A non-contact insulator mud water content detection system and method

Abstract

The application belongs to the technical field of material detection, and discloses a non-contact insulator mud water content detection system and method; the system comprises the following steps: generating a continuous microwave signal and transmitting the signal to insulator mud in a directional manner to obtain a microwave transmission total attenuation value; obtaining a transmission end distance and a receiving end distance, and combining a preset reference distance to obtain a measured thickness value; dynamically evaluating an air propagation attenuation amount of the continuous microwave signal, calculating a temperature drift attenuation amount, compensating and correcting the microwave transmission total attenuation value based on the air propagation attenuation amount and the temperature drift attenuation amount to obtain a mud correction attenuation value; decoupling the mud correction attenuation value according to the measured thickness value to obtain a specific attenuation rate; and performing water content inversion on the specific attenuation rate to obtain a water content detection value; the application realizes safe, stable, real-time and high-precision detection of the internal water content of insulator mud without contacting the mud and damaging the production process.

Description

Technical Field

[0001] This invention relates to the field of materials testing technology, and more specifically, to a non-contact insulator mortar moisture detection system and method. Background Technology

[0002] In the production of porcelain insulators, the moisture content of the clay is a key process parameter affecting subsequent molding quality, drying behavior, and firing defects. Currently, the detection of clay moisture in industrial settings mainly relies on the drying and weighing method, the contact hardness conversion method, and the infrared optical detection method. Among these, the drying and weighing method, as a standard laboratory method, requires sampling and destructive drying, resulting in a long detection cycle and failing to meet the needs of online real-time detection. The contact hardness conversion method indirectly estimates moisture by measuring the surface hardness of the clay, but it is significantly affected by the operator's technique, has poor repeatability, and only reflects the local surface condition. Infrared and optical detection methods are surface detection technologies with limited penetration capabilities and are easily affected by clay color, surface roughness, and environmental dust, making it impossible to measure the internal moisture of insulator clay sections with a thickness of 20 to 25 centimeters. In recent years, microwave transmission detection technology has attracted attention due to its good penetration capability in water-containing media. However, existing microwave moisture detection solutions are mostly designed for single-plate, bulk, or thin-layer materials, and usually adopt high-power wide-spectrum schemes to improve penetration capabilities. This results in problems such as high power consumption, significant radiation safety hazards, complex system structure, and high cost, making it difficult to promote and apply in small and medium-sized insulator manufacturing enterprises.

[0003] Furthermore, the transmission attenuation value of microwave signals after penetrating cement-containing materials is simultaneously affected by multiple factors, including moisture content, spatial distance between the transmitter and receiver, and ambient temperature. Although existing technologies have corrected and compensated for distance and temperature factors to some extent, they generally ignore the impact of mud thickness fluctuations on the detection results. In the actual production of insulator mud, the thickness of mud segments of different specifications varies, and mud segments of the same specification will also have thickness deviations during cutting and transportation. Since the microwave transmission attenuation value is directly related to the mud thickness, the attenuation value change caused by thickness variation can be misjudged as a change in moisture content, resulting in the coupling of moisture information and thickness information in the detection results, which is particularly prominent in the production scenario of mixed mud segments of multiple specifications. However, most existing microwave moisture detection solutions assume that the thickness of the tested material is constant or known in advance, and lack technical means to simultaneously measure the mud thickness and decouple the thickness factor from the attenuation signal, resulting in detection accuracy being limited by the consistency of mud thickness. Therefore, there is an urgent need for a moisture detection system that can realize non-contact microwave transmission detection of ultra-thick insulator mud and has the ability to simultaneously measure mud thickness and decouple thickness.

[0004] In view of this, the present invention proposes a non-contact insulator mortar moisture detection system and method to solve the above problems. Summary of the Invention

[0005] To overcome the aforementioned deficiencies of the prior art and achieve the above objectives, the present invention provides the following technical solution: a non-contact method for detecting moisture in insulator mortar, comprising: A continuous microwave signal is generated, and the continuous microwave signal is directionally transmitted to the insulator mud and the continuous microwave signal after penetrating the insulator mud is received to obtain the total microwave transmission attenuation value. The distance between the transmitting end and the receiving end is obtained, and combined with the preset reference spacing, the measured thickness value of the insulator mud is obtained; Based on the distance between the transmitter and receiver, the air propagation attenuation of the continuous microwave signal in the air path is dynamically evaluated, and the surface temperature of the mud is collected simultaneously. The temperature drift attenuation is calculated based on the surface temperature of the mud. The total microwave transmission attenuation is compensated and corrected based on the air propagation attenuation and the temperature drift attenuation to obtain the corrected attenuation value of the mud. Based on the measured thickness value, the corrected attenuation value of the clay is decoupled by thickness to quantitatively characterize the microwave absorption capacity of the clay per unit thickness and obtain the specific attenuation rate. By comparing the attenuation rate, the moisture content is inverted to obtain the moisture content detection value of the insulator mortar. The moisture content detection value is then displayed, stored, and an over-limit alarm is triggered.

[0006] Furthermore, methods for obtaining the total microwave transmission attenuation value include: An initial microwave signal with a preset center frequency is generated, and the initial microwave signal is amplified to obtain an amplified microwave signal; based on the amplified microwave signal, a transmission reference power value is obtained; the transmission reference power value is used to verify signal stability to obtain a stable transmission power value; the amplified microwave signal is fed into a microwave transmitting horn antenna through an RF coaxial cable and received through a microwave receiving horn antenna; Based on the microwave signal received by the microwave receiving horn antenna, the instantaneous received power value is obtained; the instantaneous received power value is subjected to multiple sampling and mean filtering to obtain the received measured power value; the validity of the received measured power value is determined, and if the received measured power value is valid, the difference between the transmitted stable power value and the received measured power value is calculated to obtain the total microwave transmission attenuation value.

[0007] Furthermore, methods for obtaining the measured thickness value of the insulator mortar include: The original distance values ​​of the transmitter and receiver are obtained, and the original distance values ​​of the transmitter and receiver are sampled and filtered multiple times to obtain the transmitter distance and receiver distance. Based on the transmitter distance, receiver distance and reference spacing, the measured thickness of the insulator mud is calculated, and the reasonableness of the measured thickness value is verified. The method for performing multiple sampling and filtering on the original distance values ​​of the transmitter is as follows: Multiple original distance values ​​of the transmitter are continuously acquired to form a transmitter distance sampling sequence; the standard deviation of all original distance values ​​of the transmitter in the transmitter distance sampling sequence is calculated to obtain the transmitter ranging fluctuation; if the transmitter ranging fluctuation is less than or equal to a preset ranging fluctuation threshold, the mean of all original distance values ​​of the transmitter in the transmitter distance sampling sequence is calculated to obtain the transmitter distance; if the transmitter ranging fluctuation is greater than the ranging fluctuation threshold, median filtering is performed on the transmitter distance sampling sequence to obtain the transmitter distance.

[0008] Furthermore, methods for compensating and correcting the total microwave transmission attenuation include: Based on the distance between the transmitter and receiver, a segmented asymmetric beam spread model is used to calculate the air attenuation components at the transmitter and receiver respectively. The air attenuation components at the transmitter and receiver are then fused to obtain the initial air propagation attenuation. Standing wave interference correction is then applied to the initial air propagation attenuation to obtain the final air propagation attenuation. Based on the surface temperature and measured thickness of the insulator clay, the equivalent body temperature of the clay is estimated; a calibration reference temperature is preset, and the equivalent temperature deviation is calculated based on the calibration reference temperature and the surface temperature of the clay; based on the equivalent temperature deviation, the distance between the transmitter and the receiver, a temperature-distance coupled multi-stage compensation model is used to calculate the temperature drift attenuation. The total microwave transmission attenuation value is subtracted by the air propagation attenuation and the temperature drift attenuation value to obtain the mud material correction attenuation value. Then, the compensation consistency self-verification and effectiveness verification are performed in sequence.

[0009] Furthermore, the method for decoupling the thickness of the clay material correction attenuation value based on the measured thickness value includes: The interface transition loss is separated from the corrected attenuation value of the mud material to obtain the volumetric absorption attenuation; the equivalent propagation path length is calculated based on the measured thickness value, and the specific attenuation rate is calculated based on the volumetric absorption attenuation and the equivalent propagation path length. The method for separating the interface transition loss of the corrected attenuation value of the mud is as follows: preset the interface transition loss benchmark value and the interface temperature correction coefficient; calculate the interface temperature deviation value based on the mud surface temperature and the calibration benchmark temperature; calculate the interface temperature correction amount based on the interface temperature correction coefficient and the interface temperature deviation value; calculate the actual interface transition loss amount based on the interface transition loss benchmark value and the interface temperature correction amount; calculate the difference between the corrected attenuation value of the mud and the actual interface transition loss amount to obtain the volume absorption attenuation amount. The method for calculating the specific attenuation rate is as follows: preset the scattering path extension coefficient, calculate the equivalent propagation path length based on the measured thickness value and the scattering path extension coefficient; calculate the ratio of volume absorption attenuation to the equivalent propagation path length to obtain the specific attenuation rate.

[0010] Furthermore, the step of retrieving moisture content by comparing the decay rate includes: Step S1: Use the free water-bound water dual-state segmented calibration model to compare the attenuation rate and perform initial moisture inversion to obtain the initial moisture content value; Step S2: Perform a second-order temperature correction on the initial moisture content value to obtain the temperature-corrected moisture content value; Step S3: Perform end-to-end attenuation reconstruction self-consistency verification on the temperature-corrected moisture content value to obtain the detection reliability; Step S4: Based on the detection confidence level, perform a reliability test on the temperature-corrected moisture content value; Step S5: If the temperature-corrected moisture content value passes the reliability test, then the temperature-corrected moisture content value is subjected to a reliability-weighted time-series smoothing process to obtain the moisture content detection value.

[0011] Furthermore, in step S1, the method for initial moisture inversion by comparing the decay rate includes: A segmented calibration model for the free water-bound water dual state is pre-constructed. The segmented calibration model for the free water-bound water dual state includes the calibration slope of the bound water segment, the calibration intercept of the bound water segment, the calibration slope of the free water segment, the calibration intercept of the free water segment, and the conversion ratio attenuation rate. The specific decay rate is input into the free water-bound water dual-state segmented calibration model, and the specific decay rate is compared with the transformation specific decay rate. If the specific decay rate is less than or equal to the transformation specific decay rate, a first-order linear inversion calculation is performed using the bound water segment calibration slope and the bound water segment calibration intercept to obtain the initial moisture content value. If the specific decay rate is greater than the transformation specific decay rate, a first-order linear inversion calculation is performed using the free water segment calibration slope and the free water segment calibration intercept to obtain the initial moisture content value.

