Intelligent building method and system for coke oven refractory bricks

Abstract

The invention discloses an intelligent masonry method and system for coke oven refractory bricks, and aims to fundamentally improve the masonry quality of the coke oven refractory bricks. The intelligent building method comprises the following steps: building a BIM information model and a virtual building system of a to-be-built area of the coke oven; the entity building system selects refractory bricks from a physical world and supplies the refractory bricks to a shooting position of the 3D camera through a conveying belt; the 3D camera is in communication connection with the virtual masonry system; the 3D camera is used for carrying out image acquisition on the refractory bricks and transmitting the acquired data to the virtual masonry system; the virtual masonry system judges whether the type of the refractory bricks meets a preset specification or standard, then performs size detection on the refractory bricks, performs virtual masonry operation after detection, measures the size of gaps between the refractory bricks, and measures and calculates the slurry filling amount and spraying process parameters when the size of the gaps between the refractory bricks reaches a slurry fullness effect; and an instruction and parameters are sent to an entity masonry system to automatically implement slurry spraying and masonry.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of intelligent masonry technology, more particularly, to an intelligent masonry method and system for refractory bricks of coke ovens. BACKGROUND

[0002] The masonry process of refractory bricks for large coke ovens is complex, labor efficiency is low, the masonry workload is large and the precision requirement is high. The robot intelligent masonry of refractory bricks not only can save a lot of labor, energy saving and environmental protection in the operation process, but also can greatly shorten the construction period. With the improvement of construction efficiency and quality requirements, the automatic smearing technology of refractory bricks has gradually become the mainstream demand. According to the classification of refractory bricks in different parts and different sizes, there are about eight hundred types of refractory bricks in a coke oven. When using a machine to masonry refractory bricks of coke ovens, not only the type of the refractory brick to be masonry needs to be identified and confirmed, but also due to the size deviation of the refractory bricks in the manufacturing process (within the specification allowed size deviation), which will cause the gap between the bricks in the masonry process and the theoretical value to deviate, causing the problem that the refractory mortar is squeezed out or not filled enough when the spraying mechanism sprays the refractory mortar. The inventor has previously alleviated this problem through some technical means, for example, the invention application with publication number CN120311985A provides a brick automatic positioning and mortar smearing equipment, which detects the three-dimensional space position of the brick surface through multiple laser displacement sensors, and transmits the measured data to the mechanical arm control system. The mechanical arm control system adjusts the motion trajectory of the mechanical arm and the position of the nozzle in real time according to the position information, so as to ensure that the nozzle and the brick surface maintain the best distance and angle, and then realize the uniform smearing of the mortar. However, how to find the size deviation of the refractory bricks before masonry, exclude the refractory bricks with too large deviation from the masonry process, and control the masonry process parameters according to different size deviations, so as to fundamentally improve the masonry quality of the refractory bricks of coke ovens, is still a technical problem that has not been solved.

[0003] Building Information Modeling (BIM) models and digital twins need to be able to exchange data and achieve interoperability, so that the building geometry, properties, and operational data extracted from BIM can be seamlessly used for the creation and updating of digital twin models. Digital twins rely on real-time data collection and sensor technology to reflect the actual conditions of buildings during operation. BIM can provide initial design and geometric data of buildings. Combining BIM and digital twin technology, various simulation and optimization tools can be developed, such as building energy efficiency analysis, environmental impact assessment, emergency situation simulation, etc., to help optimize the design, operation and maintenance strategies of buildings. However, how to apply the BIM integrated digital twin system to the masonry engineering to realize real-time data updating and optimize the masonry process is still a technical difficulty. SUMMARY

[0004] In view of the above defects in the prior art, the present application provides an intelligent laying method and system for coke oven refractory bricks, and a virtual laying system based on BIM and digital twinning is constructed to perform simulation and pre-detection. The real size of the refractory brick is detected before laying, and the real size is updated to the BIM model in real time, and it is judged whether the brick meets the reference condition and the deviation condition in the position relationship, and the spraying mechanism is controlled to calculate the spraying amount according to the actual size of the brick, so as to ensure the filling quality of the refractory mortar and not waste.

