Dynamic visual casting refractory material glass phase exudation temperature testing equipment and dynamic visual casting refractory material glass phase exudation temperature testing method

Abstract

The invention provides dynamic visual casting refractory material glass phase seepage temperature testing equipment and method, and belongs to the technical field of refractory material performance testing, and the equipment comprises a high temperature furnace body, a temperature control system, a visual observation system and a data analysis system. The visual observation system comprises a parallel light source and an image collector, a sample bearing frame used for bearing a casting refractory material sample is arranged in the high-temperature furnace body, and the parallel light source and the image collector are arranged on the two opposite sides of the sample bearing frame respectively. The image collector is used for carrying out image collection on a shadow generated by the casting refractory material sample under the irradiation of the parallel light source to obtain a shadow image; and the data analysis system is used for being connected with the temperature control system and the visual observation system, receiving and recording the temperature data of the high-temperature furnace body and receiving and processing shadow images. According to the invention, the dynamic visualization of the casting refractory material glass phase seepage temperature test process is realized, and the test accuracy and efficiency are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of refractory performance testing, in particular to a dynamic visualized glass phase exudation temperature testing device and method for fused cast refractory. BACKGROUND

[0002] Fused cast refractory is widely used in high-temperature industrial equipment such as glass melting furnace and metallurgical furnace. The glass phase exudation temperature of fused cast refractory is one of the important indicators for measuring the high-temperature performance of fused cast refractory. If the glass phase exudation temperature is too low, the refractory will soften and deform prematurely during use, which seriously affects the service life and operation safety of the equipment.

[0003] At present, the traditional methods for testing the glass phase exudation temperature are microscope observation and personnel observation, but these methods have many shortcomings. When using a high-temperature microscope for observation, the equipment cannot achieve continuous dynamic observation, and it is difficult to accurately capture the moment when the glass phase starts to exude. The test results are greatly affected by the operation proficiency of the test personnel when using the method of human eye observation and judgment, and the test deviation is about ±10℃, which is relatively large. The test data cannot be recorded and stored, which is not conducive to guiding subsequent product quality control and new product research and development. SUMMARY

[0004] The present application provides a dynamic visualized glass phase exudation temperature testing device and method for fused cast refractory, which realizes dynamic visualization of the testing process of the glass phase exudation temperature of fused cast refractory, and improves the testing accuracy and efficiency.

[0005] The technical scheme of the present application is as follows:

[0006] A dynamic visualized glass phase exudation temperature testing device for fused cast refractory, comprising a high-temperature furnace body, a temperature control system, a visualized observation system and a data analysis system, wherein:

[0007] The visualized observation system comprises a parallel light source and an image collector, and a sample support frame for supporting the fused cast refractory sample is arranged in the high-temperature furnace body. The parallel light source and the image collector are arranged on the opposite sides of the sample support frame, respectively. The image collector is used to collect the image of the shadow of the fused cast refractory sample generated under the irradiation of the parallel light source, to obtain a shadow image.

[0008] The data analysis system is connected with the temperature control system and the visualized observation system, and is used to receive and record the temperature data of the high-temperature furnace body, and to receive and process the shadow image.

[0009] Further, the furnace wall of the high-temperature furnace body comprises a stainless steel mesh plate shell and a high-temperature furnace lining, and a heating wire is arranged in the high-temperature furnace body.

[0010] Further, the high-temperature furnace body is a tubular furnace, which is arranged transversely and has a transverse furnace chamber inside, both ends of the furnace chamber are open, and the parallel light source and the image collector are respectively arranged outside both ends of the open furnace chamber.

[0011] Further, the sample support frame includes a support frame body and a light transmission cylinder, the light transmission cylinder is arranged horizontally, the parallel light source is arranged at one end of the outside of the light transmission cylinder, and the other end of the inside of the light transmission cylinder is inserted into the furnace chamber of the tubular furnace, and the support frame body is arranged at the lower part of the other end of the inside of the light transmission cylinder, so that the light of the parallel light source passes through the light transmission cylinder and irradiates on the fused cast refractory sample on the support frame body.