[0012] Furthermore, methods for pre-constructing a segmented calibration model of the free water-bound water dual state include: Multiple calibration samples with different calibration reference moisture content values ​​were prepared, and microwave transmission tests were performed sequentially under calibration reference temperature conditions to obtain the specific attenuation rate of each calibration sample. The specific attenuation rate of each calibration sample was used as the independent variable and the calibration reference moisture content value as the dependent variable to construct a calibration dataset. All data points in the calibration dataset are sorted in ascending order of specific decay rate to obtain an ordered calibration data sequence. Candidate segment points are selected from the ordered calibration data sequence. The preceding and following segments corresponding to each candidate segment point are obtained. The preceding and following segments are fitted using first-order linear regression. The total sum of squared residuals for each candidate segment point is calculated by combining all data points. The specific decay rate corresponding to the candidate segment point with the smallest total sum of squared residuals is taken as the transformation specific decay rate. Data points with a specific decay rate less than or equal to the conversion specific decay rate are assigned to the bound water-dominated segment, and those with a specific decay rate greater than or equal to the free water-dominated segment. First-order linear regression fitting is performed on the data points of the bound water-dominated segment and the data points of the free water-dominated segment respectively to obtain the calibration slope, calibration intercept, calibration slope, and calibration intercept of the bound water segment in sequence.

[0013] Furthermore, in step S3, the method for obtaining the detection confidence level includes: Substitute the temperature-corrected moisture content value into the free water-bound water dual-state segmented calibration model to calculate the corresponding expected value of specific attenuation rate; calculate the expected value of volume absorption attenuation based on the expected value of specific attenuation rate and equivalent propagation path length; calculate the expected value of mud correction attenuation based on the expected value of volume absorption attenuation and actual interface transition loss; calculate the sum of the expected value of mud correction attenuation, air propagation attenuation and temperature drift attenuation to obtain the expected value of total microwave transmission attenuation. The absolute value of the difference between the expected value of total microwave transmission attenuation and the total microwave transmission attenuation is calculated to obtain the end-to-end reconstruction residual. A preset allowable threshold for reconstruction residual is set, and the ratio of the end-to-end reconstruction residual to the allowable threshold for reconstruction residual is calculated to obtain the residual exceedance rate. If the residual exceedance rate is greater than one, the residual exceedance rate is set to one. The difference between one and the residual exceedance rate is calculated to obtain the detection reliability.

[0014] A non-contact insulator mortar moisture detection system, implementing the aforementioned non-contact insulator mortar moisture detection method, includes: The microwave acquisition module is used to generate a continuous microwave signal, directionally transmit the continuous microwave signal to the insulator mud, and receive the continuous microwave signal after it penetrates the insulator mud to obtain the total microwave transmission attenuation value. The thickness measurement module is used to obtain the distance between the transmitting end and the receiving end, and combined with the preset reference spacing, to obtain the measured thickness value of the insulator mud material. The environmental compensation module is used to dynamically evaluate the air propagation attenuation of continuous microwave signals in the air path based on the distance between the transmitter and receiver, and simultaneously collect the surface temperature of the mud, calculate the temperature drift attenuation based on the surface temperature of the mud, and compensate and correct the total microwave transmission attenuation value based on the air propagation attenuation and the temperature drift attenuation to obtain the mud correction attenuation value. The thickness decoupling module is used to decouple the corrected attenuation value of the clay material based on the measured thickness value, quantitatively characterize the microwave absorption capacity of the clay material per unit thickness, and obtain the specific attenuation rate. The moisture detection module is used to compare the attenuation rate to invert the moisture content, obtain the moisture content detection value of the insulator mud, and display, store, and alarm for exceeding the limit of the moisture content detection value.

[0015] The technical effects and advantages of the non-contact insulator mortar moisture detection system and method of the present invention are as follows: By employing low-frequency, low-power continuous microwave signals for non-contact transmission detection of insulator mortar, effective penetration of highly dense insulator mortar with a thickness of 20 to 25 centimeters is achieved under safe conditions where the transmission power does not exceed 10 milliwatts. This overcomes the shortcomings of high-power, wide-spectrum schemes, which result in high power consumption and significant radiation safety hazards. Furthermore, by simultaneously acquiring the distance between the transmitter and receiver by setting distance sensors at both the microwave transmitter and receiver ends, and combining this with the reference spacing to calculate the measured thickness of the insulator mortar in real time, the problem of lacking synchronous thickness measurement capability can be effectively solved. By employing a piecewise asymmetric beam diffusion model to independently calculate the air attenuation components at the transmitter and receiver and introducing standing wave interference correction, the periodic jump in received power caused by changes in the placement position of the mud material is effectively eliminated. By estimating the equivalent body temperature of the mud material based on the surface temperature change rate and the measured thickness value, the limitation of infrared temperature sensors that can only detect surface temperature and cannot characterize the true internal temperature state of the mud material is overcome. Furthermore, a temperature-distance coupled multi-order compensation model is adopted to simultaneously compensate for the first-order linear temperature drift effect, the second-order nonlinear dielectric relaxation shift effect, and the evaporation water vapor coupling effect, significantly improving the completeness and accuracy of temperature compensation. By separating the interface transition loss of the mud material correction attenuation value and introducing scattering path extension correction to calculate the equivalent propagation path length, the contribution of fixed interface loss independent of thickness and the contribution of forward scattering effect related to thickness nonlinearity are eliminated, making the specific attenuation rate have thickness-independent characteristics. This effectively solves the core technical problem of limited detection accuracy caused by the mutual coupling of moisture information and thickness information in multi-specification mud segment mixed production scenarios. By constructing a segmented calibration model for both free and bound water states, different calibration slopes are distinguished between the bound water-dominated absorption range and the free water-dominated absorption range, avoiding the systematic overestimation and underestimation biases generated by a single linear model in the two moisture state ranges. Through independent compensation of the indirect impact of temperature changes on the dynamic equilibrium transformation of bound and free water caused by temperature variations in the calibration relationship via second-order temperature correction of the calibration slope, layered independent compensation of the first-order temperature effect at the signal level and the second-order temperature effect at the calibration parameter level is achieved. Through end-link attenuation reconstruction self-consistency verification, a detection reliability index is quantified for each detection result, and a reliability-weighted time-series smoothing method is used to replace the traditional equal-weighted averaging, improving the robustness of the time-series output without introducing a fixed time delay. This enables safe, stable, real-time, and high-precision detection of moisture inside insulator clay without contact with the clay or disrupting the production process, providing a low-cost, easily deployable, and traceable intelligent detection solution for moisture quality control in the insulator production process. Attached Figure Description

[0016] Figure 1This is a schematic diagram of a non-contact insulator slurry moisture detection system according to Embodiment 1 of the present invention; Figure 2 This is a flowchart of a non-contact insulator slurry moisture detection method according to Embodiment 2 of the present invention. Detailed Implementation

[0017] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. 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. Example 1

[0018] Please see Figure 1 As shown in the figure, the non-contact insulator mortar moisture detection system described in this embodiment includes a microwave acquisition module, a thickness measurement module, an environmental compensation module, a thickness decoupling module, and a moisture detection module; the modules are connected by wired and / or wireless means to realize data transmission between the modules.

[0019] The microwave acquisition module is used to generate a continuous microwave signal, directionally transmit the continuous microwave signal to the insulator mud, and receive the continuous microwave signal after it penetrates the insulator mud to obtain the total microwave transmission attenuation value.

[0020] Methods for generating continuous microwave signals include: An initial microwave signal with a preset center frequency is generated by a microwave signal generator (i.e., a radio frequency signal source device used to generate a continuous wave microwave signal of a specific frequency). The center frequency is the carrier frequency of the microwave signal output by the microwave signal generator, which is pre-selected by those skilled in the art based on the dielectric properties and thickness penetration requirements of the insulator mud being tested. In this embodiment, the center frequency is preferably 1.6 GHz because microwave signals in the 1.6 GHz band have a significant dielectric absorption response to water molecules, and at the same time, they still have the ability to penetrate highly dense insulator mud with a thickness of 20 to 25 cm under low power conditions. The initial microwave signal is a single-frequency continuous wave signal that is continuously output in the time domain and maintains a constant amplitude. An initial microwave signal is input to a microwave signal amplifier (i.e., a radio frequency power amplifier circuit used for linear power amplification of radio frequency signals). The initial microwave signal is amplified to obtain an amplified microwave signal while maintaining signal linearity without amplitude distortion or phase distortion. The amplification gain of the microwave signal amplifier is preset by those skilled in the art based on the microwave penetration attenuation of the insulator mud under maximum thickness and highest expected moisture content. The output power of the amplified microwave signal does not exceed a preset power safety limit, which is preset by those skilled in the art based on human microwave radiation safety standards and industrial site safety regulations. In this embodiment, a preferred power safety limit is 10 milliwatts. A directional coupler (a passive radio frequency device used to extract a small amount of signal energy from the main microwave transmission line at a fixed coupling ratio without affecting the main signal transmission) is set at the output of the microwave signal amplifier. A detection signal is coupled out from the amplified microwave signal through the directional coupler. The detection signal is input to the transmitter power detector (a microwave power measurement device used to convert the power of the radio frequency signal into a corresponding voltage value and convert it into a power level reading) to obtain the transmission reference power value. The transmission reference power value is used to characterize the actual output microwave signal power level of the microwave transmitter and is recorded in decibels and milliwatts as a reference value for subsequent calculation of the total microwave transmission attenuation value. The transmitted reference power value is subjected to signal stability verification to obtain a stable transmitted power value. Specifically, within a preset stability verification period, multiple transmitted reference power values ​​are continuously collected at a preset verification sampling interval to form a transmitted power verification sequence. The stability verification period and the verification sampling interval are both preset by those skilled in the art based on the start-up warm-up characteristics and output power stabilization time of the microwave signal generator. The standard deviation of all transmitted reference power values ​​in the transmitted power verification sequence is calculated to obtain the power fluctuation. The power fluctuation reflects the random fluctuation amplitude of the output power of the microwave signal generator in the time dimension. A preset power stability threshold is set by those skilled in the art based on the accuracy requirements of moisture detection. If the power fluctuation is less than or equal to the power stability threshold, the microwave signal generator is determined to be in a stable output state, and the mean of all transmitted reference power values ​​in the transmitted power verification sequence is calculated to obtain the stable transmitted power value. If the power fluctuation is greater than the power stability threshold, the stability verification period is extended and the power fluctuation is recalculated until the power fluctuation meets the stability requirements.

