High-temperature camera system for furnace nose

Abstract

The invention discloses a high-temperature camera system for a furnace nose. The high-temperature camera system comprises a camera terminal, a gas source supply unit and a system control unit, the camera terminal is provided with a dual-purging device for the lighting glass, and the dual-purging device comprises a second purging channel used for forming air curtain protection and a first purging channel used for direct purging. The method comprises the following steps; video images in the furnace nose are continuously collected through a camera terminal; the collected video images are analyzed in real time through the system control unit; the invention belongs to the technical field of hot galvanizing production in the metallurgical industry, and aims to solve the problem of imaging blurring of a high-temperature camera system in a short period due to excessive zinc ash in a high-aluminum-zinc-aluminum-magnesium production line in the prior art. Intelligentization and self-adaption of the purging strategy are achieved, it is ensured that clear in-furnace images are continuously obtained in the whole production period, and therefore the hot dipping quality and the product percent of pass are improved.

Description

Technical Field

[0001] This invention relates to the field of hot-dip galvanizing production technology in the metallurgical industry, specifically to a high-temperature camera system for the furnace nose. Background Technology

[0002] In hot-dip galvanizing production, the environment inside the furnace nose is extremely harsh, with temperatures reaching hundreds of degrees Celsius, and filled with volatile zinc vapor and detached zinc ash particles. To monitor the internal condition of the furnace nose in real time, modern galvanizing production lines generally install high-temperature camera systems on the side walls of the furnace nose. These systems capture internal images using high-temperature resistant camera probes, supplemented by lighting, allowing operators to observe fluctuations in the zinc melt level, the degree of zinc ash accumulation, and the surface condition of the strip steel. However, existing high-temperature camera systems face significant challenges when dealing with high-alumina, zinc, aluminum, and magnesium products. Due to the increased aluminum content, the amount of zinc ash generated inside the furnace nose increases significantly. These fine zinc ash particles are easily adhered to the observation window glass of the camera system by the high-temperature airflow. Traditional camera systems are usually equipped with only a simple single-channel purging device, or rely on increasing the purging air flow rate to maintain glass cleanliness, but this simple approach has limited effectiveness. In the actual operation of high-alumina-zinc-alumina-magnesium production lines, the observation window glass often becomes heavily covered with zinc ash in just 2 to 3 days, resulting in blurred images; after 5 to 6 days, the image details are completely unrecognizable. The production cycle of high-alumina-zinc-alumina-magnesium products is usually as long as 10 to 12 days, which means that more than half of the production time is spent in a blind state.

[0003] There are some improvement solutions in the existing technology, such as increasing the number of purging air paths or improving the nozzle design, but these improvements often lack systematic consideration and fail to fundamentally solve the problem of zinc ash adhesion.

[0004] Especially in terms of purging strategies, existing systems mostly use fixed purging modes and parameters, which cannot be adaptively adjusted according to changes in actual working conditions. This not only fails to guarantee cleaning effectiveness but also wastes gas resources. In addition, existing equipment does not provide sufficient protection for the camera probe itself; high temperatures and zinc ash can also affect the probe's lifespan and image quality. Therefore, since the existing requirements are not met, we propose a furnace nose high-temperature camera system. Summary of the Invention

[0005] Therefore, the present invention provides a furnace nose high-temperature camera system to solve the above-mentioned problems in the prior art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: According to a first aspect of the present invention, a high-temperature imaging system for a furnace nose includes an imaging terminal, a gas supply unit, and a system control unit; the imaging terminal is provided with a dual purging device for the illumination glass, including a second purging channel for forming an air curtain protection and a first purging channel for direct purging; the method includes the following steps; The camera terminal continuously captures video images of the inside of the furnace nose; The system control unit analyzes the acquired video images in real time and calculates the sharpness index (CI). The clarity index CI is compared with the preset standard threshold S and warning value T; Based on the comparison results, the control air supply unit adjusts the operating mode of the dual purging device.

[0007] Furthermore, the step of controlling the gas supply unit to adjust the operating mode of the dual purging device based on the comparison results includes: When the clarity index CI > standard threshold S + warning value T, enter the basic barrier mode, control the second purge channel to open with the first flow rate, and close the first purge channel; When the standard threshold S + warning value T ≥ clarity index CI ≥ standard threshold S, the prevention enhancement mode is entered, and the second purge channel is controlled to open at a second flow rate greater than the first flow rate, while the first purge channel is opened intermittently in a pulse manner. When the resolution index CI is less than the standard threshold S, the system enters the powerful recovery mode, controls the second purge channel to open at maximum flow, and keeps the first purge channel open.