[0005] To achieve the above-mentioned purpose, in one aspect, the present application provides an intelligent laying method for coke oven refractory bricks, comprising the following steps:

[0006] Step S1, constructing a BIM information model and a virtual laying system for a coke oven laying area to be laid;

[0007] Step S2, the physical laying system selects refractory bricks from the physical world and supplies them to the shooting position of the 3D camera through the conveyor belt; the 3D camera is communicatively connected with the virtual laying system to realize real-time transmission of data;

[0008] Step S3, collecting and mapping the construction site information including the laying robot, sensors, and materials into data information, and importing the data information into the virtual laying system;

[0009] Step S4, the 3D camera collects images of the refractory bricks and transmits the collected data to the virtual laying system; the virtual laying system processes the image data through feature extraction and matching algorithms to determine whether the type of the refractory brick meets the preset specifications or standards, thereby verifying the accuracy of the refractory brick; if the type of the refractory brick is confirmed to be accurate, the virtual laying system performs size detection of the refractory brick and simultaneously judges whether the size deviation is within the allowable range; if the type of the refractory brick is not accurate, the physical laying system moves the refractory brick to the refractory brick recycling area through the conveyor belt;

[0010] Step S5, when the size deviation of the refractory brick is within the allowable range, the virtual laying system automatically performs virtual laying operation, places the refractory brick at the predetermined designated position, and updates the refractory brick size data in the BIM model; if the size deviation of the refractory brick is not within the allowable range, a brick type replacement program is started;

[0011] Step S6, the virtual laying system measures the gap size between the refractory bricks during virtual laying operation, calculates the mortar filling amount and spraying process parameters when the gap size between the refractory bricks reaches the mortar fullness effect, and sends instructions and parameters to the physical laying system to automatically implement mortar spraying and laying;

[0012] Step S7, after the above process is completed, when a layer of refractory brick masonry task of a wall is completed, the virtual masonry system inquires whether to continue masonry; if the masonry is continued, the next layer of refractory brick masonry task is started, the refractory bricks are transported to the designated position and the steps S2 to S6 are repeated, otherwise the virtual masonry system is automatically turned off.

[0013] The present application sets up real-time communication between the virtual masonry system integrated with BIM and the physical masonry system, detects the size of the special-shaped brick and checks the size of the brick joint by using the virtual masonry system before masonry, analyzes the simulation after meeting the size requirements of the brick, checks the masonry planning process in real time, and realizes that the system detection meets the requirements, and sends instructions to the physical masonry system for masonry, so that the masonry efficiency can be greatly improved and the masonry quality can be improved.

[0014] Further, the virtual masonry system based on the digital twin system of Unity further comprises a refractory brick data acquisition module, an equipment information acquisition module, a refractory brick model automatic identification module, a refractory brick size deviation automatic detection module and a brick joint gap size detection module.

[0015] Further, in the step S3, the virtual masonry system groups the collected data information by structure type, sensor type and data type; then, sorts the data information according to the masonry planning sequence; finally, integrates the sorted data information into the database.

[0016] Further, the sensor comprises one or more of a position state sensing sensor of a masonry robot, a temperature sensor, a vibration sensor, a visual sensor, a displacement sensor, a pressure sensor and a flow sensor.

[0017] Further, in the step S4, the 3D camera performs point cloud scanning on the refractory brick, transmits the scanned refractory brick size data to the virtual masonry system, performs data screening first, then performs data recognition through the feature extraction and matching algorithm based on point cloud data in the refractory brick model automatic identification module, and finally transmits to the refractory brick size deviation automatic detection module.

[0018] Further, in the steps S1 and S4, the IFC file containing BIM information is processed by using P-Prolog logic language, and the refractory brick size information and the position information between the refractory bricks are directly extracted by filtering the redundant information in the IFC file.

[0019] Further, in the step S5, the refractory brick replacement program comprises transporting the unqualified bricks to the refractory brick recycling position, issuing an alarm prompt, and re-executing the step S4 after replacing the refractory bricks.

[0020] Further, in the step S6, the virtual masonry system calculates the gap size of the firebricks according to the size of the firebricks and the positioning axis information.

