Method, device and equipment for sensing reaction state in reaction kettle and medium

Abstract

The invention provides a method, a device, equipment and a medium for sensing a reaction state in a reaction kettle, which are applied to the technical field of machine vision and image processing, and are used for analyzing collected continuous video frame images of materials in the reaction kettle through a reaction state sensing algorithm, sensing the reaction state in the reaction kettle in real time, and improving the detection accuracy. Opening and closing of a nitrogen valve are automatically controlled by combining liquid level height information, so that material overflow is prevented, the safety and stability of the reaction process are ensured, the limitation of traditional manual observation and sensor monitoring is broken through, the effective rate of nitrogen pressing in the kettle is remarkably improved, the requirement for manual intervention is reduced, and the production cost is reduced. The safety risk caused by manual misoperation or untimely monitoring is reduced, meanwhile, the supervision cost is reduced, and the stability of the production process is improved.

Description

Technical Field

[0001] The present application relates to the technical field of machine vision and image processing, and particularly relates to a method, device, equipment and medium for perceiving the reaction state in a reaction kettle. Background Art

[0002] In the industrial production process, as a core reaction device, the accurate monitoring of the intensity of the reaction inside the reaction kettle is an important task. When the reaction is intense, it is necessary to press the material with nitrogen in real time to ensure that there is no raw material overflow. Therefore, the real-time perception of the reaction state in the reaction kettle is crucial for ensuring production safety and improving production efficiency.

[0003] In the existing industrial systems, the perception of the reaction state in the kettle is mainly achieved through manual observation, and the opening and closing of the valve are manually operated. However, this method has many problems. It is not only inefficient and difficult to achieve continuous and real-time monitoring, but also manual operation is prone to safety hazards due to fatigue, negligence or misjudgment.

[0004] In order to overcome the deficiencies of the manual method, currently, attempts are made to obtain the reaction information in the reaction kettle through sensors and deep learning technologies. However, there are also obvious deficiencies. On the one hand, the sensors can only provide limited information and are easily interfered by the environment, resulting in inaccurate monitoring results. On the other hand, although the deep learning method can process complex images or data, it requires a large amount of labeled data for training and has relatively high requirements for hardware resources, making it difficult to be quickly deployed and applied in the actual industrial environment.

[0005] Based on this, a new solution for perceiving the reaction state in the reaction kettle is needed. Summary of the Invention

[0006] In view of this, the embodiments of the present specification provide a method, device, equipment and medium for perceiving the reaction state in a reaction kettle. By analyzing the reaction state information in the reaction kettle through a reaction state perception algorithm, the intensity of the reaction is judged, and accordingly, the nitrogen valve is controlled to prevent material overflow, thereby solving the problems that the existing traditional industrial manual intervention method cannot automatically adjust the perception of the reaction state in the kettle and the nitrogen valve.

[0007] The embodiments of the present specification provide the following technical solutions:

[0008] The embodiments of the present specification provide a method for perceiving the reaction state in a reaction kettle, including:

[0009] A stable light source is set on one side inside the reaction kettle, and an image acquisition device is used on the other side of the reaction kettle to continuously collect the reaction images of the materials inside the reaction kettle to obtain continuous video frame images;

[0010] The server analyzes the continuously collected video frame images through a reaction state perception algorithm to obtain the reaction state information inside the reactor;

[0011] Collect the liquid level height data;

[0012] The server transmits the reaction state information to the central control system, and the central control system controls the opening and closing state of the nitrogen valve according to a preset control strategy to achieve the control of the reaction process inside the reactor;

[0013] Among them, the preset control strategy includes:

[0014] According to the reaction state information and the liquid level height information, judge whether an abnormal reaction state occurs inside the reactor; when an abnormal reaction state is detected, automatically open the nitrogen valve.