[0008] Furthermore, in the enhanced prevention mode, the pulse frequency of the first purge channel gradually increases as the clarity index (CI) value approaches the standard threshold S.

[0009] Furthermore, the Clarity Index (CI) is a quantitative indicator obtained by performing gradient analysis on video images.

[0010] Furthermore, it also includes recording historical data of the Clarity Index (CI) and corresponding purge mode switching records to form an operational database. Based on the historical data in the operational database, a clarity change trend prediction model is established to adjust the purge mode in advance.

[0011] Furthermore, a transition range is set during the switching of different purging modes to avoid frequent mode switching.

[0012] Furthermore, it also includes a step of cooling the camera probe, the camera probe including a temperature detection module, and further includes: The actual temperature is obtained by monitoring the internal temperature of the camera probe in real time through a temperature detection module. Compare the actual temperature with the preset temperature standard threshold and temperature warning value; Based on the comparison results, the control air supply unit adjusts the operating mode of the cooling air path.

[0013] Furthermore, the step of controlling the air supply unit to adjust the cooling air path operation mode based on the comparison result includes: When the actual temperature P1 < temperature standard threshold P - temperature warning value U, the basic cooling mode is entered, and the cooling air path is opened with the first cooling flow rate. When the temperature standard threshold P ≥ the actual temperature P1 ≥ the temperature standard threshold P - the temperature warning value U, the enhanced cooling mode is entered, and the cooling air path is controlled to open with a second cooling flow rate greater than the first cooling flow rate. When the actual temperature P1 > the standard temperature threshold P, the system enters the maximum cooling mode and controls the cooling air path to open at the maximum cooling flow rate.

[0014] Furthermore, the operating mode of the cooling air path is coordinated with the operating mode of the dual purging device. When there is a conflict in the control commands, they are executed according to the preset priority. Among them, the strong recovery mode and the maximum cooling mode have the highest priority, followed by the prevention enhancement mode and the enhanced cooling mode, and the basic barrier mode and the basic cooling mode have the lowest priority.

[0015] Furthermore, in the basic cooling mode, a step is also included in which a portion of the cooling gas is guided to the surface of the camera probe lens to form a protective gas film.

[0016] The present invention has the following advantages: 1. This furnace nose high-temperature camera system innovatively solves the problem of zinc ash adhesion from a physical structure perspective by adopting a dual purging mechanism. The gas curtain protective layer effectively blocks most of the zinc ash from approaching the observation window by establishing a gas barrier in the front space, while the direct purging device targets and removes the residual zinc ash that has penetrated the gas curtain. This graded protection system greatly extends the cleaning cycle of the observation window and ensures that clear and usable furnace images are obtained throughout the entire production cycle, providing a reliable basis for process adjustment and quality control. 2. The furnace nose high-temperature camera system adopts a double-layer protection structure for the camera probe. While the cooling gas carries away the heat of the probe, it is also guided to the lens surface to form a protective gas film. This design not only prevents zinc ash from adhering to the lens surface, but also ensures the normal operating temperature of the core camera components in a high-temperature environment, which significantly improves the service life of the equipment and reduces the frequency of maintenance and downtime losses. 3. This furnace nose high-temperature camera system incorporates an intelligent collaborative control strategy that achieves an optimal balance between energy efficiency and performance. By analyzing image clarity and probe temperature in real time, the system automatically switches operating modes under different conditions. It employs an energy-saving basic mode when the image is clear, activates a preventative enhancement mode when clarity declines, and engages a full-power recovery mode when the image is blurred. This on-demand intelligent control method ensures effective monitoring while maximizing gas consumption and reducing production costs. Attached Figure Description

[0017] Figure 1 This is a cross-sectional view of the furnace body of a furnace nose high-temperature camera system proposed in this invention; Figure 2 Main view of the mounting plate; Figure 3 This is a schematic diagram of the control logic; Figure 4 This is a schematic diagram of the module connections; Figure 5 This is a schematic diagram of the working principle and gas path.