[0021] In another aspect, the present application provides an intelligent masonry system for coke oven firebricks, which implements the intelligent masonry method for coke oven firebricks as described above, comprising:

[0022] The physical masonry system comprises a masonry robot and its supporting device, a firebrick conveying device, a sensor, and a 3D camera, and implements the masonry of the coke oven firebricks.

[0023] The virtual masonry system comprises a central processing unit, which collects the construction site information including the masonry robot, the sensor, and the materials; processes the image data of the firebricks through a feature extraction and matching algorithm to determine whether the type of the firebricks meets the preset specifications or standards; performs size detection of the firebricks and determines whether the size deviation is within the allowable range; performs virtual masonry operation of the firebricks, updates the size data of the firebricks in the BIM model in real time, measures the gap size between the firebricks, calculates the mud filling amount and the spraying process parameters when the gap size between the firebricks reaches the mud fullness effect, and sends instructions and parameters to the physical masonry system to implement the spraying and masonry of the mud.

[0024] Further, the virtual masonry system further comprises a display device for visualizing the model and monitoring the masonry process.

[0025] Compared with the prior art, the above-mentioned application has the following advantages or beneficial effects:

[0026] (1) The intelligent masonry method of the present application sets up real-time communication between the virtual masonry system integrated with BIM and the physical masonry system, detects the size of the special-shaped bricks and checks the brick joint size using the virtual masonry system before masonry, performs simulation analysis after meeting the size requirements of the bricks, and real-time checks the masonry planning process. After the system detection meets the requirements, the physical masonry system is instructed to perform masonry, thereby greatly improving the masonry efficiency and enhancing the masonry quality.

[0027] (2) The present application designs an entity information transmission system of 3D camera and sensor, then sorts the data information according to the masonry planning sequence, and finally integrates the sorted data information. After completing information collection, the communication connection between the masonry robot and the computer is established to realize the construction of the virtual masonry system. The information transmission of the 3D camera and the sensor can improve the efficiency of engineering dynamic monitoring and provide stable information exchange for the virtual system.

[0028] (3) The virtual masonry system integrated with BIM can provide technical support for intelligent masonry of the masonry robot, such as model visualization, masonry process optimization, masonry process monitoring display, and the like, so that manual intervention is more rapid and effective.

[0029] (4) In the present application, by using the P-Prolog logic language to process the IFC file containing BIM information, the brick size information and the position information between the bricks are directly extracted by filtering the redundant information in the IFC file, and are expressed in a simple and clear format, so that the data reading efficiency is greatly improved, and the data accuracy is convenient for subsequent operators to check. BRIEF DESCRIPTION OF DRAWINGS

[0030] The present application and its features and advantages will become more apparent from the following detailed description of non-limiting embodiments with reference to the attached drawings. Throughout the drawings, the same reference numerals indicate the same parts.

[0031] Figure 1 Data updating flowchart of the intelligent masonry method for refractory bricks in an embodiment of the present application;

[0032] Figure 2 Operation flowchart of the virtual masonry system in an embodiment of the present application;

[0033] Figure 3 Schematic diagram of the preset structure model and the simulation structure model of the refractory brick placement position in the virtual masonry system in an embodiment of the present application. DETAILED DESCRIPTION

[0034] The structure of the present application will be further described below in combination with the drawings and specific embodiments, but not as a limitation of the present application. The order of actions, steps, etc. in the devices and methods shown in the claims, specification and drawings of the present application can be implemented in any order as long as there is no specific order limitation, and the output of the previous processing is not used in the subsequent processing.

[0035] In the following detailed description, many specific details are set forth in order to provide a more thorough understanding of the present application. However, it will be apparent to one skilled in the art that known algorithms and models are not shown in detail to avoid obscuring the main idea of the present application; and the technologies involved in the following effect implementation examples are not described in detail, which are prior art that can be retrieved.

[0036] The technical solutions of the present application will be described in detail below with specific embodiments and examples.

