video recorder (124) in real time through the network switch (123), and transmits the video signal to the hard disk video recorder (124) through the network switch (123). The HDMI line outputs a color image in real time and displays it on a liquid crystal display (126). Feature value extraction and early warning calculation are performed in the industrial computer (125) based on the video signal read in real time. Feature elements corresponding to abnormal events that have occurred in the production process are stored as historical sample feature elements, or real-time edge feature elements extracted by real-time online calculation are compared with the stored historical sample feature elements. When the correlation is ≥0.85, it is determined that an abnormal event is about to occur. The industrial computer (125) outputs the video information to the liquid crystal display (126) via the network switch (123) for early warning.

3. A semi-closed ore-fired furnace internal condition monitoring and early warning system according to claim 2, characterized in that: The camera barrel lens (101) is a sapphire high temperature resistant extended zoom 1.0 mm pinhole lens; the camera barrel lens (101) has an observation angle of 100° horizontally and 70° vertically, and is in a wind curtain blowing mode, forming a rotating wind curtain in front of the lens, increasing the strength and blowing area of ​​the wind curtain; The purge cooling air inlet of the camera barrel lens (101) is connected to a lens purge cooling air pipe (110); cooling air is connected through the lens purge cooling air pipe (110) to achieve cooling of the camera barrel lens (101); the other end of the lens purge cooling air pipe (110) is connected to a cooling air control valve group (113); The barrel cooling water inlet of the camera barrel lens (101) is connected to a lens barrel cooling water inlet pipe (111); the other end of the lens barrel cooling water inlet pipe (111) is connected to a cooling water control valve group (114); the barrel cooling water outlet of the camera barrel lens (101) is connected to the lens barrel cooling water return pipe (112); the other end of the lens barrel cooling water return pipe (112) is connected to a cooling water control valve group (114).

4. A semi-closed ore-fired furnace internal condition monitoring and early warning system according to claim 3, characterized in that: The lens purge cooling air pipe (110), the lens barrel cooling water inlet pipe (111) and the lens barrel cooling water return pipe (112) are all made of soft flexible pipes, which do not hinder the forward and backward movement of the camera barrel lens (101) and the camera (102).

5. A semi-closed ore-fired furnace internal condition monitoring and early warning system according to claim 2, characterized in that: The camera (102) and the camera barrel lens (101) adopt a flange plus sealing gasket method, and are mechanically hard-connected with a piston-type sliding mechanism in a closed sliding mechanism (104), and the three can move forward and backward at the same time.

6. A semi-closed ore-fired furnace internal condition monitoring and early warning system according to claim 2, characterized in that: The closed sliding mechanism (104) is connected to a sliding driving air pipe (109) at the end away from the furnace body, and the closed sliding mechanism (104) is also provided with a forward limit switch (105), a return limit switch (106), an air locking and exhaust device (107) and a counterweight (108); After the input gas source reaches the set pressure, the internal piston sliding mechanism overcomes the pulling force of the counterweight (108) and moves forward under the action of pressure; when the cooling gas control valve group (113) switches the gas path or a gas failure occurs, the counterweight (108) pulls the internal piston sliding mechanism back to its original position, and the gas in the mechanism is discharged through the cooling gas control valve group (113) or through a pressure-adjustable gas lock exhaust device (107), so that the camera barrel lens (101) automatically returns to its original position to avoid high-temperature burning when the system is powered off or the gas is cut off.

7. A semi-closed ore-fired furnace internal condition monitoring and early warning system according to claim 6, characterized in that: The cooling air control valve group (113) is arranged in the lower compartment of the field control cabinet, connected to the camera barrel lens (101) via the lens purge cooling air pipe (110), connected to the closed sliding mechanism (104) via the sliding drive air pipe (109), and connected to the PLC controller (121) through a signal line; the cooling air control valve group (113) is controlled by the PLC controller (121) to transport the gas output by the filter (115) to the camera barrel lens (101) and the closed sliding mechanism (104) respectively; Clean, dry compressed air is input from the air compression station, sent to the control system through the filter (115), and then finely filtered and decompressed before being distributed to the inner cavity of the camera barrel lens (101) cover and the probe cover interlayer to cool the camera (102) and the camera barrel lens (101); When the compressed air pressure delivered by the air compressor station is lower than the specified value of 0.35 MPa, the pressure switch on the air path in the control system will reflect the information of insufficient pressure to the PLC controller (121) to control the probe to be withdrawn outside the furnace and return to its original position.

8. The semi-closed ore-fired furnace internal condition monitoring and early warning system according to claim 2 is characterized in that: The air pressure transmitter (116) is arranged in the upper compartment of the field control cabinet, and the sampling point is arranged at the cooling air control valve group (113) for measuring the air pressure of the air source, and the air pressure signal is connected to the PLC controller (121); The water pressure transmitter (117) is arranged in the upper compartment of the field control cabinet, and the sampling point is arranged at the cooling water control valve group (114) for measuring the cooling water pressure. The air pressure signal is connected to the PLC controller (121).

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