[0012] Further, the sample support frame and the parallel light source are integrally arranged on the case, the case is provided with a horizontal sliding structure, the high-temperature furnace body is arranged on the horizontal sliding structure, and the high-temperature furnace body can move horizontally along the horizontal sliding structure, so that the relative position of the sample support frame in the furnace chamber of the high-temperature furnace body is changed.

[0013] Further, the temperature control system includes a control panel, a temperature control instrument and a thermocouple.

[0014] Further, the image collector is arranged on a three-dimensional adjusting base, and the sample support frame is provided with a lifting and leveling mechanism.

[0015] A test method of the dynamic visualized fused cast refractory glass phase exudation temperature test equipment, comprising:

[0016] S1: preparing a fused cast refractory sample with a set size, cleaning and drying the sample, and then placing the sample on the sample support frame in the high-temperature furnace body;

[0017] S2: heating the high-temperature furnace body at a set heating rate by the temperature control system, and collecting images of the shadow of the fused cast refractory sample under the irradiation of the parallel light source at a set time interval by the image collector, to obtain shadow images;

[0018] S3: receiving the temperature data of the high-temperature furnace body and the shadow images of the image collector by the data analysis system, and recording each shadow image and the corresponding temperature data when the shadow image is collected;

[0019] S4: judging whether there is a glass phase exudation sign by the shadow image, recording the temperature data when the glass phase exudation sign is judged to appear, and obtaining the glass phase exudation temperature result.

[0020] Further, whether there is a glass phase exudation sign is judged by the following method:

[0021] By observing the edges of the shadow area of ​​the cast refractory sample contained in the shadow image with the human eye, when serrated edges are observed, it is considered that there are signs of glass phase exudation.

[0022] Alternatively, the following methods can be used to determine whether there are signs of glass phase exudation:

[0023] The data analysis system performs edge detection on the shadow region of the cast refractory sample contained in the shadow image and calculates the area of ​​the shadow region.

[0024] When the edges of the shadow region are jagged and the area of ​​the shadow region changes abruptly, it is considered that there are signs of glass phase exudation.

[0025] The present invention has the following beneficial effects:

[0026] This invention provides a dynamic visualization testing device for the glass phase exudation temperature of fused cast refractory materials. It enables real-time and continuous observation of the surface state of fused cast refractory samples during heating, accurately capturing the moment the glass phase begins to exudate. Compared to traditional microscopic observation methods, this significantly improves the visualization level of the test. Directly photographing high-temperature fused cast refractory samples cannot yield observable images; this invention avoids this limitation by capturing shadow images. Traditional high-temperature microscopic observation places high demands on the high-temperature resistance of the observation lens; this invention avoids this problem by observing the sample's state through a camera capturing the shadow of the sample under a parallel light source. This invention determines the glass phase exudation temperature of the sample using shadow images, improving testing accuracy and significantly reducing testing errors compared to direct human observation of high-temperature fused cast refractory samples. This invention can store glass phase exudation temperature data, facilitating subsequent result analysis and summarization. It provides comprehensive data support for researchers to improve the high-temperature performance of fused cast refractory materials, contributing to the optimization of refractory material performance and the development of new products. Attached Figure Description

[0027] Fig. 1 This is a schematic diagram of the dynamic visualization test device for glass phase exudation temperature of cast refractory materials according to the present invention.

[0028] Fig. 2 This is a schematic diagram of the imaging principle of the present invention;

[0029] Fig. 3 This is a shadow image of the glass phase exudation. Detailed Implementation

[0030] To make the technical problems, technical solutions and advantages of the present invention clearer, a detailed description will be given below in conjunction with the accompanying drawings and specific embodiments.

[0031] This invention provides a dynamic and visual testing device for the glass phase exudation temperature of cast refractory materials, such as... Figs. 1-3 As shown, it includes a high-temperature furnace body 1, a temperature control system, a visualization observation system, and a data analysis system, wherein:

[0032] The high-temperature furnace body 1 is used to accommodate the molten cast refractory material samples and provide a high-temperature environment. The high-temperature furnace body 1 is made of a material with high temperature resistance and good thermal insulation properties, has sufficient space to accommodate the molten cast refractory material samples, and can withstand the high-temperature environment.