[0037] EMBODIMENT

[0038] Reference Figure 1 and Figure 2The embodiment relates to an intelligent bricklaying system for coke oven refractory bricks, comprising a physical bricklaying system and a virtual bricklaying system. The physical bricklaying system comprises a bricklaying robot and its supporting device, a refractory brick conveying device, a sensor, and a 3D camera, and implements the bricklaying of coke oven refractory bricks. The virtual bricklaying system comprises a central processor such as a computer, and collects information of a construction site including the bricklaying robot, the sensor, and materials. The image data of the refractory bricks are processed by a feature extraction and matching algorithm to determine whether the type of the refractory bricks meets the preset specifications or standards. The size of the refractory bricks is detected, and it is determined whether the size deviation is within the allowable range. The virtual bricklaying operation updates the size data of the refractory bricks in the BIM model in real time, measures the gap size between the refractory bricks, calculates the mud filling amount and the spraying process parameters when the gap size between the refractory bricks reaches the mud fullness effect, and sends instructions and parameters to the physical bricklaying system to implement the spraying and bricklaying of the mud. The intelligent bricklaying method for coke oven refractory bricks comprises the following steps:

[0039] Step S1: constructing a BIM information model of a coke oven area to be bricklayed and a virtual bricklaying system. More specifically, a three-dimensional modeling software is used to model the refractory bricks in the area to be bricklayed, and an IFC file is exported. The model is simplified to reduce the size of the physical model. After modeling is completed, the model is imported into rendering software. The brick model is converted in coordinates and units in the rendering software and then imported into the virtual bricklaying system. The refractory bricks in the model are virtually bricklayed. The specific process is as follows:

[0040] First, a BIM model is obtained according to the modeling of the bricklaying drawing;

[0041] Then, additional elements such as spatial coordinate information are added to the BIM model;

[0042] Then, the bricklaying planning information is analyzed;

[0043] Finally, the planned information is imported into a computer to construct a digital twin system based on Unity as the basis of the virtual bricklaying system. In addition, the virtual bricklaying system is also provided with a refractory brick data acquisition module, a device information acquisition module, a refractory brick model automatic identification module, a refractory brick size deviation automatic detection module, and a brick joint gap size detection module.

[0044] Step S2: the physical bricklaying system selects the required refractory bricks from the physical world and supplies them to the shooting position of the 3D camera through a conveyor belt; the 3D camera is communicatively connected with the virtual bricklaying system to realize real-time data transmission. The specific process is as follows:

[0045] First, the bricks needed to be built in the bricklaying layer are selected according to the bricklaying drawing;

[0046] Then, the bricks are conveyed to the 3D camera shooting position by the conveyor belt.

[0047] In step S3, the construction site information including the masonry robot, sensors, and materials is collected and mapped into data information, which is imported into the virtual masonry system. The specific process is exemplified as follows:

[0048] Firstly, the sensors of the construction site and the masonry robot are started. Exemplarily, the sensors include one or more of the position state sensing sensor, temperature sensor, vibration sensor, visual sensor, displacement sensor, pressure sensor, and flow sensor of the masonry robot.

[0049] Then, the data information collected by the sensors is grouped by structure type, sensor type, and data type.

[0050] Then, the data information is sorted according to the masonry planning sequence.

[0051] Finally, the sorted data information is integrated into the database, which is convenient for comparison with the preset standard parameters of the masonry process.

[0052] In step S4, the 3D camera collects image data of the refractory bricks and transmits the collected point cloud data to the virtual masonry system. The virtual masonry system processes the image data through a feature extraction and matching algorithm based on the point cloud data to determine whether the type of the refractory bricks meets the preset specifications or standards, thereby verifying the accuracy of the refractory bricks. Exemplarily, the feature extraction and matching algorithm can be a known algorithm such as the ORB (Oriented FAST and Rotated BRIEF) image feature extraction and matching algorithm, a feature extraction network based on a pre-trained CNN (such as ResNet), etc. More specifically, the 3D camera performs point cloud scanning on the refractory bricks, first determines the shape template of the bricks by the 3D camera, and then calculates the detailed dimensions of the bricks by the 3D camera. See Figure 3 After transmitting the scanned refractory brick size data to the virtual masonry system, the data is first screened, and then recognized by the feature extraction and matching algorithm based on the point cloud data in the refractory brick model automatic recognition module. The brick model is compared and determined by the virtual masonry system template library.