[0018] In the diagram: 1. Furnace body; 2. Connecting lug; 4. Camera probe; 5. Lighting lamp; 61. Sleeve; 62. Glass; 63. Through groove; 64. Mounting plate; 65. First purging channel; 66. Second purging channel; Detailed Implementation

[0019] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] Example 1; Reference Figure 1 - Figure 5 A furnace nose high-temperature camera system is designed to continuously obtain clear images of the inside of the furnace body 1 in a harsh environment with high zinc ash. The system includes the furnace body 1 and connecting ears 2 disposed on both sides of the furnace body 1. The inner wall of the connecting ears 2 is connected to the inner wall of the furnace body 1, and a camera terminal module is installed on the connecting ears 2. The camera terminal module includes a mounting plate 64 and a camera probe 4 and a lighting lamp 5 mounted on the mounting plate 64. The output end of the camera probe 4 extends through the mounting plate 64 into the connecting lug 2 for acquiring real-time images inside the furnace. A sleeve 61 is provided between the lighting lamp 5 and the mounting plate 64. The sleeve 61 has a mounting hole at one end away from the mounting plate 64 and an open structure at the other end. High-temperature resistant glass 62 is fixedly installed on the inner wall of the sleeve 61 away from the mounting plate 64. The probe end of the lighting lamp 5 passes through the mounting hole and contacts the glass 62 to provide backlight illumination for the camera. A through groove 63 is provided on the mounting plate 64, which corresponds to the open structure of the sleeve 61. The core purpose of setting up the sleeve 61 is to keep the glass 62 away from the high zinc ash atmosphere inside the furnace nose and to reserve space for adding a purge gas path. The mounting plate 64 is provided with a second blowing channel 66, which communicates with the inner wall of the through groove 63; a first blowing channel 65 is installed on one side of the sleeve 61, and its blowing end is directly aligned with the bottom surface of the glass 62. The system works as follows: The input ends of the first purge channel 65 and the second purge channel 66 are both connected to the gas supply module; the gas supply module introduces the purge gas through the first purge channel 65 and the second purge channel 66 respectively; the gas blown out through the second purge channel 66 forms a wide and stable air curtain isolation layer in the through groove 63 to prevent zinc ash from approaching; this distance is intentionally designed to ensure that the gas can fully diffuse into an effective protective barrier and avoid creating dead airflow angles; at the same time, the first purge channel 65 is connected to the inner wall of the sleeve 61 and is located below the glass 62, directly and powerfully purging the working surface of the lighting glass 62 to remove stubborn zinc ash that may penetrate the air curtain; The gas supply module includes a nitrogen source, a gas pump, a filter device, and a valve group system, which controls the nitrogen supply parameters. This embodiment constructs a basic dual protection mechanism through innovative mechanical structure design. Example 2: Based on Embodiment 1, this embodiment further optimizes the design of the camera probe 4; the camera probe 4 includes a camera housing, and a camera module, a signal transmission module, a temperature detection module, and a camera probe lens installed inside the camera housing; the camera module is responsible for image acquisition, the signal transmission module is responsible for data transmission, and the temperature detection module is responsible for real-time monitoring of the internal temperature of the camera probe 4; The outer wall of the camera housing is fitted with an outer shell, forming a sealed space between the outer shell and the camera housing; a precision nozzle is provided on one side below the lens of the camera probe, the input end of the nozzle is connected to the output end of the sealed space, and the input end of the sealed space is connected to the air supply module. In this embodiment, the air supply module has expanded its functionality, also including a cold air source, a second air pump, and a second filter device. The cooling air path is independently controlled by a control valve group system. Cold air is introduced into a sealed space and circulates between the camera housing and the outer protective shell, effectively cooling the core components of the camera through forced convection heat exchange. At the same time, the gas after heat exchange is directionally ejected through precision nozzles, forming a continuous airflow to sweep the bottom of the camera probe lens. This airflow forms a protective air film on the lens surface to prevent zinc ash from adhering directly, and further removes heat from the lens surface. Working Principle: This embodiment introduces an independent probe cooling and self-cleaning system, which, based on the protection of the observation window in Embodiment 1, adds protection for the core imaging components. After fulfilling its heat dissipation function, the cooling gas is given a second function—lens cleaning and dust prevention, achieving cascaded energy utilization and significantly improving the service life and reliability of the camera probe 4 in extreme environments. Example 3: Based on Embodiment 2, this embodiment introduces a complete intelligent control system, which solves the problems of the aforementioned solution, such as the purging process relying on manual experience, inability to adaptively adjust according to working conditions, high gas consumption, and unstable effect. Furthermore, the system also includes an image analysis module, a core logic processor, an airflow management module, and a human-machine interaction module electrically connected to the signal transmission module. The image analysis module is responsible for real-time processing of the acquired images, calculating and outputting the quantitative index CI representing image sharpness. The core logic processor, as the system decision center, executes a preset multi-parameter collaborative control strategy. The airflow management module is electrically connected to the air supply module and is responsible for precisely controlling the valve group system. The system control unit can be implemented in a highly integrated hardware form. In this embodiment, the driving and control logic of the image analysis module, core logic processor, airflow management module, and human-machine interaction module are all programmed and integrated on a control motherboard of an embedded microcontroller. This microcontroller (e.g., using an ARM Cortex-M series high-performance core) serves as the core processor of the system, responsible for image acquisition, sharpness analysis, running the three-standard hierarchical control strategy, generating airflow control commands, and managing the human-machine interaction interface (such as connecting to a touch screen or button display) for parameter setting and status display. The collaborative control strategy of the core logic processor is as follows: A. Intelligent control of cooling air: The logic core processor sets the standard threshold P and warning value U of the camera housing temperature through the human-machine interaction module; A1. Basic Cooling Mode: When the actual temperature P1 < P - U, the probe cooling basic mode is executed, and the cold air bottom flow rate is controlled to open (10%) through the valve group system. A2. Enhanced Cooling Mode: When P ≥ P1 ≥ P - U, the probe cooling power mode is activated, and the valve group system controls the increase of the cold air flow (50%). A3. Maximum Cooling Mode: When P1 > P, the probe cooling maximum mode is executed, and the maximum flow rate of the cold air is controlled by the valve group system (100%). This system can automatically adjust its mode in reverse according to temperature changes, thereby achieving dynamic thermal management; Regarding the intelligent control of the purge gas: The logic core processor sets the standard threshold S of the clarity index CI and the warning value T through the human-machine interaction module; B1. Basic Barrier Mode: This mode is executed when CI > S + T; the purge gas flow of the second purge channel 66 is controlled to open at a low flow rate through the valve group system to maintain the basic air curtain with the lowest energy consumption; the purge gas of the first purge channel 65 is closed; at the same time, if the temperature conditions permit, the probe cooling will enter the basic mode simultaneously. B2. Prevention Enhancement Mode: This mode is executed when S + T ≥ CI ≥ S; the purge air flow of the second purge channel 66 is increased by controlling the valve group system to consolidate the air curtain; the purge air of the first purge channel 65 is opened in an intermittent pulse manner to perform preventive fixed-point cleaning; the probe cooling is switched to the strong mode simultaneously. B3. Powerful Recovery Mode: This mode is executed when CI < S; the purge air of the second purge channel 66 is controlled by the valve group system to open at the maximum flow rate to powerfully eliminate interference; the purge air of the first purge channel 65 is continuously opened for powerful cleaning; the probe cooling enters the maximum mode simultaneously. Working Principle: This embodiment introduces intelligent closed-loop control based on dual feedback of image clarity and probe temperature, achieving a leap from "continuous blind purging" to "precise supply on demand." The system can automatically and seamlessly switch between three modes: basic protection, enhanced prevention, and powerful recovery, based on real-time operating conditions. When there are conflicts in the control commands for cooling gas, the system follows the principle of safety priority, prioritizing the execution of the higher-level mode. The priority is: powerful recovery mode (= maximum cooling mode) > enhanced prevention mode (= powerful cooling mode) > basic barrier mode (= basic cooling mode). This multi-parameter, multi-level collaborative intelligent control strategy ensures optimal protection while optimizing energy consumption, marking the evolution of the system from a mechanical device to a complete intelligent solution.