[0033] Specifically, the furnace wall of the high-temperature furnace body 1 includes a stainless steel perforated plate shell and a high-temperature resistant furnace lining, etc., and a heating wire (such as a platinum heating wire) is installed inside the high-temperature furnace body 1 for heating.

[0034] The temperature control system is connected to the high-temperature furnace body 1 and is used to precisely control the heating rate and internal temperature of the furnace body 1. The temperature control system includes a control panel 7, intelligent temperature controllers, thermocouples (e.g., S-type thermocouples), and a silicon controlled rectifier (SCR) module. The thermocouples are horizontally positioned below the cast refractory sample 4 inside the high-temperature furnace body, enabling rapid sensing of the furnace temperature to achieve the goals of furnace temperature control and precise measurement of the sample temperature. The temperature control system can control the heating and cooling of the high-temperature furnace body via software, using a set heating program and thermocouple feedback signals to control the heating power.

[0035] The visualization observation system includes a parallel light source 2 and an image acquisition device 3. Inside the high-temperature furnace body 1, there is a sample support frame 5 for supporting the cast refractory material sample 4 (e.g., cast zirconia-corundum refractory). The parallel light source 2 and the image acquisition device 3 are respectively positioned on opposite sides of the sample support frame 5. The image acquisition device 3 is used to acquire images of the shadow 6 produced by the cast refractory material sample 4 under the illumination of the parallel light source 2, obtaining shadow images to observe the state of the sample. Fig. 2 , 3 As shown.

[0036] During the experiment, the cast refractory sample 4 was at a very high temperature (over 1000 degrees Celsius). If the image acquisition device 3 were used to directly photograph the cast refractory sample 4 at this high temperature, the resulting image would be a very bright mass of light, making it impossible to discern image details, observe the state of the sample, or observe the timing of glass phase exudation. Furthermore, directly acquiring images of the cast refractory sample 4 at this high temperature through the image acquisition device 3 places very high demands on the device's high-temperature resistance, which is usually difficult to achieve.

[0037] Therefore, this invention does not directly photograph the high-temperature fused cast refractory sample 4, but instead photographs the shadow formed by it under a parallel light source. By observing the shape of the shadow, the surface state of the fused cast refractory sample 4 can be indirectly observed, thereby indirectly observing the timing of glass phase exudation. This solves the defect of the image acquisition device 3 being unable to clearly image the high-temperature fused cast refractory sample 4, while also avoiding the high-temperature resistance requirements of the image acquisition device 3.

[0038] A parallel light source ensures imaging stability, and the image acquisition unit 3 includes a high-definition industrial camera and a professional macro lens to guarantee image quality. By acquiring the shadow image of the cast refractory sample 4 through the visualization observation system, the surface condition of the cast refractory sample 4 inside the high-temperature furnace can be observed in real time.

[0039] The data analysis system is used to connect with the temperature control system and the visualization observation system to receive and record the temperature data of the high-temperature furnace body and to receive and process shadow images.

[0040] The data analysis system can observe and record the morphology of the cast refractory sample 4 as it changes with temperature in real time. It records the temperature and image data corresponding to each morphology of the cast refractory sample 4 in real time. Simultaneously, it can process the stored data to generate temperature change curves and calculate parameters such as the glass phase exudation temperature. The system detects the surface state of the cast refractory sample 4 using shadow images. When signs of glass phase exudation are detected in the shadow image, the system records the temperature data at that moment to obtain the glass phase exudation temperature result.