[0021] Methods for directionally transmitting continuous microwave signals into insulator mortar and receiving the microwave signals after they have penetrated the insulator mortar include: The amplified microwave signal is fed into a microwave transmitting horn antenna (i.e., a horn-shaped transmitting antenna used to convert the amplified microwave signal in guided mode into a microwave beam radiating in free space) via an RF coaxial cable. The microwave transmitting horn antenna adopts a directional horn structure and has a preset beamwidth and antenna gain. The beamwidth characterizes the angular spread range of the microwave beam in space and is pre-selected by those skilled in the art based on the cross-sectional dimensions of the insulator clay and the detection distance to ensure that the microwave beam can effectively cover the detection cross-sectional area of ​​the insulator clay under test. The antenna gain characterizes the ability of the microwave transmitting horn antenna to concentrate microwave energy in the main radiation direction. The higher the antenna gain, the stronger the energy concentration in the main radiation direction. The directional horn structure is used to suppress the radiation divergence and leakage of microwave energy in non-detection directions and improve the directional irradiation efficiency of the microwave signal on the insulator clay. A microwave receiving horn antenna (i.e., a horn-type receiving antenna used to capture microwave beams in free space and convert them into guided wave mode) is set on the opposite side of the microwave transmitting horn antenna. The microwave receiving horn antenna adopts a directional horn structure that matches the microwave transmitting horn antenna. It is used to directionally receive microwave signals that continue to propagate along the main radiation direction after penetrating the insulator mud, while suppressing the interference of stray microwave signals from non-main radiation directions in the industrial environment on the reception results. The microwave transmitting horn antenna and the microwave receiving horn antenna are installed and fixed in a coaxial, opposite-beam configuration using a testing bracket (i.e., a rigid mounting structure for fixing the relative spatial positions of the microwave transmitting horn antenna and the microwave receiving horn antenna), maintaining a preset reference distance between the two antennas. This reference distance is a fixed straight-line distance between the radiating surface of the microwave transmitting horn antenna and the receiving surface of the microwave receiving horn antenna, and is preset by those skilled in the art based on the maximum cross-sectional thickness of the insulator mortar and the testing space allowance. The insulator mortar to be tested is placed on the opposite-beam path between the microwave transmitting horn antenna and the microwave receiving horn antenna. The microwave transmitting horn antenna amplifies the microwave signal and converts it into a directional microwave beam that propagates along the main radiation direction. The directional microwave beam passes sequentially through the air gap at the transmitting end, the insulator body, and the air gap at the receiving end. The air gap at the transmitting end is the air propagation path between the radiating surface of the microwave transmitting horn antenna and the near-end surface of the insulator body. The air gap at the receiving end is the air propagation path between the far-end surface of the insulator body and the receiving surface of the microwave receiving horn antenna. The near-end surface is the outer surface of the insulator body facing the microwave transmitting horn antenna. The far-end surface is the outer surface of the insulator body facing the microwave receiving horn antenna.

[0022] Methods for obtaining the total microwave transmission attenuation include: The microwave signal received by the microwave receiving horn antenna is input to the receiver power detector (i.e., a microwave power measuring device used to detect the power level of the received radio frequency signal) through an RF coaxial cable to obtain the instantaneous received power value; wherein, the instantaneous received power value is used to characterize the power level of the microwave signal captured by the microwave receiving horn antenna at a single sampling moment after penetrating the insulator mud. The instantaneous received power value is subjected to multiple sampling and mean filtering to obtain the measured received power value, thereby suppressing the influence of transient electromagnetic noise and random interference on the detection results. Specifically, within a preset detection sampling window, multiple instantaneous received power values ​​are continuously acquired at a preset detection sampling frequency to form a received power sampling sequence. The detection sampling window and detection sampling frequency are both preset by those skilled in the art based on the conveying speed and real-time detection requirements of the insulator mud production line. The mean of all instantaneous received power values ​​in the received power sampling sequence is calculated to obtain the measured received power value. The measured received power value is used to characterize the average power level of the microwave receiver after noise suppression. The validity of the received measured power value is determined. Specifically, a minimum detectable power threshold is preset, which is pre-set by those skilled in the art based on the noise floor of the receiver power detector and the system detection sensitivity. If the received measured power value is greater than the minimum detectable power threshold, the received measured power value is determined to be valid, and the subsequent calculation of the total microwave transmission attenuation value continues. If the received measured power value is less than or equal to the minimum detectable power threshold, the received measured power value is determined to be invalid, indicating that the microwave signal cannot be effectively detected due to excessive attenuation caused by excessive mud thickness or excessive moisture content. An insufficient signal alarm is issued and the current detection process is terminated. If the received measured power value is valid, the difference between the transmitted stable power value and the received measured power value is calculated to obtain the total microwave transmission attenuation value. This total microwave transmission attenuation value characterizes the total power loss experienced by a continuous microwave signal as it propagates from the microwave transmitting horn antenna to the microwave receiving horn antenna. The total microwave transmission attenuation value contains three attenuation components: the first is the dielectric attenuation caused by the dielectric absorption of microwave energy by water molecules in the insulator clay when the microwave signal penetrates the clay body. This is directly related to the moisture content and thickness of the insulator clay and is the core information carrier for subsequent moisture content inversion. The second is the air propagation attenuation caused by beam spatial diffusion when the microwave signal propagates in the air gaps at the transmitting and receiving ends. This is related to the path length of the air gaps at the transmitting and receiving ends. The third is the temperature drift attenuation caused by the influence of ambient temperature changes on the dielectric constant of the clay and the microwave propagation characteristics. Both air propagation attenuation and temperature drift attenuation are coupling factors that interfere with the extraction of clay moisture information and need to be corrected and eliminated in the subsequent environmental compensation module based on the corresponding distance and temperature information.

[0023] The thickness measurement module is used to obtain the distance between the transmitting end and the receiving end, and combined with the preset reference spacing, to obtain the measured thickness value of the insulator mud.

[0024] Methods for obtaining the distance between the transmitter and receiver include: A transmitter distance sensor (i.e., a non-contact ranging device used to measure the straight-line distance between the sensor mounting reference surface and the surface of the object being measured in real time) is installed on one side of the microwave transmitting horn antenna. The measuring axis of the transmitter distance sensor is parallel and coplanar with the main radiation direction of the microwave transmitting horn antenna, so that the measuring direction of the transmitter distance sensor is consistent with the transmission direction of the microwave beam. The mounting reference surface of the transmitter distance sensor and the radiating aperture of the microwave transmitting horn antenna are in the same vertical plane. The transmitter distance sensor is used to measure the spatial distance between the radiating aperture of the microwave transmitting horn antenna and the near-end surface of the insulator mortar in real time. A receiver distance sensor is installed on one side of the microwave receiving horn antenna. The installation method of the receiver distance sensor is the same as that of the transmitter distance sensor. The receiver distance sensor is used to measure the spatial distance between the receiving port surface of the microwave receiving horn antenna and the far end surface of the insulator mud in real time. The distance is measured at the near end of the insulator mud by the transmitting end distance sensor to obtain the original distance value of the transmitting end; the distance is measured at the far end of the insulator mud by the receiving end distance sensor to obtain the original distance value of the receiving end; wherein, the original distance value of the transmitting end and the original distance value of the receiving end are the instantaneous distance measurement readings output by the transmitting end distance sensor and the receiving end distance sensor at a single sampling moment, respectively.

[0025] The original distance values ​​at both the transmitting and receiving ends are sampled and filtered multiple times to obtain the transmitting and receiving distances. Specifically, within a preset distance sampling window, multiple original distance values ​​at the transmitting end are continuously acquired by the transmitting end distance sensor at a preset distance sampling frequency, forming a transmitting end distance sampling sequence. The distance sampling window and distance sampling frequency are preset by those skilled in the art based on the conveying speed and real-time measurement requirements of the insulator mud production line. The standard deviation of all original distance values ​​at the transmitting end in the transmitting end distance sampling sequence is calculated to obtain the transmitting end ranging fluctuation. The transmitting end ranging fluctuation reflects the ranging stability of the transmitting end distance sensor within the distance sampling window. A preset ranging fluctuation threshold is established, which is pre-set by those skilled in the art based on the measurement accuracy level of the distance sensor and the accuracy requirements for mud thickness detection. If the ranging fluctuation at the transmitting end is less than or equal to the ranging fluctuation threshold, the mean of all original distance values ​​of the transmitting end in the distance sampling sequence is calculated to obtain the transmitting end distance. If the ranging fluctuation at the transmitting end is greater than the ranging fluctuation threshold, it is determined that there is abnormal ranging interference within the distance sampling window. Median filtering is then performed on the transmitting end distance sampling sequence, and the result after median filtering is taken as the transmitting end distance. The transmitting end distance is used to characterize the stable spatial distance between the radiating aperture of the microwave transmitting horn antenna and the near-end surface of the insulator mud, i.e., the actual propagation path length of the microwave beam in the air gap at the transmitting end. Median filtering is a well-known technique in the art, and the specific processing procedure will not be elaborated on here. The original distance value of the receiver is processed by using the same multiple sampling and filtering method as the distance of the transmitter to obtain the receiver distance. The receiver distance is used to characterize the stable spatial distance between the receiving port surface of the microwave receiving horn antenna and the far end surface of the insulator mud, that is, the actual propagation path length of the microwave beam in the air gap of the receiver.

[0026] Methods for obtaining the measured thickness of insulator mortar include: The measured thickness of the insulator mortar is calculated based on the transmitter distance, receiver distance, and reference spacing. Specifically, the sum of the transmitter and receiver distances is calculated to obtain the total air path length. This total air path length characterizes the sum of the path lengths of the microwave beam propagating in the transmitter and receiver air gaps. The difference between the reference spacing and the total air path length is calculated to obtain the measured thickness value. This measured thickness value characterizes the actual geometric thickness of the insulator mortar along the microwave beam transmission direction, i.e., the actual propagation path length of the microwave beam penetrating the insulator mortar body. The measured thickness value is validated for reasonableness. Specifically, a reasonable lower limit and a reasonable upper limit for thickness are preset, both of which are pre-set by those skilled in the art based on the production specifications of the insulator mortar. If the measured thickness value is greater than or equal to the reasonable lower limit and less than or equal to the reasonable upper limit, the measured thickness value is deemed reasonable, and the measured thickness value is output to the subsequent thickness decoupling module for thickness decoupling calculation of the mortar correction attenuation value. If the measured thickness value is less than the reasonable lower limit, it is determined that the insulator mortar may not be placed at the measured position or the insulator mortar has not reached the detection station, a material shortage alarm is issued, and the current detection process is terminated. If the measured thickness value is greater than the reasonable upper limit, it is determined that the distance sensor measurement result may be abnormal or the insulator mortar specification exceeds the preset range, a thickness over-limit alarm is issued, and the current detection process is terminated.

[0027] The environmental compensation module is used to dynamically evaluate the air propagation attenuation of continuous microwave signals in the air path based on the distance between the transmitter and receiver, and simultaneously collect the surface temperature of the mud material. It calculates the temperature drift attenuation based on the surface temperature of the mud material, and compensates and corrects the total microwave transmission attenuation value based on the air propagation attenuation and the temperature drift attenuation to obtain the mud material corrected attenuation value.