[0053] If the type of the refractory bricks is confirmed to be accurate, it is conveyed to the refractory brick size deviation automatic detection module, and the virtual masonry system performs size detection of the refractory bricks and simultaneously determines whether the size deviation is within the allowable range. If the type of the refractory bricks is not accurate, the physical masonry system moves the refractory bricks to the refractory brick recycling area by the conveyor belt.

[0054] As a preferred embodiment, in steps S1 and S4, the IFC file containing BIM information is processed by using P-Prolog logic language, and the size information of the firebrick and the position information between the firebricks are directly extracted by filtering the redundant information in the IFC file.

[0055] In step S5, when the size deviation of the firebrick is within the allowable range, the virtual masonry system will automatically perform virtual masonry operation, place the firebrick at the predetermined designated position, and update the size data of the firebrick in the BIM model; if the size deviation of the firebrick is not within the allowable range, a brick replacement program will be started. The firebrick replacement program can include transporting the unqualified brick to a firebrick recycling position, issuing an alarm prompt, and re-executing the step S4 after replacing the firebrick.

[0056] In step S6, the virtual masonry system measures the gap size between the firebricks during virtual masonry operation, calculates the process parameters including the amount of mud filling and the required pressure and speed of spraying when the gap size between the firebricks reaches the mud fullness effect through a large number of experiments, and issues instructions and parameters to the physical masonry system to automatically implement mud spraying and masonry.

[0057] In step S7, after completing the above process, when completing the firebrick masonry task of one layer of one wall, the virtual masonry system inquires whether to continue masonry; if the masonry continues, the next layer of firebrick masonry task is started, the firebrick is transported to the designated position, and the steps S2 to S6 are repeated, otherwise the virtual masonry system is automatically turned off.

[0058] As can be seen from the above description, the intelligent masonry of the coke oven firebrick of the present application is simulated and pre-detected by constructing a virtual masonry system based on BIM and digital twinning. The real size of the firebrick is detected before masonry, and the real size is updated to the BIM model in real time, and whether the brick meets the reference condition and the deviation condition in the position relationship is judged, and the spraying mechanism is controlled to calculate the spraying amount according to the actual size of the brick, to ensure the filling quality of the fireclay and not to waste.

[0059] Those skilled in the art should understand that those skilled in the art can realize variations in combination with the prior art and the above embodiments, which are not described here. Such variations do not affect the essential content of the present application, which is not described here.

[0060] The preferred embodiments of the present application have been described. It is to be understood that the application is not limited to the above specific embodiments, and that devices and structures not described in detail should be understood to be implemented in the ordinary way in the art; any person skilled in the art can make many possible changes and modifications to the technical solutions of the present application, or modify them into equivalent embodiments with equivalent changes, without departing from the scope of the technical solutions of the present application, which does not affect the essential content of the present application. Therefore, any simple modification, equivalent change and modification made to the above embodiments according to the technical essence of the present application, without departing from the content of the technical solutions of the present application, still belongs to the scope of protection of the technical solutions of the present application.

Claims

1. An intelligent method for laying refractory bricks for coke ovens, characterized in that, Includes the following steps: Step S1: Construct a BIM information model and virtual masonry system for the area to be paved in the coke oven; Step S2: The physical masonry system selects refractory bricks from the physical world and supplies them to the shooting position of the 3D camera via a conveyor belt; the 3D camera is connected to the virtual masonry system to achieve real-time data transmission; Step S3: Collect and map construction site information, including masonry robots, sensors, and materials, into data information and import it into the virtual masonry system; Step S4: The 3D camera acquires images of the refractory bricks and transmits the acquired data to the virtual masonry system. The virtual bricklaying system processes image data using feature extraction and matching algorithms to determine whether the type of refractory bricks conforms to preset specifications or standards, thereby verifying the accuracy of the refractory bricks. If the type of refractory bricks is confirmed to be accurate, the virtual bricklaying system performs dimensional detection of the refractory bricks and simultaneously determines whether the dimensional deviation is within the allowable range. If the type of refractory bricks is inaccurate, the physical bricklaying system will move the refractory bricks to the refractory brick recycling area via a conveyor belt. Step S5: When the dimensional deviation of the refractory brick is within the allowable range, the virtual masonry system will automatically perform virtual masonry operation, place the refractory brick in the predetermined designated position, and update the refractory brick dimensional data in the BIM model; if the dimensional deviation of the refractory brick is not within the allowable range, the brick type replacement program will be started. Step S6: During the virtual masonry operation, the virtual masonry system measures the gap size between refractory bricks, calculates the gap size between refractory bricks to achieve the effect of full slurry filling, including the slurry filling amount and spraying process parameters, and sends instructions and parameters to the physical masonry system to automatically implement slurry spraying and masonry. Step S7: After completing the above process, when the task of laying one layer of refractory bricks for one wall is completed, the virtual masonry system requests whether to continue the masonry. If the masonry continues, the next layer of refractory bricks will be laid, the refractory bricks will be transferred to the designated position and steps S2 to S6 will be repeated. Otherwise, the virtual masonry system will automatically shut down.