[0041] This invention provides a dynamic visualization testing device for the glass phase exudation temperature of fused cast refractory materials. It enables real-time and continuous observation of the surface state of fused cast refractory samples during heating, accurately capturing the moment the glass phase begins to exudate. Compared to traditional microscopic observation methods, this significantly improves the visualization level of the test. Directly photographing high-temperature fused cast refractory samples cannot yield observable images; this invention avoids this limitation by capturing shadow images. Traditional high-temperature microscopic observation places high demands on the high-temperature resistance of the observation lens; this invention avoids this problem by observing the sample's state through a camera capturing the shadow of the sample under a parallel light source. This invention determines the glass phase exudation temperature of the sample using shadow images, improving testing accuracy and significantly reducing testing errors compared to direct human observation of high-temperature fused cast refractory samples. This invention can store glass phase exudation temperature data, facilitating subsequent result analysis and summarization. It provides comprehensive data support for researchers to improve the high-temperature performance of fused cast refractory materials, contributing to the optimization of refractory material performance and the development of new products.

[0042] In one example, the high-temperature furnace body 1 is a tubular furnace, which is arranged horizontally and has a transverse furnace chamber inside, with open structures at both ends of the furnace chamber. The parallel light source 2 and the image acquisition device 3 are located outside the open ends of the furnace chamber, respectively.

[0043] According to national standards, the dimensions of the cast refractory sample 4 are very small, measuring 4mm × 4mm × 4mm. Therefore, the opening of the furnace is also small, resulting in negligible heat loss. Furthermore, the heating wire can be placed at the cast refractory sample 4 to maintain its temperature. The heat loss at the opening has a negligible impact on the cast refractory sample 4.

[0044] The sample support frame 5 includes a support frame body 51 and a light-transmitting tube 52. The light-transmitting tube 52 is horizontally positioned and has an internal channel for light to pass through. The cross-section of the channel can be circular or similar. A parallel light source 2 is positioned at one outer end of the light-transmitting tube 52, and the inner end of the light-transmitting tube 52 is inserted into the furnace chamber of a tube furnace. The support frame body 51 is positioned at the lower part of the inner end of the light-transmitting tube 52, so that the light from the parallel light source 2 passes through the light-transmitting tube and illuminates the cast refractory sample 4 located on the support frame body 52.

[0045] The open structures at both ends of the furnace can be either fully open or partially open. The size of the partially open structure is sufficient to allow the shadow of the cast refractory sample 4 to pass through completely, that is, to capture the complete shadow of the cast refractory sample 4.

[0046] In this invention, the sample support 5 and the parallel light source 2 are integrally mounted on the housing 10. For example, the parallel light source 2 is located inside the light-shielding housing, and the light-shielding housing and the sample support 5 are an integral structure. The light-shielding housing is connected to the housing 10.

[0047] The chassis 10 is equipped with a horizontal sliding structure 8, and the high-temperature furnace body 1 is mounted on the horizontal sliding structure 8. The horizontal sliding structure 8 can be a guide rail or other structure capable of horizontal sliding. The high-temperature furnace body 1 can move horizontally along the horizontal sliding structure 8, so that the position of the sample support 5 within the furnace chamber 1 of the high-temperature furnace body can move relative to the sample support 5.

[0048] In this invention, the sample support frame 5 is equipped with a lifting and leveling mechanism, which is used to lift the sample when it is placed and adjust the placed sample to a horizontal position to ensure that the position of the sample does not change during the test.

[0049] Image acquisition device 3 can be set on a three-dimensional adjustment base. After the sample is placed in the designated position, the lens position of image acquisition device 3 is adjusted by the three-dimensional adjustment base to make the position and clarity of the captured shadow image optimal.

[0050] The aforementioned data analysis system can be an embedded computer, which can be integrated into a control panel. Alternatively, it can be a standalone data processing computer to enhance data processing capabilities. The standalone data processing computer can be housed within a chassis or connected via wired or wireless means and placed in other locations.

[0051] This invention also provides a testing method for a dynamic visualization testing device for the glass phase exudation temperature of cast refractory materials, the method comprising:

[0052] S1: Prepare a cast refractory material sample of a specified size, and after cleaning and drying, place it on the sample support frame inside the high-temperature furnace.

[0053] Specifically, a 4mm × 4mm × 4mm fused cast zirconia-corundum refractory sample can be prepared. This sample is placed in an ultrasonic cleaner with an appropriate amount of deionized water and cleaned for 10 minutes to remove dust, oil, and other impurities from the sample surface. After cleaning, the sample is removed and placed in an electrically heated constant-temperature drying oven at 110℃ to ensure complete drying. This ensures the initial state of the sample meets the testing requirements and avoids the influence of surface impurities on the test results for the glass phase exudation temperature.