[0028] Methods for dynamically evaluating the air propagation attenuation of continuous microwave signals in an air path include: Based on the distance between the transmitter and the receiver, a segmented asymmetric beam spread model is used to calculate the air attenuation component at the transmitter and the air attenuation component at the receiver respectively. The air attenuation components at the transmitter and the receiver are then fused to obtain the initial air propagation attenuation. Specifically, a preset beam spread reference distance is defined by a person skilled in the art based on the near-field to far-field transition characteristic distance corresponding to the aperture size of the microwave transmitting horn antenna and the operating wavelength. The beam spread reference distance is used to characterize the reference distance at which the beam cross-sectional area begins to significantly expand with the propagation distance after the microwave beam is radiated from the antenna aperture. A preset air attenuation rate coefficient is defined by gradually changing the distance between the two antennas in a preset distance step under no-load conditions without placing insulator mud between the microwave transmitting horn antenna and the microwave receiving horn antenna, recording the difference between the stable transmitted power value and the measured received power value at each distance, and fitting the logarithmic relationship between the difference and the distance between the two antennas. The ratio of the transmitter distance to the beam spread reference distance is calculated to obtain the transmitter distance ratio; the sum of the transmitter distance ratio and one is calculated to obtain the transmitter spread factor; the commonly used logarithmic value of the transmitter spread factor is calculated to obtain the transmitter logarithmic spread; the product of the air attenuation rate coefficient and the transmitter logarithmic spread is calculated to obtain the transmitter air attenuation component; wherein, the transmitter air attenuation component is used to characterize the signal loss caused by the reduction in power density reaching the near-end surface of the insulator clay due to the expansion of the beam cross-section with the propagation distance in the transmitter air gap; Using the same method as for calculating the air attenuation component at the transmitting end, the transmitting end distance in the calculation process is replaced with the receiving end distance to calculate the air attenuation component at the receiving end. The air attenuation component at the receiving end is used to characterize the signal loss caused by the further reduction in power density of the microwave signal reaching the receiving port of the microwave receiving horn antenna due to the continued beam expansion in the air gap after penetrating the insulator mud. The sum of the air attenuation component at the transmitting end and the air attenuation component at the receiving end is calculated to obtain the initial air propagation attenuation. It should be noted that the attenuation components of the transmitting and receiving air gaps are calculated independently and then summed using a segmented asymmetric beam diffusion model, rather than estimating the total air path length as a single attenuation. The technical basis for this is that after the microwave beam penetrates the insulator clay body, the clay medium produces scattering and absorption re-radiation effects on the incident beam. This causes the microwave signal exiting from the far-end surface to no longer maintain the original wavefront structure and focusing characteristics of the incident beam, but instead propagates back to the receiving end with the far-end surface as an equivalent secondary radiation surface. Therefore, the beam diffusion characteristics in the transmitting air gap and the receiving air gap are independent of each other and cannot be combined into a single attenuation value based on the total air path length for overall estimation.

[0029] The initial air propagation attenuation is corrected by standing wave interference to obtain the air propagation attenuation. Specifically, when the microwave beam reaches the near-end surface of the insulator clay, partial reflection occurs at the interface due to the abrupt change in dielectric impedance between the air and the clay medium. The reflected wave returns along the incident path and superimposes with the subsequently incident microwave signal within the air gap at the transmitting end to form a standing wave interference field. The standing wave interference field causes the effective received power at the microwave receiver to undergo periodic sinusoidal oscillation modulation as the distance from the transmitting end changes, and the oscillation period is directly related to the operating wavelength of the microwave signal. A similar abrupt change in dielectric impedance from the clay medium to the air also occurs at the far-end surface, producing a similar standing wave interference effect within the air gap at the receiving end. Calculate the operating wavelength based on the center frequency of the microwave signal; the expression for the operating wavelength is: In the formula, For the operating wavelength, The speed at which electromagnetic waves propagate in the air ( ), The center frequency is used; the standing wave amplitude coefficient and standing wave phase offset are preset. The standing wave amplitude coefficient and standing wave phase offset are obtained by gradually changing the distance of the transmitting end under no-load conditions with a sampling step size of less than one-quarter of the working wavelength, recording the oscillation law of the received power changing with distance, and performing sine fitting on the oscillation components; the standing wave amplitude coefficient is used to characterize the power modulation amplitude caused by standing wave interference; the standing wave phase offset is used to characterize the initial phase state at the antenna aperture. The ratio between the transmitter distance and the operating wavelength is calculated by multiplying it by pi and adding the standing wave phase offset to obtain the transmitter standing wave phase angle. The sine of the transmitter standing wave phase angle is calculated and multiplied by the standing wave amplitude coefficient to obtain the transmitter standing wave correction. The transmitter distance is replaced with the receiver distance using the same method to calculate the receiver standing wave correction. The sum of the transmitter and receiver standing wave corrections is calculated to obtain the standing wave interference correction. The sum of the initial air propagation attenuation and the standing wave interference correction is calculated to obtain the air propagation attenuation. The air propagation attenuation is used to characterize the comprehensive power loss of the microwave signal in the air path after simultaneously covering beam spread attenuation and standing wave interference modulation effects. It should be noted that the standing wave interference correction can eliminate the periodic jump in received power caused by the slight change in the placement position of the insulator mortar on the beam path, and avoid the jump being mistakenly attributed to the change in the moisture content of the mortar.

[0030] Methods for synchronously collecting the surface temperature of mud include: An infrared temperature sensor (i.e., a thermal radiation temperature measurement device that achieves non-contact surface temperature measurement by receiving infrared thermal energy radiated from the surface of an object) is installed on the testing bracket. The field of view of the infrared temperature sensor is pointed towards the outer surface area of ​​the insulator mud being tested. The infrared temperature sensor performs non-contact temperature acquisition on the outer surface of the insulator mud to obtain instantaneous surface temperature values. Within a preset temperature sampling window, multiple instantaneous surface temperature values ​​are continuously acquired at a preset temperature sampling frequency to form a surface temperature sampling sequence. The temperature sampling window and temperature sampling frequency are preset by those skilled in the art based on the rate of change of mud surface temperature and the requirements for detection synchronization. The average value of all instantaneous surface temperature values ​​in the surface temperature sampling sequence is calculated to obtain the mud surface temperature. The mud surface temperature is used to characterize the average temperature level of the outer surface of the insulator mud being tested at the current testing time. Methods for calculating temperature drift attenuation based on the surface temperature of the clay material include: Based on the surface temperature and measured thickness of the insulator clay, the equivalent volume temperature of the clay is estimated. This equivalent volume temperature characterizes the overall temperature level of the insulator clay body's comprehensive influence on microwave dielectric absorption across its entire thickness. Since infrared temperature sensors can only detect temperatures within a few millimeters of the outer surface of the insulator clay, while microwave signals penetrate the entire thickness of the clay to 20-25 centimeters, a temperature gradient exists between the outer surface temperature and the internal temperature due to the clay's low thermal diffusion characteristics. When the insulator clay enters the testing station after extrusion molding, residual processing heat remains inside, while the outer surface has already cooled due to heat exchange with the ambient air, resulting in a temperature distribution that is cold on the outside and hot on the inside. If the surface temperature of the clay is directly used as the input for temperature compensation, the compensation will deviate from the true internal temperature state of the clay, thus introducing systematic moisture detection errors. Specifically, the surface temperature of the mud material in the current test and the surface temperature of the mud material in the previous test are obtained and marked as the current surface temperature and the previous surface temperature, respectively; the time corresponding to the current surface temperature is marked as the current test time, and the time corresponding to the previous surface temperature is marked as the previous test time; the difference between the current test time and the previous test time is calculated to obtain the test time difference; the difference between the current surface temperature and the previous surface temperature is calculated and then divided by the test time difference to obtain the surface temperature change rate; wherein, the surface temperature change rate is used to reflect the trend and speed of change of the mud material surface temperature in the time dimension; a thermal inertia correction coefficient is preset, which is determined by those skilled in the art. The thermal diffusivity of the insulator clay and typical processing temperature conditions are preset. The product of the thermal inertia correction coefficient and the surface temperature change rate is calculated, and then multiplied by the square of the measured thickness value to obtain the temperature gradient correction amount. The temperature gradient correction amount is used to quantify the estimated deviation between the outer surface temperature and the internal average temperature of the clay. The sum of the clay surface temperature and the temperature gradient correction amount is calculated to obtain the equivalent body temperature of the clay. It should be understood that when the surface temperature change rate is negative, it indicates that the surface of the insulator clay is cooling down. When the temperature gradient correction amount is negative, the equivalent body temperature of the clay is higher than the surface temperature of the clay, reflecting the physical reality that the internal temperature of the insulator clay is higher than the surface temperature.

[0031] A preset calibration reference temperature is established. This reference temperature is the ambient temperature at which the microwave attenuation and moisture relationship calibration was performed during the system's factory calibration. This temperature is pre-recorded by those skilled in the art based on the actual temperature conditions during calibration. The difference between the equivalent body temperature of the mud and the calibration reference temperature is calculated to obtain the equivalent temperature deviation value. This deviation value characterizes the magnitude of the shift in the equivalent body temperature of the mud relative to the calibration reference temperature at the current detection time. Based on the equivalent temperature deviation value, the distance between the transmitter and receiver, a temperature-distance coupled multi-order compensation model is used to calculate the temperature drift attenuation. The expression for the temperature-distance coupled multi-order compensation model is as follows: In the formula, This is the temperature drift decay. This is the equivalent temperature deviation value. Distance from the transmitter For the distance to the receiving end, It is the first-order temperature drift coefficient. It is the second-order temperature drift coefficient. The evaporation coupling coefficient is... It belongs to the first-order temperature drift component. It belongs to the second-order temperature drift component. It belongs to the evaporation coupling component. It belongs to the evaporation coupling compensation component; The first-order and second-order temperature drift coefficients were obtained by performing microwave transmission tests on standard insulator clay samples with the same moisture content and thickness under multiple sets of known temperature conditions. The changes in the total microwave transmission attenuation value under each temperature condition relative to the total microwave transmission attenuation value at the calibration reference temperature were recorded. The first-order temperature drift coefficient was used to compensate for the first-order linear drift effect of the dielectric loss characteristics of water molecules in the insulator clay caused by temperature changes. The second-order temperature drift coefficient was used to compensate for the second-order change effect of dielectric loss caused by the nonlinear shift of the dielectric relaxation frequency of water molecules in the microwave band with increasing temperature. It should be noted that using a second-order polynomial model instead of the traditional single linear temperature coefficient can more accurately describe the nonlinear response law of the dielectric absorption characteristics of water molecules with temperature changes in the microwave band. The evaporation coupling coefficient is obtained by performing microwave transmission tests on the same standard insulator clay samples under multiple combinations of different temperatures and antenna spacings. The residual attenuation is obtained by subtracting the first-order and second-order temperature drift components from the total microwave transmission attenuation value, and then fitting the linear relationship between the residual attenuation and the evaporation coupling component. It should be understood that the physical mechanism of the evaporation coupling compensation component is as follows: when the surface temperature of the insulator clay is higher than the calibration reference temperature, the evaporation rate of moisture on the surface of the insulator clay is accelerated. The water vapor generated by evaporation forms a local high-humidity microenvironment in the air gap between the outer surface of the insulator clay and the antenna aperture. The water vapor molecules in this humid air layer produce additional absorption and attenuation of the microwave signal passing through it. This evaporation water vapor attenuation effect is neither a dielectric absorption attenuation of the insulator clay body nor a beam diffusion attenuation of the pure air path, but a coupling effect of temperature change and air gap distance.