[0015] The embodiment of this specification also provides a device for perceiving the reaction state inside a reactor, which applies the method for perceiving the reaction state inside a reactor described in any item of this application. The device for perceiving the reaction state inside a reactor includes: an image acquisition module, an image analysis module, a liquid level height acquisition module, and a control module;

[0016] The image acquisition module is used to continuously acquire the reaction images of the materials inside the reactor to obtain continuously video frame images;

[0017] The image analysis module is used for the server to analyze the continuously collected video frame images through a reaction state perception algorithm to obtain the reaction state information inside the reactor;

[0018] The liquid level height acquisition module is used to collect the liquid level height data;

[0019] The control module is used to transmit the reaction state information to the central control system through the server, and the central control system controls the opening and closing state of the nitrogen valve according to a preset control strategy to achieve the control of the reaction process inside the reactor;

[0020] Among them, the preset control strategy includes:

[0021] According to the reaction state information and the liquid level height information, judge whether an abnormal reaction state occurs inside the reactor; when an abnormal reaction state is detected, automatically open the nitrogen valve.

[0022] The embodiment of this specification also provides an electronic device for perceiving the reaction state inside a reactor, including: a memory, a processor, and a computer program. The computer program is stored in the memory, and the processor runs the computer program to execute the method for perceiving the reaction state inside a reactor described in any item of this application.

[0023] The embodiments of this specification also provide a readable storage medium, in which a computer program is stored. When the computer program is executed by a processor, it is used to implement the method for perceiving the reaction state in the reactor described in any one of the present applications.

[0024] Compared with the prior art, the beneficial effects that can be achieved by at least one of the above technical solutions adopted in the embodiments of this specification at least include:

[0025] By analyzing the continuous video frame images of the materials in the reactor collected by the reaction state perception algorithm, the reaction state in the reactor is perceived in real time, and the opening and closing of the nitrogen valve are automatically controlled in combination with the liquid level height information, so as to prevent material overflow, ensure the safety and stability of the reaction process, break through the limitations of traditional manual observation and sensor monitoring, significantly improve the efficiency of nitrogen pressure feeding in the reactor, reduce the need for manual intervention, reduce the safety risks caused by human misoperation or untimely monitoring, and at the same time reduce the supervision cost and improve the stability of the production process. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings in the following description are only some embodiments of the present application. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.

[0027] Figure 1 is the flow chart of the method for perceiving the reaction state in the reactor in the present application;

[0028] Figure 2 is the specific structural schematic diagram of the process of the present invention;

[0029] Figure 3 The flow chart of the image perception of the reaction state in the reactor of the present invention;

[0030] Among them: 1. Reactor; 2. Nitrogen valve; 3. Stable light source; 4. Image acquisition device; 5. Server; 6. Central control system; 7. Liquid level height acquisition device. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0031] The embodiments of the present application will be described in detail below with reference to the drawings.

[0032] The following specific examples illustrate the implementation manners of the present application. Those skilled in the art can easily understand other advantages and effects of the present application from the content disclosed in this specification. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. The present application can also be implemented or applied through other different specific implementation manners. Various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present application. It should be noted that, without conflict, the following embodiments and the features in the embodiments can be combined with each other. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative efforts belong to the scope of protection of the present application.

[0033] It should be noted that the following describes various aspects of the embodiments within the scope of the appended claims. It should be apparent that the aspects described herein can be embodied in a wide variety of forms, and any specific structure and / or function described herein is illustrative only. Based on the present application, those skilled in the art should understand that one aspect described herein can be implemented independently of any other aspect, and two or more of these aspects can be combined in various ways. For example, any number and aspects described herein can be used to implement the device and / or practice the method. Additionally, this device and / or this method can be implemented using other structures and / or functionality in addition to one or more of the aspects described herein.

[0034] It should also be noted that the drawings provided in the following embodiments only schematically illustrate the basic concept of the present application. The drawings only show the components related to the present application, rather than being drawn according to the number, shape, and size of the components in actual implementation. The type, quantity, and proportion of each component in its actual implementation can be arbitrarily changed, and the component layout type may also be more complex.

[0035] In addition, in the following description, specific details are provided to facilitate a thorough understanding of the examples. However, those skilled in the art will understand that the examples can be practiced without these specific details.