Claims

1. A furnace nose high-temperature camera system, comprising a furnace body, connecting ears disposed on both sides of the furnace body, and a camera terminal module mounted on the connecting ears; characterized in that: The camera terminal module includes a mounting plate, a camera probe, a lighting lamp, and a sleeve; The output end of the camera probe extends through the mounting plate into the connecting ear; a sleeve is provided between the lighting lamp and the mounting plate, one end of the sleeve has a mounting hole, the other end has an open structure, and high-temperature resistant glass is fixedly installed on its inner wall; the probe end of the lighting lamp passes through the mounting hole and contacts the glass. The mounting plate has a through groove corresponding to the opening structure of the sleeve, and a second purging channel communicating with the inner wall of the through groove; a first purging channel is provided on one side of the sleeve, and its blowing end is aligned with the bottom surface of the glass. The system also includes an air supply unit and a system control unit; the air supply unit is connected to the first purging channel and the second purging channel; the system control unit includes an image analysis module, a core logic processor, and an airflow management module; The image analysis module is connected to the camera probe and is used to analyze image sharpness and output sharpness index (CI). The core logic processor controls the airflow management module based on the comparison results of the sharpness index (CI) with the preset standard threshold (S) and the warning value (T). The airflow management module is connected to the air supply unit and is used to control the operating mode of the first purging channel and the second purging channel.