[0054] When placing the sample, the sample support frame needs to be lowered, the sample placed on the sample support frame, and then raised to the designated position. At the same time, the three-dimensional adjustment base of the image acquisition unit 3 should be adjusted, and the focus and brightness of the visualization observation system should be adjusted to ensure that the image position and clarity are at the optimal state.

[0055] Then set the heating program: set the relevant parameters in the software. The equipment can acquire all images of the sample at each stage from room temperature to the end of the test. Set the software sampling interval to 15 seconds. The heating rate can be adjusted within a certain range according to the type and characteristics of the cast refractory material. For example, to heat to 200℃, the heating rate is set to 5℃ / min; above 200℃, the heating rate is set to 10℃ / min, and the target temperature is set to 1500℃.

[0056] S2: The high-temperature furnace body is heated according to the set heating rate by the temperature control system, and the shadow of the cast refractory material sample under the illumination of a parallel light source is acquired by the image acquisition device at the set time interval to obtain the shadow image.

[0057] After the heating program is started in this step, the high-temperature furnace body begins to heat at the set heating rate. During the heating process, the surface condition of the sample can be continuously observed using a visual observation system.

[0058] S3: The data analysis system receives the temperature data of the high-temperature furnace body and the shadow image of the image acquisition device, and records each shadow image and the corresponding temperature data when the shadow image is acquired.

[0059] S4: Determine whether there are signs of glass phase exudation through the shadow image. When it is determined that there are signs of glass phase exudation, record the temperature data at this time to obtain the glass phase exudation temperature result.

[0060] In one example, when heated to 1420°C, the visualization system observed tiny, serrated glass droplets on the sample surface, indicating the beginning of glass phase exudation. Fig. 3 The image shown is an image of the shadow of the sample under a parallel light source. The data analysis system recorded the temperature at this time as 1420℃, which is the glass phase exudation temperature of the fused cast zirconia-corundum refractory material.

[0061] S5: Repeat the test and obtain the glass phase exudation temperature of the second test result as 1416℃. The test result is the arithmetic mean of the test results of the two samples, accurate to the integer. The exudation temperature test result of the cast zirconia corundum refractory is 1418℃.

[0062] In this invention, the edges of the shadow area of ​​the cast refractory material sample contained in the shadow image can be observed by the human eye. When serrations are observed at the edges, it is considered that there are signs of glass phase exudation.

[0063] Although this invention involves observing shadow images with the human eye, it offers superior results compared to directly observing high-temperature cast refractory material samples. The appearance of the glassy phase is typically brief, requiring continuous and careful observation by the human eye, and misjudgments cannot be corrected through repeated observation. In contrast, the shadow images and their temperatures are stored, allowing for detailed and repeated observation with higher accuracy.

[0064] In this invention, the data analysis system can also be used to determine whether signs of glass phase exudation have appeared. Specifically, this includes:

[0065] 1. The data analysis system performs edge detection on the shadow region of the cast refractory material sample contained in the shadow image and calculates the area of ​​the shadow region.

[0066] This invention can use various edge detection algorithms disclosed in the prior art for edge detection, and this invention does not limit itself to any particular algorithm. After an edge is detected, the number of pixels contained within the edge can be counted as the area.

[0067] 2. When the edge of the shadow region is jagged and the area of ​​the shadow region changes abruptly, it is considered that there are signs of glass phase exudation.

[0068] Once edges are detected, contour features such as length, direction, and shape can be analyzed to identify jagged edges. The areas of shadowed regions in two adjacent images (or every few images in between) can be compared to determine if abrupt changes occur. Alternatively, area curves can be generated to pinpoint the locations of abrupt area changes.