[0036] In existing industrial systems, the reaction kettle is a core device, and the real-time monitoring of the internal reaction state is crucial for safety and efficiency. Traditional methods rely on manual observation or sensor data collection at fixed time nodes. However, manual observation depends on empirical judgment, cannot capture sudden and intense reactions in real time, and is prone to raw material spills or safety accidents. Although sensors and deep learning technologies are used to monitor the reaction state, the information provided by sensors is limited and easily affected by the environment, while deep learning methods require a large amount of data and high hardware costs, making it difficult to deploy quickly and apply in real time.

[0037] In view of this, the inventor conducted in-depth research and improvement exploration on the method for perceiving the reaction state in the reactor, and found that video images can intuitively reflect the reaction dynamics (such as the shape of bubbles, the fluctuation of the liquid level, etc.), and the hardware cost of the camera is low and it is easy to deploy; and collect the liquid level height data, combine it with the reaction state to judge the severity of the reaction, and control the opening and closing state of the nitrogen valve according to the severity of the reaction.

[0038] In the improvement of the function for perceiving the reaction state in the reactor, it was further found that continuous video frames can capture the continuity of the reaction process, thereby significantly improving the sensitivity and accuracy of monitoring.

[0039] Based on this, the embodiments of this specification propose a method for perceiving the reaction state in the reactor: as Figure 1 shown, the overall idea is: by setting a stable light source and an image acquisition device in the reactor, continuously acquire the reaction images of the materials in the reactor to obtain continuous video frame images, then use the reaction state perception algorithm to analyze the images, extract the reaction state information, and at the same time, collect the liquid level height data, and transmit the reaction state information and the liquid level height data to the central control system. The central control system judges whether an abnormal reaction state appears in the reactor according to the preset control strategy, combining the reaction state and the liquid level height information. If an abnormal reaction state is detected, the nitrogen valve is automatically opened for pressure feeding to prevent the raw materials from overflowing and ensure the safety of the reaction process.

[0040] The following will describe the technical solutions provided by the embodiments of this application with reference to the accompanying drawings.

[0041] As Figure 1 and Figure 2 shown, the embodiments of this specification provide a method for perceiving the reaction state in the reactor, including: Step S1, set a stable light source 3 on one side in the reactor, and use an image acquisition device 4 on the other side of the reactor to continuously acquire the reaction images of the materials in the reactor to obtain continuous video frame images.

[0042] In implementation, as Figure 2 shown, when there is a reaction of materials in the reactor, under the illumination of the stable light source, the image acquisition device continuously acquires the reaction images in the reactor to form continuous video frames, and the image acquisition device can be connected to a computer or a server to store the acquired reaction images.

[0043] A signal lamp can be selected to provide a stable light source, so as to obtain high-definition physical reaction images.

[0044] Step S2, the server analyzes the acquired continuous video frame images through the reaction state perception algorithm to obtain the reaction state information in the reactor.

[0045] Specifically, the continuous video frame images can capture features such as the size, quantity, color of bubbles, and the fluctuation of the liquid level during the reaction process. By analyzing these continuous video frames through a reaction state perception algorithm, the server can obtain the real-time reaction state and accurately judge the current reaction state inside the reaction kettle.

[0046] Step S3: Collect liquid level height data.

[0047] In implementation, a liquid level height collection device 7 is connected to the upper end of the reaction kettle 1 to collect the liquid level height information in real time and transmit it to the central control system 6.

[0048] It can be collected by, but not limited to, a radar liquid level sensor, and high-precision liquid level height information can be obtained without affecting the stirring operation inside the kettle.

[0049] Step S4: The server 5 transmits the reaction state information to the central control system 6, and the central control system 6 controls the opening and closing state of the nitrogen valve 2 according to a preset control strategy to achieve the control of the reaction process inside the reaction kettle;

[0050] Among them, the preset control strategy includes:

[0051] According to the reaction state information and the liquid level height information, judge whether an abnormal reaction state occurs inside the reaction kettle; when an abnormal reaction state is detected, automatically open the nitrogen valve.

[0052] In implementation, as Figure 2 shown, a nitrogen valve 2 is connected to the upper end of the reaction kettle 1. When the reaction inside the reaction kettle starts, judge whether the reaction inside the reaction kettle is intense according to the reaction state information and the liquid level height information. If it exceeds the preset threshold, it means the reaction is intense, and the nitrogen valve is opened, and nitrogen enters the kettle for pressure feeding to prevent the raw materials from overflowing.