2. The furnace nose high-temperature camera system according to claim 1, characterized in that, The core logic processor is configured to execute the following control strategy: When the clarity index CI > standard threshold S + warning value T, the system enters the basic barrier mode, controls the second purge channel to open with the first flow rate, and closes the first purge channel. When the standard threshold S + warning value T ≥ clarity index CI ≥ standard threshold S, the prevention enhancement mode is entered, and the second purge channel is controlled to open at a second flow rate greater than the first flow rate, while the first purge channel is opened intermittently in a pulse manner. When the resolution index CI is less than the standard threshold S, the system enters a powerful recovery mode, controlling the second purge channel to open at maximum flow while the first purge channel remains open.

3. The furnace nose high-temperature camera system according to claim 2, characterized in that, In the enhanced prevention mode, the pulse frequency of the first purge channel gradually increases as the clarity index (CI) value approaches the standard threshold S.

4. The furnace nose high-temperature camera system according to claim 3, characterized in that, The Clarity Index (CI) is a quantitative indicator obtained by performing gradient analysis on video images.

5. A furnace nose high-temperature camera system according to claim 1, characterized in that, The camera probe includes a camera housing, a camera module, a signal transmission module, a temperature detection module, and a camera probe lens; the outer wall of the camera housing is provided with an outer shell, forming a sealed space between the two; a nozzle communicating with the sealed space is provided below the camera probe lens.

6. A furnace nose high-temperature camera system according to claim 5, characterized in that, The air supply unit also includes a cooling air path, which is connected to the input end of the sealed space; the core logic processor is also configured to control the operation mode of the cooling air path based on the comparison result between the actual temperature P1 fed back by the temperature detection module and the preset temperature standard threshold P and the temperature warning value U.

7. A furnace nose high-temperature camera system according to claim 6, characterized in that, The strategy for controlling the cooling airflow operation mode of the core logic processor includes: The actual temperature is obtained by monitoring the internal temperature of the camera probe in real time through a temperature detection module. Compare the actual temperature with the preset temperature standard threshold and temperature warning value; Based on the comparison results, the control air supply unit adjusts the operating mode of the cooling air path.

8. A furnace nose high-temperature camera system according to claim 1, characterized in that, The steps for controlling the air supply unit to adjust the cooling air circuit operation mode according to the comparison results include: when the actual temperature P1 < temperature standard threshold P - temperature warning value U, the basic cooling mode is entered, and the cooling air circuit is controlled to open with the first cooling flow rate.

9. A furnace nose high-temperature camera system according to claim 8, characterized in that, The step of controlling the air supply unit to adjust the cooling air circuit operation mode according to the comparison results also includes entering the enhanced cooling mode when the temperature standard threshold P ≥ the actual temperature P1 ≥ the temperature standard threshold P - the temperature warning value U, and controlling the cooling air circuit to open with a second cooling flow rate greater than the first cooling flow rate.

10. A furnace nose high-temperature camera system according to claim 9, characterized in that, The steps for controlling the air supply unit to adjust the cooling air circuit operation mode based on the comparison results also include: when the actual temperature P1 > the temperature standard threshold P, entering the maximum cooling mode and controlling the cooling air circuit to open with the maximum cooling flow.

11. A furnace nose high-temperature camera system according to claim 10, characterized in that, The operating mode of the cooling air path is coordinated with the operating mode of the dual purging device. When there is a conflict in the control commands, the preset priority is followed.

12. A furnace nose high-temperature camera system according to claim 11, characterized in that, Among the basic cooling modes, the Powerful Recovery Mode and Maximum Cooling Mode have the highest priority, followed by the Prevention Enhancement Mode and Enhanced Cooling Mode, while the Basic Barrier Mode and Basic Cooling Mode have the lowest priority.

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