2. The intelligent masonry method for coke oven refractory bricks according to claim 1, characterized in that, The virtual masonry system is a Unity-based digital twin system and also includes a refractory brick data acquisition module, an equipment information acquisition module, a refractory brick model automatic identification module, a refractory brick size deviation automatic detection module, and a brick joint gap size detection module.

3. The intelligent construction method for coke oven refractory bricks according to claim 1, characterized in that, In step S3, the virtual masonry system groups the collected data information by structure type, sensor type, and data type; then, it sorts the data information according to the masonry planning sequence; finally, it integrates the sorted data information into the database.

4. The intelligent masonry method for coke oven refractory bricks according to claim 3, characterized in that, The sensors include one or more of the following: position and status sensing sensors for the bricklaying robot, temperature sensors, vibration sensors, vision sensors, displacement sensors, pressure sensors, and flow sensors.

5. The intelligent masonry method for coke oven refractory bricks according to claim 2, characterized in that, In step S4, the 3D camera performs point cloud scanning on the refractory bricks. After transmitting the scanned refractory brick size data to the virtual masonry system, the data is first filtered, and then identified by the feature extraction and matching algorithm based on point cloud data in the refractory brick model automatic identification module. Finally, the data is transmitted to the refractory brick size deviation automatic detection module.

6. The intelligent masonry method for coke oven refractory bricks according to claim 1, characterized in that, In steps S1 and S4, the IFC file containing BIM information is processed using the P-Prolog logic language. By filtering out redundant information in the IFC file, the size information of the refractory bricks and the positional information between the refractory bricks are directly extracted.

7. The intelligent construction method for coke oven refractory bricks according to claim 1, characterized in that, In step S5, the refractory brick replacement procedure includes transporting the unqualified bricks to the refractory brick recycling location, issuing an alarm prompt, and re-executing step S4 after replacing the refractory bricks.

8. The intelligent masonry method for coke oven refractory bricks according to claim 1, characterized in that, In step S6, the virtual masonry system calculates the gap size of the refractory bricks based on the size of the refractory bricks and the positioning axis information.

9. An intelligent masonry system for coke oven refractory bricks, characterized in that, The intelligent masonry method for coke oven refractory bricks as described in any one of claims 1 to 8 includes: The physical bricklaying system, including a bricklaying robot and its support device, a refractory brick conveying device, sensors, and a 3D camera, is used to lay coke oven refractory bricks. The virtual bricklaying system, including a central processing unit, collects construction site information, including information from bricklaying robots, sensors, and materials. It processes the image data of refractory bricks using feature extraction and matching algorithms to determine if the type of refractory brick conforms to preset specifications or standards. It performs dimensional checks on the refractory bricks and determines if dimensional deviations are within acceptable limits. The virtual refractory bricklaying operation updates the refractory brick dimensional data in the BIM model in real time, measures the gap dimensions between refractory bricks, calculates the mortar filling amount and spraying process parameters to achieve the desired mortar filling effect, and sends instructions and parameters to the physical bricklaying system to implement mortar spraying and bricklaying.

10. The intelligent masonry system for coke oven refractory bricks according to claim 9, characterized in that, The virtual masonry system also includes a visualization model and a display device for monitoring the masonry process.

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