[0053] In some embodiments, the nitrogen valve 2 can be selected as a pneumatic valve, and the automatic on-off of the valve is remotely controlled through the central control system.

[0054] In some embodiments, before the server analyzes the collected continuous video frame images through a reaction state perception algorithm, preprocessing is performed on the continuous video frame images, and the preprocessing includes: image flipping, image cropping, and image enhancement, optimizing the image quality, removing noise, and enhancing useful information, thereby improving the performance of the reaction state perception algorithm.

[0055] In some embodiments, the preprocessed continuous frame images should reach at least 24 frames per second, forming a rich image data set. The continuous frame images can provide more context information, help reduce misjudgment and missed judgment, and achieve real-time monitoring of the material reaction state.

[0056] In some embodiments, as Figure 3As shown in the figure, the collected images of the material reaction state are remotely transmitted to the central control room through optical fibers. The server analyzes the collected continuous video frame data set through the reaction state perception algorithm. After identifying the real-time reaction state in the kettle, the processed reaction state signal is transmitted to the central control system. The central control system receives the reaction state signal in real time and combines the current liquid level height information to automatically control the opening and closing of the nitrogen cut-off valve and regulate the material pressing process. By using computer vision and image processing, through the real-time monitoring of the reaction state in the kettle, the system can automatically control the opening and closing of the nitrogen valve, solve the problem that the current reaction state in the kettle still needs to be observed manually and the nitrogen valve still needs to be adjusted manually, reduce the losses caused by human errors, improve the resource utilization rate, and ensure the consistency and accuracy of the production process.

[0057] In some embodiments, the reaction state perception algorithm is written using the Python programming language, the OpenCV vision library, and the Numpy library.

[0058] Specifically, OpenCV is an open-source computer vision library that contains a large number of image processing and computer vision algorithms. In the reaction state perception algorithm, OpenCV is used for tasks such as image preprocessing, feature extraction, and object detection. For example: correcting the installation angle deviation of the camera and focusing on the key area (such as the liquid surface bubble generation area).

[0059] Numpy is a numerical calculation extension library for Python that supports a large number of dimensional array and matrix operations. In addition, it also provides a large number of mathematical function libraries for array operations. In the reaction state perception algorithm, Numpy can be used to process and analyze a large amount of data, including image data and feature data, so as to realize the detection and distinction of no bubbles, small bubbles, and large bubbles in the reaction kettle.

[0060] Based on the number, size, and duration of the detected small bubbles and large bubbles, the algorithm can judge the reaction state in the reaction kettle.

[0061] For example: Small bubbles usually appear white, similar to foam, and the quantity is relatively large, reaching three digits; large bubbles appear in the form of bubbling, with a relatively small quantity, usually single digits, and are yellow.

[0062] In some embodiments, if large bubbles are continuously detected and their duration exceeds the preset duration, and the liquid level height data exceeds the preset threshold, it is determined as an abnormal reaction state, an abnormal reaction state signal is output, and the nitrogen valve is controlled to open; if there are only small bubbles or no bubbles, it is determined as a normal reaction state, and the nitrogen valve is kept closed.

[0063] For example: The reaction in the kettle starts. When the liquid level reaches a certain height, the current reaction state is judged. If there is a phenomenon of large bubbles for ten consecutive seconds, the reaction state is considered to be a violent reaction. Then the nitrogen valve is opened, and nitrogen enters the kettle for pressure feeding to prevent the raw materials from overflowing.

[0064] In some embodiments, the transmission between the server and the central control system is carried out through a protocol board card.

[0065] When it is judged that the reaction state in the kettle is a violent reaction, the reaction state signal is transmitted to the central control system by using a Modbus protocol board card.

[0066] In an industrial automation system, a Modbus protocol board card can serve as a bridge to connect different devices, realizing seamless communication and data sharing between devices, and is easy to implement and debug, reducing the difficulty of system integration and maintenance.