[0032] Methods for compensating and correcting the total microwave transmission attenuation include: The total microwave transmission attenuation value is obtained by subtracting the air propagation attenuation and the temperature drift attenuation in sequence. The mud-corrected attenuation value is used to characterize the attenuation caused by the dielectric absorption of microwave signals by the insulator mud body after removing the two types of environmental interference factors, namely air propagation attenuation and temperature drift attenuation. The consistency of the corrected attenuation values ​​for the mud material is self-verified. Specifically, a sliding window of corrected attenuation values ​​of a preset length is maintained. After each detection, the corresponding corrected attenuation value of the mud material is stored in the sliding window. When the number of corrected attenuation values ​​in the sliding window reaches the preset length, the standard deviation of all corrected attenuation values ​​in the sliding window is calculated to obtain the corrected attenuation fluctuation. At the same time, the standard deviation of the total microwave transmission attenuation value corresponding to each detection in the sliding window is calculated to obtain the original attenuation fluctuation. The ratio of the corrected attenuation fluctuation to the original attenuation fluctuation is calculated to obtain the compensation convergence ratio. The compensation convergence ratio is used to characterize the effect of environmental compensation on eliminating environmental fluctuation components in the total microwave transmission attenuation value. If the compensation convergence ratio is less than one, it indicates that the fluctuation of the attenuation value after environmental compensation is less than the fluctuation of the original attenuation value before compensation, that is, environmental compensation effectively reduces the measurement fluctuation caused by environmental factors. If the compensation convergence ratio is greater than or equal to one, it indicates that environmental compensation has failed to effectively reduce measurement fluctuation or even introduced additional fluctuations, which may be caused by sensor drift or aging of compensation model parameters, and a compensation model calibration prompt is issued. The preset length is preset by those skilled in the art based on the detection cycle and the minimum sample size required for statistical evaluation. The validity of the mud correction attenuation value is verified. Specifically, if the mud correction attenuation value is greater than zero, it is determined to be valid, and the mud correction attenuation value is output to the subsequent thickness decoupling module for thickness decoupling calculation. If the mud correction attenuation value is less than or equal to zero, the environmental compensation result is determined to be abnormal, indicating that the total compensation of air propagation attenuation and temperature drift attenuation exceeds the total microwave transmission attenuation value. This may be due to overcompensation caused by measurement deviation of distance sensor or temperature sensor. An alarm for compensation abnormality is issued and the current detection process is terminated.

[0033] The thickness decoupling module is used to decouple the corrected attenuation value of the clay based on the measured thickness value, quantitatively characterize the microwave absorption capacity of the clay per unit thickness, and obtain the specific attenuation rate.

[0034] Methods for decoupling thickness based on measured thickness values ​​and correction attenuation values ​​of clay include: The interface transition loss of the corrected attenuation value of the insulator clay is separated to obtain the volumetric absorption attenuation. The volumetric absorption attenuation characterizes the microwave power attenuation, which is purely caused by the dielectric absorption of water molecules within the insulator clay and is related to the clay thickness. Specifically: The interface transition loss baseline value and interface temperature correction coefficient are preset. The interface transition loss baseline value is obtained by conducting microwave transmission tests on multiple groups of standard insulator clay samples with the same moisture content but different thicknesses under the calibration baseline temperature. The measured thickness value of each sample is the independent variable, and the clay correction attenuation value of each sample is the dependent variable. The intercept value of the fitted line on the dependent variable axis is taken as the interface transition loss baseline value. The intercept value physically corresponds to the limit value of the clay correction attenuation value when the clay thickness approaches zero, that is, the pure interface power loss when the microwave signal only crosses the two dielectric interfaces without any dielectric absorption of the clay body. The interface transition loss baseline value is used to characterize the total fixed power loss caused by dielectric impedance mismatch when the microwave signal crosses the two dielectric interfaces of the near-end surface and the far-end surface at the calibration baseline temperature. The interface temperature correction coefficient is obtained by repeatedly performing the above-mentioned multi-thickness calibration test under multiple different temperature conditions, extracting the intercept value of the fitted straight line under each temperature condition, and performing linear fitting with the temperature deviation value (the difference between each temperature condition and the calibration reference temperature) as the independent variable and the intercept change (the difference between the intercept value of each temperature condition and the interface transition loss reference value) as the dependent variable. The interface temperature correction coefficient is used to compensate for the influence of the dielectric constant drift of the surface layer of the clay caused by temperature changes on the interface reflection characteristics. It should be noted that the interface reflection characteristics are determined by the dielectric state within a few millimeters of the outermost layer of the insulator clay. Therefore, the interface temperature correction uses the clay surface temperature rather than the clay equivalent body temperature as the temperature input. The difference between the surface temperature of the mud and the calibration reference temperature is calculated to obtain the interface temperature deviation value; the product of the interface temperature correction coefficient and the interface temperature deviation value is calculated to obtain the interface temperature correction amount; the sum of the interface transition loss reference value and the interface temperature correction amount is calculated to obtain the actual interface transition loss amount; wherein, the actual interface transition loss amount is used to characterize the total fixed power loss generated by the microwave signal crossing the interface of the two media under the temperature conditions of the current test; the difference between the mud correction attenuation value and the actual interface transition loss amount is calculated to obtain the volume absorption attenuation amount.

[0035] It should be understood that although the attenuation value of the insulator clay has been stripped of environmental interference factors such as air propagation attenuation and temperature drift attenuation, it still contains two types of attenuation components with different physical properties: the first is the volume absorption attenuation caused by the dielectric absorption of water molecules as the microwave signal propagates layer by layer along the thickness direction inside the insulator clay body. This component increases proportionally with the increase of clay thickness and is the core component carrying the information of clay moisture content; the second is the sum of incident reflection loss and outgoing reflection loss caused by the sudden change in dielectric impedance of the two media at the near-end surface (air-to-clay medium interface) and the far-end surface (clay-to-air medium interface), respectively, which is marked as interface transition loss. The magnitude of interface transition loss depends on the degree of dielectric impedance mismatch between air and insulator clay and is independent of clay thickness. It belongs to the fixed power loss generated when the microwave signal crosses the interface of the two media. If the interface transition loss is not separated from the mud correction attenuation value and the mud correction attenuation value is directly decoupled based on the measured thickness value, the resulting specific attenuation rate will be mixed with the contribution of interface transition loss, which is unrelated to the thickness. This will cause a systematic deviation in the specific attenuation rate of insulator mud with the same moisture content at different thicknesses: when the thickness is thinner, the proportion of interface transition loss in the mud correction attenuation value is larger, and the calculated specific attenuation rate is higher; when the thickness is thicker, the proportion of interface transition loss in the mud correction attenuation value is smaller, and the calculated specific attenuation rate is lower. This systematic deviation causes a false coupling between the subsequent moisture inversion results and the mud thickness, which is particularly prominent in multi-specification mud section mixed production scenarios.

[0036] The equivalent propagation path length is calculated based on the measured thickness value, and the specific attenuation rate is calculated based on the volume absorption attenuation and the equivalent propagation path length; specifically: A preset scattering path extension coefficient is established. This coefficient is obtained by conducting microwave transmission tests on multiple sets of standard insulator clay samples with the same moisture content but different thicknesses under calibrated reference temperature conditions. The difference between the clay correction attenuation value and the interface transition loss reference value for each standard insulator clay sample is calculated to obtain the volume absorption attenuation of each standard insulator clay sample. A second-order polynomial is fitted with the measured thickness of each standard insulator clay sample as the independent variable and the volume absorption attenuation as the dependent variable, and the ratio of the second-order term coefficient to the first-order term coefficient is calculated. The scattering path extension coefficient is used to characterize the extension ratio of the actual microwave propagation path due to forward scattering per unit thickness relative to the geometric straight path. The scattering path extension coefficient mainly depends on the microstructure characteristics of the insulator clay (such as mineral particle size distribution, porosity, and density). This microstructure remains relatively stable in the same batch of clay and has a weak relationship with the change in the moisture content of the clay. Therefore, the scattering path extension coefficient can be used as a pre-calibrated material constant in the detection of different moisture contents. The equivalent propagation path length is calculated based on the measured thickness value and the scattering path extension coefficient; the expression for the equivalent propagation path length is: In the formula, For equivalent propagation path length, This is the measured thickness value. is the scattering path extension coefficient; where, the equivalent propagation path length is used to characterize the actual energy propagation path length of the microwave signal inside the insulator clay body due to the forward scattering effect, and the equivalent propagation path length is greater than or equal to the measured thickness value. The ratio of volumetric absorption attenuation to equivalent propagation path length is calculated to obtain the specific attenuation rate. The specific attenuation rate is used to quantitatively characterize the dielectric absorption capacity of the insulator mortar for microwave signals per unit equivalent propagation path length. A higher specific attenuation rate indicates a higher moisture content in the insulator mortar. The specific attenuation rate eliminates the fixed loss contribution independent of thickness through interface transition loss separation and eliminates the scattering effect contribution related to thickness nonlinearity through scattering path extension correction. This makes the specific attenuation rate output a consistent value for the same moisture content on insulator mortars of different thicknesses, thus exhibiting thickness-independent characteristics. The validity of the attenuation rate is verified by comparison. Specifically, a reasonable lower limit and a reasonable upper limit for the specific attenuation rate are preset. Both the reasonable lower limit and the reasonable upper limit for the specific attenuation rate are preset by those skilled in the art based on the microwave absorption characteristics of the insulator clay within the allowable moisture content range of the process. If the specific attenuation rate is greater than or equal to the reasonable lower limit and less than or equal to the reasonable upper limit, the specific attenuation rate is determined to be valid, and the specific attenuation rate is output to the subsequent moisture detection module for moisture content inversion. If the specific attenuation rate is less than the reasonable lower limit or greater than the reasonable upper limit, the thickness decoupling result is determined to be abnormal, which may be caused by interface transition loss estimation deviation, scattering correction deviation, or structural defects in the insulator clay body. A decoupling abnormality alarm is issued and the current detection process is terminated.