[0069] The above description represents the preferred embodiments of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A dynamic visualization device for testing the glass phase exudation temperature of cast refractory materials, characterized in that, This includes a high-temperature furnace body, a temperature control system, a visualization observation system, and a data analysis system, among which: The visualization observation system includes a parallel light source and an image acquisition device. The high-temperature furnace is equipped with a sample support frame for supporting the cast refractory material sample. The parallel light source and the image acquisition device are respectively set on opposite sides of the sample support frame. The image acquisition device is used to acquire images of the shadow produced by the cast refractory material sample under the illumination of the parallel light source to obtain the shadow image. The data analysis system is used to connect with the temperature control system and the visualization observation system to receive and record the temperature data of the high-temperature furnace body and to receive and process the shadow image.

2. The dynamic visualization testing device for the glass phase exudation temperature of cast refractory materials according to claim 1, characterized in that, The furnace wall of the high-temperature furnace body includes a stainless steel perforated plate outer shell and a high-temperature resistant furnace lining, and heating wires are installed inside the high-temperature furnace body.

3. The dynamic visualization testing device for the glass phase exudation temperature of cast refractory materials according to claim 2, characterized in that, The high-temperature furnace body is a tubular furnace, which is arranged horizontally and has a horizontal furnace chamber inside. The furnace chamber has open structures at both ends, and the parallel light source and image acquisition device are located outside the open ends of the furnace chamber, respectively.

4. The dynamic visualization testing device for the glass phase exudation temperature of cast refractory materials according to claim 3, characterized in that, The sample support frame includes a support frame body and a light transmission tube. The light transmission tube is horizontally positioned, and the parallel light source is located at one of the outer ends of the light transmission tube. The inner end of the light transmission tube is inserted into the furnace chamber of the tube furnace. The support frame body is located at the lower part of the inner end of the light transmission tube, so that the light from the parallel light source passes through the light transmission tube and illuminates the molten refractory material sample located on the support frame body.

5. The dynamic visualization test device for glass phase exudation temperature of cast refractory materials according to claim 4, characterized in that, The sample support and the parallel light source are integrated on the chassis. The chassis is provided with a horizontal sliding structure. The high-temperature furnace body is set on the horizontal sliding structure. The high-temperature furnace body can move horizontally along the horizontal sliding structure, so that the position of the sample support is relatively moved within the furnace chamber of the high-temperature furnace body.

6. The dynamic visualization testing device for the glass phase exudation temperature of cast refractory materials according to claim 5, characterized in that, The temperature control system includes a control panel, a temperature controller, and thermocouples.

7. The dynamic visualization testing device for the glass phase exudation temperature of cast refractory materials according to claim 6, characterized in that, The image acquisition device is mounted on a three-dimensional adjustment base, and the sample support frame is equipped with a lifting and leveling mechanism.

8. A test method for the dynamic visualization test device for the glass phase exudation temperature of cast refractory materials according to any one of claims 1-7, characterized in that, include: S1: Prepare a cast refractory material sample of a set size, and place it on the sample support frame inside the high-temperature furnace after cleaning and drying. S2: The high-temperature furnace body is heated by the temperature control system at a set heating rate, and the shadow of the cast refractory material sample under the illumination of the parallel light source is captured by the image acquisition device at set time intervals to obtain the shadow image. S3: Receive the temperature data of the high-temperature furnace body and the shadow image of the image acquisition device through the data analysis system, and record each shadow image and the corresponding temperature data when the shadow image is acquired; S4: Determine whether there are signs of glass phase exudation through the shadow image. When it is determined that there are signs of glass phase exudation, record the temperature data at this time to obtain the glass phase exudation temperature result.

9. The test method according to claim 8, characterized in that, The following methods can be used to determine whether signs of glass phase exudation are present: By observing the edges of the shadow area of ​​the cast refractory sample contained in the shadow image with the human eye, when serrated edges are observed, it is considered that there are signs of glass phase exudation. Alternatively, the following methods can be used to determine whether there are signs of glass phase exudation: The data analysis system performs edge detection on the shadow region of the cast refractory sample contained in the shadow image and calculates the area of ​​the shadow region. When the edges of the shadow region are jagged and the area of ​​the shadow region changes abruptly, it is considered that there are signs of glass phase exudation.

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