[0067] The central control system, namely the Distributed Control System (DCS), can monitor the states of various production links in the factory in real time, including key parameters such as the reaction state in the kettle, ensuring the stability and safety of the production process. The DCS system has the characteristics of high integration and modularity, and can be customized and expanded according to specific industrial requirements, reducing the overall cost of the system.

[0068] Finally, the central control system will scan the reaction state signal of the material in real time, and combine the current liquid level height information to control the on-off of the nitrogen valve.

[0069] In some embodiments, the reaction kettle is subjected to a closed light-shielding treatment, including: adopting a stainless-steel closed environment to make the system not affected by external light, avoiding the interference of light on the internal chemical reactions of the system, and reducing light pollution.

[0070] In some embodiments, a high-resolution explosion-proof camera is used to collect the reaction images of the materials in the reaction kettle, so as to clearly capture the images of the materials in the kettle, and transmit the continuous frame images to the computer remotely through optical fibers to ensure the change process of the stability parameters during the whole monitoring process of the system.

[0071] Based on the same inventive concept, the embodiment of the specification of the present application also provides a reaction state sensing device in a reaction kettle, which applies the reaction state sensing method in any one of the present application. The reaction state sensing device in the reaction kettle includes: an image acquisition module, an image analysis module, a liquid level height acquisition module, and a control module;

[0072] The image acquisition module is used to continuously acquire the reaction images of the materials in the reaction kettle to obtain continuous video frame images;

[0073] The image analysis module is used for the server to analyze the continuously acquired video frame images through the reaction state perception algorithm to obtain the reaction state information in the reactor;

[0074] The liquid level height acquisition module is used for acquiring liquid level height data;

[0075] The control module is used for the server to transmit the reaction state information to the central control system, and the central control system controls the opening and closing state of the nitrogen valve according to the preset control strategy to realize the control of the reaction process in the reactor;

[0076] Among them, the preset control strategy includes:

[0077] Judge whether an abnormal reaction state occurs in the reactor according to the reaction state information and the liquid level height information; when an abnormal reaction state is detected, automatically open the nitrogen valve.

[0078] The reaction state perception device in the embodiment of this specification can correspondingly be used to execute Figure 1 the steps in the method embodiment shown, and its implementation principle and technical effect are similar, which will not be elaborated here.

[0079] Based on the same inventive concept, the embodiment of the specification of this application also provides an electronic device for perceiving the reaction state in a reactor, and this device includes: a processor, a memory, and a computer program; among them

[0080] The memory is used for storing the computer program, and this memory can also be a flash memory. The computer program is, for example, an application program, a functional module, etc. that implement the above method.

[0081] The processor is used for executing the computer program stored in the memory to realize each step executed by the device in the above method. Specifically, reference can be made to the relevant descriptions in the previous method embodiment.

[0082] Optionally, the memory can be either independent or integrated with the processor.

[0083] When the memory is a device independent of the processor, the device can also include:

[0084] A bus for connecting the memory and the processor.

[0085] Based on the same inventive concept, the embodiment of the specification of this application also provides a readable storage medium, and a computer program is stored in the readable storage medium, and when the computer program is executed by a processor, it is used to realize the methods provided by the above various implementation manners.

[0086] Among them, the readable storage medium can be a computer storage medium or a communication medium. The communication medium includes any medium that facilitates the transfer of a computer program from one place to another. The computer storage medium can be any available medium accessible by a general or special purpose computer. For example, the readable storage medium is coupled to the processor so that the processor can read information from the readable storage medium and write information to the readable storage medium. Of course, the readable storage medium can also be a component of the processor. The processor and the readable storage medium can be located in an Application Specific Integrated Circuit (ASIC). Additionally, the ASIC can be located in a user device. Of course, the processor and the readable storage medium can also exist as discrete components in a communication device. The readable storage medium can be a read only memory (ROM), a random access memory (RAM), a CD-ROM, magnetic tape, a floppy disk, and an optical data storage device, etc.

[0087] In this specification, for the same or similar parts among the various embodiments, reference can be made to each other. Each embodiment focuses on the differences from other embodiments. In particular, for the embodiments described later, the description is relatively simple, and for the relevant parts, reference can be made to the partial descriptions of the foregoing embodiments.