[0037] It should be noted that during the process of microwave signals penetrating the insulator clay body, the microstructure inside the clay (including mineral particles, organic inclusions, and micropores) generates a forward scattering effect on the microwave beam. Each scattering event causes a slight deflection of the microwave propagation path, resulting in the actual propagation path of the microwave energy being extended relative to the geometric straight path along the thickness direction. When the clay thickness is thin, the number of scattering events is limited, and the path extension effect can be ignored. However, when the clay thickness reaches 20 to 25 cm, the accumulation of a large number of forward scattering events makes the path extension effect significant, and the path extension increases nonlinearly with thickness. This is because the greater the thickness, the higher the probability that the deflected microwaves will be rescattered in the remaining propagation path, forming a compound scattering superposition effect. If the volume absorption attenuation is directly divided by the geometric straight thickness (i.e., the measured thickness value), the resulting specific attenuation rate will be systematically higher on thick clay due to ignoring the scattering path extension, resulting in a thickness-related nonlinear residual error.

[0038] The moisture detection module is used to compare the attenuation rate to invert the moisture content, obtain the moisture content detection value of the insulator mud, and display, store, and alarm for exceeding the limit of the moisture content detection value.

[0039] The steps for retrieving moisture content by comparing the decay rate include: Step S1: Use the free water-bound water dual-state segmented calibration model to compare the attenuation rate and perform initial moisture inversion to obtain the initial moisture content value; Step S2: Perform a second-order temperature correction on the initial moisture content value to obtain the temperature-corrected moisture content value; Step S3: Perform end-to-end attenuation reconstruction self-consistency verification on the temperature-corrected moisture content value to obtain the detection reliability; Step S4: Based on the detection confidence level, perform a reliability test on the temperature-corrected moisture content value; Step S5: If the temperature-corrected moisture content value passes the reliability test, then the temperature-corrected moisture content value is subjected to a reliability-weighted time-series smoothing process to obtain the moisture content detection value.

[0040] In step S1 above, the method for initial moisture inversion by comparing the attenuation rate includes: A segmented calibration model for the free water-bound water dual state is pre-constructed. The segmented calibration model for the free water-bound water dual state includes the calibration slope of the bound water segment, the calibration intercept of the bound water segment, the calibration slope of the free water segment, the calibration intercept of the free water segment, and the conversion ratio attenuation rate. The specific decay rate is input into the free water-bound water dual-state segmented calibration model, and the specific decay rate is compared with the transformation specific decay rate. If the specific decay rate is less than or equal to the transformation specific decay rate, a first-order linear inversion calculation is performed using the bound water segment calibration slope and the bound water segment calibration intercept to obtain the initial moisture content value. If the specific decay rate is greater than the transformation specific decay rate, a first-order linear inversion calculation is performed using the free water segment calibration slope and the free water segment calibration intercept to obtain the initial moisture content value.

[0041] The methods for pre-constructing a segmented calibration model of free water and bound water in two states include: Multiple sets of standard insulator mortar calibration samples with different known moisture contents were prepared. The moisture content of each calibration sample covered the complete range of moisture content allowed by the insulator mortar process and extended appropriately at both ends. The moisture content of each calibration sample was accurately determined by drying and weighing and used as the calibration reference moisture content value. Under the calibration reference temperature conditions, microwave transmission tests were performed on each calibration sample sequentially. Following the complete processing flow of microwave acquisition module, thickness measurement module, environmental compensation module, and thickness decoupling module, the specific attenuation rate corresponding to each calibration sample was obtained. A calibration dataset was constructed with the specific attenuation rate of each calibration sample as the independent variable and the calibration reference moisture content value as the dependent variable. The data points in the calibration dataset correspond one-to-one with the calibration samples. A segmented feature analysis was performed on the comparative decay rate-moisture content calibration dataset to determine the moisture state transition points. Specifically, all data points in the calibration dataset were sorted in ascending order of specific decay rate to obtain an ordered calibration data sequence. From the ordered calibration data sequence, the first... From the data point to the last one Up to the last data point, each data point is sequentially treated as a candidate segmentation point; where... The specific values ​​are preset by those skilled in the art based on actual conditions; in this embodiment, the preferred values ​​are... To ensure that at least two data points are retained on each side of the candidate segment point for linear regression fitting, the following steps are taken: For each candidate segment point, all data points in the ordered calibration data sequence preceding the corresponding candidate segment point are marked as the front segment point, and all data points in the ordered calibration data sequence following the corresponding candidate segment point are marked as the back segment point. For each candidate segment point, first-order linear regression fitting is performed on all corresponding front and back segment points to obtain the front and back fitting lines. Based on all data points in the ordered calibration data sequence, the sum of squared residuals of the front and back fitting lines corresponding to each candidate segment point is calculated sequentially, and the sum of the two sums of squared residuals is calculated to obtain the total sum of squared residuals for each candidate segment point. The candidate segment point with the smallest total sum of squared residuals is selected as the moisture state transition point. The moisture state transition point is used to identify the critical moisture content in the specific decay rate-moisture content calibration relationship, which transitions from the bound water-dominated absorption range to the free water-dominated absorption range. The specific decay rate corresponding to the water state transition point is labeled as the transition specific decay rate. The specific decay rate of each data point is compared with the transition specific decay rate. Data points with a specific decay rate less than or equal to the transition specific decay rate are assigned to the bound water dominant segment, and data points with a specific decay rate greater than the transition specific decay rate are assigned to the free water dominant segment. First-order linear regression is performed on the data points of the bound water dominant segment to obtain the bound water segment calibration slope and bound water segment calibration intercept. First-order linear regression is also performed on the data points of the free water dominant segment to obtain the free water segment calibration slope and free water segment calibration intercept. The bound water segment calibration slope, bound water segment calibration intercept, free water segment calibration slope, free water segment calibration intercept, and transition specific decay rate are integrated to form a free water-bound water dual-state segmented calibration model.

[0042] It should be understood that moisture in insulator mortar exists in two physical states: bound water, which consists of water molecules adsorbed on the surface and interlayer structure of clay mineral particles, exhibits weak dielectric relaxation response in a microwave field due to lattice constraints on molecular rotational freedom, resulting in a relatively low contribution to the relative attenuation rate; and free water, which consists of freely moving water molecules existing in the pores between mortar particles, can undergo sufficient dipole rotational relaxation in a microwave field, exhibiting a significantly higher dielectric absorption efficiency than bound water. As the total moisture content of the mortar increases from low to high, the adsorption sites of bound water on the surface of clay minerals gradually tend towards... When saturated, newly added water mainly enters the pore space in the form of free water. Since the microwave absorption contribution per unit mass of free water is significantly higher than that of bound water, the rate of specific attenuation with increasing water content changes between the bound water-dominated and free water-dominated regions. The calibration curve exhibits a segmented characteristic of transitioning from a low slope segment to a high slope segment. If a single linear model is used to uniformly fit all calibration data, the slope of the fitted line is the compromise value of the true slopes of the two intervals, resulting in a systematic overestimation of water content in the bound water-dominated region and a systematic underestimation of water content in the free water-dominated region.

[0043] In step S2 above, the method for obtaining the temperature-corrected moisture content value includes: The equivalent body temperature of the clay material and the calibration reference temperature are obtained, and the difference between the equivalent body temperature and the calibration reference temperature is calculated to obtain the inversion temperature deviation value. A calibration slope temperature drift coefficient is preset. This coefficient is obtained by performing a complete microwave transmission test and moisture calibration process on the same standard insulator clay material calibration samples under multiple different temperature conditions, extracting the linear relationship between the relative rate of change of the calibration slope relative to the calibration reference temperature and the temperature deviation value under each temperature condition. The product of the calibration slope temperature drift coefficient and the inversion temperature deviation value is calculated to obtain the relative slope offset. The sum of one and the relative slope offset is calculated to obtain the temperature proportional correction factor. The ratio of the initial moisture content value to the temperature proportional correction factor is calculated to obtain the temperature-corrected moisture content value. When the inversion temperature deviation value is greater than zero, the temperature proportional correction factor is greater than one, and the temperature-corrected moisture content value is less than the initial moisture content value, achieving a downward correction for overestimation of moisture under high-temperature conditions.

[0044] It should be noted that the temperature drift attenuation compensation in the environmental compensation module acts on the original attenuation level of the microwave signal to eliminate the direct impact of temperature changes on microwave dielectric loss (i.e., the first-order temperature effect). However, temperature changes also indirectly affect the slope of the calibration relationship between specific attenuation rate and moisture content by changing the dynamic adsorption-desorption equilibrium between bound water and free water in the insulator slurry (i.e., the second-order temperature effect). When the equivalent body temperature of the slurry is higher than the calibration reference temperature, some bound water is desorbed from the mineral surface and converted into free water due to sufficient heat energy, resulting in an increase in the proportion of free water under the same total moisture content, and a corresponding increase in specific attenuation rate. This causes the calibration model based on the calibration reference temperature to overestimate the moisture content. This second-order temperature effect is independent of the first-order temperature effect and acts on the parameter level of the calibration model rather than the signal level. It needs to be corrected independently during the moisture inversion stage.

[0045] In step S3 above, the method for obtaining the detection confidence level includes: Substituting the temperature-corrected moisture content value into the free water-bound water dual-state segmented calibration model, the corresponding expected value of specific attenuation rate is calculated in reverse. The equivalent propagation path length and actual interface transition loss are obtained, and the product of the expected specific attenuation rate and the equivalent propagation path length is calculated to obtain the expected value of volumetric absorption attenuation. The sum of the expected value of volumetric absorption attenuation and the actual interface transition loss is calculated to obtain the expected value of mud-corrected attenuation. The air propagation attenuation and temperature drift attenuation are obtained, and the sum of the expected value of mud-corrected attenuation, air propagation attenuation, and temperature drift attenuation is calculated to obtain the expected value of total microwave transmission attenuation. The total microwave transmission attenuation is obtained, and the absolute value of the difference between the expected value and the total microwave transmission attenuation is calculated to obtain the end-to-end reconstruction residual. The end-to-end reconstruction residual is used to evaluate the overall consistency level of the complete signal processing link from the total microwave transmission attenuation value through step-by-step processing to moisture content inversion. A preset reconstructed residual tolerance threshold is established, which is pre-set by those skilled in the art based on the overall measurement accuracy requirements of the system. The ratio of the full-link reconstructed residual to the reconstructed residual tolerance threshold is calculated to obtain the residual exceedance rate. If the residual exceedance rate is greater than one, it is set to one. The difference between one and the residual exceedance rate is calculated to obtain the detection reliability. The detection reliability is used to quantify the reliability of the current moisture detection result, and its value ranges from zero to one. The closer the detection reliability is to one, the better the consistency of the full-link processing and the more reliable the detection result. It should be understood that the principle of the self-consistency verification of the end-to-end attenuation reconstruction is as follows: if the compensation, correction and inversion of each link of the microwave acquisition module, thickness measurement module, environmental compensation module, thickness decoupling module and moisture detection module are all accurate, then the expected value of the total microwave transmission attenuation value reconstructed from the moisture content value obtained by the final inversion along the signal processing link should be highly consistent with the actual measured total microwave transmission attenuation value; if the end-to-end reconstruction residual is too large, it indicates that at least one link in the processing link has a deviation in the compensation parameter or correction model.