[0088] As described above, the above are only specific embodiments of the present application, but the protection scope of the present application is not limited thereto. Any changes or substitutions that can be easily thought of by those skilled in the art within the technical scope disclosed in the present application should be covered by the protection scope of the present application. Therefore, the protection scope of the present application should be subject to the protection scope of the claims.

Claims

1. A method for perceiving the reaction state inside a reactor, characterized in that, Including: A stable light source is set on one side inside the reaction kettle, and an image acquisition device is used on the other side of the reaction kettle to continuously acquire reaction images of the materials inside the reaction kettle, obtaining continuous video frame images; The server analyzes the acquired continuous video frame images through a reaction state perception algorithm to obtain reaction state information inside the reaction kettle; Collect liquid level height data; The server transmits the reaction state information to the central control system, and the central control system controls the opening and closing state of the nitrogen valve according to a preset control strategy to achieve the control of the reaction process inside the reaction kettle; Wherein, the preset control strategy includes: According to the reaction state information and the liquid level height information, judge whether an abnormal reaction state occurs inside the reaction kettle; when an abnormal reaction state is detected, automatically open the nitrogen valve.

2. The method for sensing the reaction state in the reactor according to claim 1, wherein Before the server analyzes the acquired continuous video frame images through a reaction state perception algorithm, preprocess the continuous video frame images, and the preprocessing includes: image flipping, image cropping, and image enhancement.

3. The method for perceiving the reaction state in the reactor according to claim 1, characterized in that, The reaction state perception algorithm is written using the Python programming language, the OpenCV vision library, and the Numpy library.

4. The method for perceiving the reaction state in the reactor according to claim 1, wherein The reaction state information includes: bubble characteristics and the duration of the corresponding bubble characteristics, and the bubble characteristics include: no bubble characteristics, small bubble characteristics, and large bubble characteristics; When the duration of the large bubble characteristics reaches a preset duration and the liquid level height data exceeds a preset threshold, an abnormal reaction state signal is output to control the opening of the nitrogen valve; otherwise, the nitrogen valve is kept closed.

5. The method for sensing the reaction state in the reactor according to claim 1, characterized in that, The liquid level height data is collected through a radar liquid level sensor.

6. The method for sensing the reaction state in the reactor according to claim 1, wherein The transmission between the server and the central control system is carried out through a protocol board.

7. The method for sensing the reaction state inside the reactor according to claim 1, wherein Perform a closed and light-shielding treatment on the reaction kettle, including: adopting a stainless steel closed environment; And / or, use a high-resolution explosion-proof camera to collect reaction images of the materials inside the reaction kettle.

8. A reaction state sensing device inside a reaction kettle, characterized in that, Applying the reaction state perception method inside the reaction kettle according to any one of claims 1-7, the reaction state perception device inside the reaction kettle includes: an image acquisition module, an image analysis module, a liquid level height acquisition module, and a control module; The image acquisition module is used to continuously acquire reaction images of the materials inside the reaction kettle, obtaining continuous video frame images; The image analysis module is used for the server to analyze the acquired continuous video frame images through a reaction state perception algorithm to obtain reaction state information inside the reaction kettle; The liquid level height acquisition module is used to collect liquid level height data; The control module is used to transmit the reaction state information to the central control system through the server, and the central control system controls the opening and closing state of the nitrogen valve according to a preset control strategy to achieve the control of the reaction process inside the reaction kettle; Wherein, the preset control strategy includes: According to the reaction state information and the liquid level height information, judge whether an abnormal reaction state occurs inside the reaction kettle; when an abnormal reaction state is detected, automatically open the nitrogen valve.

9. An electronic device for perceiving the reaction state inside a reaction kettle, characterized in that, Including: A memory, a processor, and a computer program, the computer program is stored in the memory, and the processor runs the computer program to execute the reaction state perception method inside the reaction kettle according to any one of claims 1-7.

10. A readable storage medium, characterized in that, The readable storage medium stores a computer program, and when the computer program is executed by a processor, it is used to implement the method for sensing the reaction state in the reactor according to any one of claims 1-7.

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