[0046] In step S4 above, the method for reliability testing of the temperature-corrected moisture content value includes: A preset reliability lower limit is established, and the detection reliability is compared with the reliability lower limit. The reliability lower limit is preset by a person skilled in the art based on the reliability requirements of moisture detection in the insulator manufacturing process. If the detection reliability is greater than or equal to the preset reliability lower limit, the temperature-corrected moisture content value is determined to have passed the reliability test. If the detection reliability is less than the reliability lower limit, the temperature-corrected moisture content value is determined to have failed the reliability test, and an insufficient reliability alarm is issued.

[0047] In step S5 above, the method for obtaining the moisture content detection value includes: A moisture detection sliding window with a preset window length is maintained. The preset window length is set by those skilled in the art based on the detection cycle and output smoothness requirements. Each time a moisture detection is completed, if the temperature-corrected moisture content value passes the reliability test, the corresponding temperature-corrected moisture content value and the detection confidence level are stored in the moisture detection sliding window. When the number of detection confidence levels in the moisture detection sliding window reaches the preset window length, the sum of all detection confidence levels in the moisture detection sliding window is calculated to obtain the total confidence level. The ratio of each detection confidence level to the total confidence level is calculated to obtain the confidence level weight corresponding to each temperature-corrected moisture content value. Based on each confidence level weight, a weighted average of all temperature-corrected moisture content values ​​in the moisture detection sliding window is calculated to obtain the moisture content detection value. It should be noted that by using detection confidence as a weighting coefficient instead of the traditional equal-weighted time series average, the detection results with higher confidence receive a greater contribution weight in the smooth output, while the influence of detection results with lower confidence (which may be caused by transient interference or local defects on the surface of the mud) is automatically suppressed, thereby improving the robustness of the time series output without introducing a fixed time delay.

[0048] Methods for displaying, storing, and alarming for excessive moisture content readings include: The data processing and display terminal displays the moisture content detection value, detection reliability, measured thickness value, and mud surface temperature in real time through its display interface; the data processing and display terminal is an industrial touch screen or industrial control computer. The moisture content, reliability, specific attenuation rate, measured thickness, surface temperature of the mud, total microwave transmission attenuation, and time of each test are integrated to form a test record, which is then stored in the historical data storage area of ​​the data processing and display terminal to support historical data query and trend analysis.

[0049] A two-level over-limit alarm system is implemented for moisture content detection values. Specifically, a qualified upper limit, a qualified lower limit, a warning upper limit, and a warning lower limit for moisture content are preset. The warning upper limit is lower than the qualified upper limit, and the warning lower limit is higher than the qualified lower limit. The qualified upper and lower limits are preset by those skilled in the art based on the moisture content control requirements of the insulator mortar production process. The warning upper and lower limits are preset by those skilled in the art based on the process warning margin. If the detected moisture content is greater than the upper limit of acceptable moisture content, a high moisture content alarm will be triggered; if the detected moisture content is less than the lower limit of acceptable moisture content, a low moisture content alarm will be triggered; if the detected moisture content is greater than the upper warning limit of moisture content but less than or equal to the upper limit of acceptable moisture content, a high moisture content warning will be triggered; if the detected moisture content is greater than or equal to the lower limit of acceptable moisture content but less than the lower warning limit of moisture content, a low moisture content warning will be triggered; if the detected moisture content is greater than or equal to the lower warning limit of moisture content but less than or equal to the upper warning limit of moisture content, the moisture content is determined to be within the normal range, and no alarm or warning will be triggered. It should be understood that the dual-level over-limit alarm judgment mechanism sets two thresholds: a warning boundary and a qualified boundary. When the moisture content has not exceeded the qualified range but is close to the qualified boundary, the operator is notified in advance so that the mud processing parameters can be adjusted in time to avoid the moisture content from deviating further from the qualified range and producing unqualified mud.

[0050] This embodiment uses a low-frequency, low-power continuous microwave signal to perform non-contact transmission detection on insulator mortar. Under the safe condition that the transmission power does not exceed 10 milliwatts, it achieves effective penetration of highly dense insulator mortar with a thickness of 20 to 25 centimeters, overcoming the shortcomings of high-power wide-spectrum schemes that result in high power consumption and significant radiation safety hazards. By setting distance sensors at both the microwave transmitter and receiver to synchronously acquire the distance between the transmitter and receiver, and combining the reference spacing to calculate the measured thickness of the insulator mortar in real time, the problem of lacking synchronous thickness measurement capability can be effectively solved. By employing a piecewise asymmetric beam diffusion model to independently calculate the air attenuation components at the transmitter and receiver and introducing standing wave interference correction, the periodic jump in received power caused by changes in the placement position of the mud material is effectively eliminated. By estimating the equivalent body temperature of the mud material based on the surface temperature change rate and the measured thickness value, the limitation of infrared temperature sensors that can only detect surface temperature and cannot characterize the true internal temperature state of the mud material is overcome. Furthermore, a temperature-distance coupled multi-order compensation model is adopted to simultaneously compensate for the first-order linear temperature drift effect, the second-order nonlinear dielectric relaxation shift effect, and the evaporation water vapor coupling effect, significantly improving the completeness and accuracy of temperature compensation. By separating the interface transition loss of the mud material correction attenuation value and introducing scattering path extension correction to calculate the equivalent propagation path length, the contribution of fixed interface loss independent of thickness and the contribution of forward scattering effect related to thickness nonlinearity are eliminated, making the specific attenuation rate have thickness-independent characteristics. This effectively solves the core technical problem of limited detection accuracy caused by the mutual coupling of moisture information and thickness information in multi-specification mud segment mixed production scenarios. By constructing a segmented calibration model for both free and bound water states, different calibration slopes are distinguished between the bound water-dominated absorption range and the free water-dominated absorption range, avoiding the systematic overestimation and underestimation biases generated by a single linear model in the two moisture state ranges. Through independent compensation of the indirect impact of temperature changes on the dynamic equilibrium transformation of bound and free water caused by temperature variations in the calibration relationship via second-order temperature correction of the calibration slope, layered independent compensation of the first-order temperature effect at the signal level and the second-order temperature effect at the calibration parameter level is achieved. Through end-link attenuation reconstruction self-consistency verification, a detection reliability index is quantified for each detection result, and a reliability-weighted time-series smoothing method is used to replace the traditional equal-weighted averaging, improving the robustness of the time-series output without introducing a fixed time delay. This enables safe, stable, real-time, and high-precision detection of moisture inside insulator clay without contact with the clay or disrupting the production process, providing a low-cost, easily deployable, and traceable intelligent detection solution for moisture quality control in the insulator production process.

[0051] Example 2 Please see Figure 2 As shown, the parts not described in detail in this embodiment are described in Embodiment 1. A non-contact method for detecting the moisture content of insulator mortar is provided, the method including: A continuous microwave signal is generated, and the continuous microwave signal is directionally transmitted to the insulator mud and the continuous microwave signal after penetrating the insulator mud is received to obtain the total microwave transmission attenuation value. The distance between the transmitting end and the receiving end is obtained, and combined with the preset reference spacing, the measured thickness value of the insulator mud is obtained; Based on the distance between the transmitter and receiver, the air propagation attenuation of the continuous microwave signal in the air path is dynamically evaluated, and the surface temperature of the mud is collected simultaneously. The temperature drift attenuation is calculated based on the surface temperature of the mud. The total microwave transmission attenuation is compensated and corrected based on the air propagation attenuation and the temperature drift attenuation to obtain the corrected attenuation value of the mud. Based on the measured thickness value, the corrected attenuation value of the clay is decoupled by thickness to quantitatively characterize the microwave absorption capacity of the clay per unit thickness and obtain the specific attenuation rate. By comparing the attenuation rate, the moisture content is inverted to obtain the moisture content detection value of the insulator mortar. The moisture content detection value is then displayed, stored, and an over-limit alarm is triggered.

[0052] Example 3 This application also provides an electronic device. The electronic device may include one or more processors and one or more memories. The memories store computer-readable code that, when executed by the one or more processors, can perform a non-contact method for detecting moisture in insulator mortar as described above.

[0053] The method or system according to the embodiments of this application can also be implemented using the architecture of the electronic device shown in this application. The electronic device may include a bus, one or more CPUs, ROM, RAM, a communication port connected to a network, input / output, a hard disk, etc. The storage device in the electronic device, such as a ROM or hard disk, may store a non-contact insulator mortar moisture detection method provided in this application. Furthermore, the electronic device may also include a user interface. Of course, the architecture shown in this application is merely exemplary; when implementing different devices, one or more components of the electronic device shown in this application may be omitted according to actual needs.

[0054] Example 4 One embodiment of this application discloses a computer-readable storage medium. The computer-readable storage medium stores computer-readable instructions. When the computer-readable instructions are executed by a processor, a non-contact insulator mortar moisture detection method according to an embodiment of this application, as described with reference to the above figures, can be performed. The storage medium includes, but is not limited to, volatile memory and / or non-volatile memory. Volatile memory may include, for example, random access memory (RAM) and cache memory. Non-volatile memory may include, for example, read-only memory (ROM), hard disk, flash memory, etc.

[0055] Furthermore, according to embodiments of this application, the processes described above with reference to the flowchart can be implemented as computer software programs. For example, this application provides a non-transitory machine-readable storage medium storing machine-readable instructions that can be executed by a processor to perform instructions corresponding to the method steps provided in this application, such as a non-contact method for detecting moisture in insulator mortar. When this computer program is executed by a central processing unit (CPU), it performs the functions defined in the method of this application.

[0056] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

[0057] All formulas in this manual are dimensionless and calculated numerically. The formulas are derived from software simulations based on a large amount of collected data to obtain the most recent real-world results. The preset parameters and thresholds in the formulas are set by those skilled in the art according to the actual situation.

[0058] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A non-contact method for detecting moisture content in insulator mortar, characterized in that, include: A continuous microwave signal is generated, and the continuous microwave signal is directionally transmitted to the insulator mud and the continuous microwave signal after penetrating the insulator mud is received to obtain the total microwave transmission attenuation value. The distance between the transmitter and receiver is obtained, and combined with the preset reference spacing, the actual thickness value of the insulator mud is obtained; Based on the distance between the transmitter and receiver, the air propagation attenuation of the continuous microwave signal in the air path is dynamically evaluated, and the surface temperature of the mud is collected simultaneously. The temperature drift attenuation is calculated based on the surface temperature of the mud. The total microwave transmission attenuation is compensated and corrected based on the air propagation attenuation and the temperature drift attenuation to obtain the corrected attenuation value of the mud. Based on the measured thickness value, the corrected attenuation value of the clay is decoupled by thickness to quantitatively characterize the microwave absorption capacity of the clay per unit thickness and obtain the specific attenuation rate. By comparing the attenuation rate, the moisture content is inverted to obtain the moisture content detection value of the insulator mortar. The moisture content detection value is then displayed, stored, and an over-limit alarm is triggered.

2. The non-contact insulator mortar moisture detection method according to claim 1, characterized in that, Methods for obtaining the total microwave transmission attenuation include: An initial microwave signal with a preset center frequency is generated, and the initial microwave signal is amplified to obtain an amplified microwave signal; based on the amplified microwave signal, a transmission reference power value is obtained; the transmission reference power value is used to verify signal stability to obtain a stable transmission power value; the amplified microwave signal is fed into a microwave transmitting horn antenna through an RF coaxial cable and received through a microwave receiving horn antenna; Based on the microwave signal received by the microwave receiving horn antenna, the instantaneous received power value is obtained; the instantaneous received power value is subjected to multiple sampling and mean filtering to obtain the received measured power value; the validity of the received measured power value is determined, and if the received measured power value is valid, the difference between the transmitted stable power value and the received measured power value is calculated to obtain the total microwave transmission attenuation value.

3. The non-contact insulator mortar moisture detection method according to claim 2, characterized in that, Methods for obtaining the measured thickness of insulator mortar include: The original distance values ​​of the transmitter and receiver are obtained, and the original distance values ​​of the transmitter and receiver are sampled and filtered multiple times to obtain the transmitter distance and receiver distance. Based on the transmitter distance, receiver distance and reference spacing, the measured thickness of the insulator mud is calculated, and the reasonableness of the measured thickness value is verified. The method for performing multiple sampling and filtering on the original distance values ​​of the transmitter is as follows: Multiple original distance values ​​of the transmitter are continuously acquired to form a transmitter distance sampling sequence; the standard deviation of all original distance values ​​of the transmitter in the transmitter distance sampling sequence is calculated to obtain the transmitter ranging fluctuation; if the transmitter ranging fluctuation is less than or equal to a preset ranging fluctuation threshold, the mean of all original distance values ​​of the transmitter in the transmitter distance sampling sequence is calculated to obtain the transmitter distance; if the transmitter ranging fluctuation is greater than the ranging fluctuation threshold, median filtering is performed on the transmitter distance sampling sequence to obtain the transmitter distance.

4. The non-contact insulator mortar moisture detection method according to claim 3, characterized in that, Methods for compensating and correcting the total microwave transmission attenuation include: Based on the distance between the transmitter and receiver, a segmented asymmetric beam spread model is used to calculate the air attenuation components at the transmitter and receiver respectively. The air attenuation components at the transmitter and receiver are then fused to obtain the initial air propagation attenuation. Standing wave interference correction is then applied to the initial air propagation attenuation to obtain the final air propagation attenuation. Based on the surface temperature and measured thickness of the insulator clay, the equivalent body temperature of the clay is estimated; a calibration reference temperature is preset, and the equivalent temperature deviation is calculated based on the calibration reference temperature and the surface temperature of the clay; based on the equivalent temperature deviation, the distance between the transmitter and the receiver, a temperature-distance coupled multi-stage compensation model is used to calculate the temperature drift attenuation. The total microwave transmission attenuation value is subtracted by the air propagation attenuation and the temperature drift attenuation value to obtain the mud material correction attenuation value. Then, the compensation consistency self-verification and effectiveness verification are performed in sequence.

5. The non-contact method for detecting moisture content in insulator mortar according to claim 4, characterized in that, Methods for decoupling thickness based on measured thickness values ​​and correction attenuation values ​​of clay include: The interface transition loss is separated from the corrected attenuation value of the mud material to obtain the volumetric absorption attenuation; the equivalent propagation path length is calculated based on the measured thickness value, and the specific attenuation rate is calculated based on the volumetric absorption attenuation and the equivalent propagation path length. The method for separating the interface transition loss of the corrected attenuation value of the mud is as follows: preset the interface transition loss benchmark value and the interface temperature correction coefficient; calculate the interface temperature deviation value based on the mud surface temperature and the calibration benchmark temperature; calculate the interface temperature correction amount based on the interface temperature correction coefficient and the interface temperature deviation value; calculate the actual interface transition loss amount based on the interface transition loss benchmark value and the interface temperature correction amount; calculate the difference between the corrected attenuation value of the mud and the actual interface transition loss amount to obtain the volume absorption attenuation amount. The method for calculating the specific attenuation rate is as follows: preset the scattering path extension coefficient, calculate the equivalent propagation path length based on the measured thickness value and the scattering path extension coefficient; calculate the ratio of volume absorption attenuation to the equivalent propagation path length to obtain the specific attenuation rate.

6. The non-contact insulator mortar moisture detection method according to claim 5, characterized in that, include: The steps for retrieving moisture content by comparing the decay rate include: Step S1: Use the free water-bound water dual-state segmented calibration model to compare the attenuation rate and perform initial moisture inversion to obtain the initial moisture content value; Step S2: Perform a second-order temperature correction on the initial moisture content value to obtain the temperature-corrected moisture content value; Step S3: Perform end-to-end attenuation reconstruction self-consistency verification on the temperature-corrected moisture content value to obtain the detection reliability; Step S4: Based on the detection confidence level, perform a reliability test on the temperature-corrected moisture content value; Step S5: If the temperature-corrected moisture content value passes the reliability test, then the temperature-corrected moisture content value is subjected to a reliability-weighted time-series smoothing process to obtain the moisture content detection value.

7. The non-contact insulator mortar moisture detection method according to claim 6, characterized in that, In step S1, the method for initial moisture inversion by comparing the decay rate includes: A segmented calibration model for the free water-bound water dual state is pre-constructed. The segmented calibration model for the free water-bound water dual state includes the calibration slope of the bound water segment, the calibration intercept of the bound water segment, the calibration slope of the free water segment, the calibration intercept of the free water segment, and the conversion ratio attenuation rate. The specific decay rate is input into the free water-bound water dual-state segmented calibration model, and the specific decay rate is compared with the transformation specific decay rate. If the specific decay rate is less than or equal to the transformation specific decay rate, a first-order linear inversion calculation is performed using the bound water segment calibration slope and the bound water segment calibration intercept to obtain the initial moisture content value. If the specific decay rate is greater than the transformation specific decay rate, a first-order linear inversion calculation is performed using the free water segment calibration slope and the free water segment calibration intercept to obtain the initial moisture content value.

8. The non-contact method for detecting moisture content in insulator mortar according to claim 7, characterized in that, Methods for pre-constructing a segmented calibration model of free water and bound water in two states include: Multiple calibration samples with different calibration reference moisture content values ​​were prepared, and microwave transmission tests were performed sequentially under calibration reference temperature conditions to obtain the specific attenuation rate of each calibration sample. The specific attenuation rate of each calibration sample was used as the independent variable and the calibration reference moisture content value as the dependent variable to construct a calibration dataset. All data points in the calibration dataset are sorted in ascending order of specific decay rate to obtain an ordered calibration data sequence. Candidate segment points are selected from the ordered calibration data sequence. The preceding and following segments corresponding to each candidate segment point are obtained. The preceding and following segments are fitted using first-order linear regression. The total sum of squared residuals for each candidate segment point is calculated by combining all data points. The specific decay rate corresponding to the candidate segment point with the smallest total sum of squared residuals is taken as the transformation specific decay rate. Data points with a specific decay rate less than or equal to the conversion specific decay rate are assigned to the bound water-dominated segment, and those with a specific decay rate greater than or equal to the free water-dominated segment. First-order linear regression fitting is performed on the data points of the bound water-dominated segment and the data points of the free water-dominated segment respectively to obtain the calibration slope, calibration intercept, calibration slope, and calibration intercept of the bound water segment in sequence.

9. A non-contact method for detecting moisture content in insulator mortar according to claim 8, characterized in that, In step S3, the methods for obtaining the detection confidence level include: Substitute the temperature-corrected moisture content value into the free water-bound water dual-state segmented calibration model to calculate the corresponding expected value of specific attenuation rate; calculate the expected value of volume absorption attenuation based on the expected value of specific attenuation rate and equivalent propagation path length; calculate the expected value of mud correction attenuation based on the expected value of volume absorption attenuation and actual interface transition loss; calculate the sum of the expected value of mud correction attenuation, air propagation attenuation and temperature drift attenuation to obtain the expected value of total microwave transmission attenuation. The absolute value of the difference between the expected value of total microwave transmission attenuation and the total microwave transmission attenuation is calculated to obtain the end-to-end reconstruction residual. A preset allowable threshold for reconstruction residual is set, and the ratio of the end-to-end reconstruction residual to the allowable threshold for reconstruction residual is calculated to obtain the residual exceedance rate. If the residual exceedance rate is greater than one, the residual exceedance rate is set to one. The difference between one and the residual exceedance rate is calculated to obtain the detection reliability.

10. A non-contact insulator mortar moisture detection system, implementing the non-contact insulator mortar moisture detection method according to any one of claims 1-9, characterized in that, include: The microwave acquisition module is used to generate a continuous microwave signal, directionally transmit the continuous microwave signal to the insulator mud, and receive the continuous microwave signal after it penetrates the insulator mud to obtain the total microwave transmission attenuation value. The thickness measurement module is used to obtain the distance between the transmitting end and the receiving end, and combined with the preset reference spacing, to obtain the measured thickness value of the insulator mud material. The environmental compensation module is used to dynamically evaluate the air propagation attenuation of continuous microwave signals in the air path based on the distance between the transmitter and receiver, and simultaneously collect the surface temperature of the mud, calculate the temperature drift attenuation based on the surface temperature of the mud, and compensate and correct the total microwave transmission attenuation value based on the air propagation attenuation and the temperature drift attenuation to obtain the mud correction attenuation value. The thickness decoupling module is used to decouple the corrected attenuation value of the clay material based on the measured thickness value, quantitatively characterize the microwave absorption capacity of the clay material per unit thickness, and obtain the specific attenuation rate. The moisture detection module is used to compare the attenuation rate to invert the moisture content, obtain the moisture content detection value of the insulator mud, and display, store, and alarm for exceeding the limit of the moisture content detection value.

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