An intelligent monitoring system of a 3D millimeter wave imaging radar fused with thermal imaging

Abstract

This invention discloses an intelligent monitoring system based on 3D millimeter-wave imaging radar and integrated with thermal imaging functionality. Addressing the volumetric measurement needs of industrial materials, the 3D millimeter-wave imaging radar overcomes the limitation of traditional level radar, which can only measure height but not volume. This invention, based on a 3D millimeter-wave radar, integrates thermal imaging functionality, enabling real-time measurement of the temperature information of industrial materials while simultaneously measuring their volume. The 3D millimeter-wave imaging radar includes a millimeter-wave radar and auxiliary equipment, a two-dimensional adjustable rotating platform, and a control system. The thermal imaging equipment is mounted externally to the 3D millimeter-wave imaging radar. Therefore, this system can measure both the volumetric volume and temperature information of materials in real time.

Description

Technical Field

[0001] This invention relates to the technical field of industrial material volume measurement, and more particularly to a control method and system for 3D millimeter-wave imaging radar. Background Technology

[0002] In large-scale heavy industry, especially in traditional sectors such as coal, steel, grain, and cement, material quantity is a crucial element, affecting both input and output. Material storage often utilizes large cylindrical tanks or warehouses. Traditionally, material measurement relied on manual rope hoisting; later, it evolved into material level measurement, using height to determine the approximate proportion of material within the tank.

[0003] In recent years, 3D measurement equipment has emerged both domestically and internationally, primarily based on millimeter-wave, laser, and camera technologies. Due to the high dust levels and low light conditions in industrial environments, millimeter-wave technology has become a major development direction. 3D millimeter-wave imaging radar scans the distances to different positions on the material level surface to create a 3D image of the surface, and then calculates the volume of material within the silo based on the height of the material level surface at different locations. However, current 3D imaging radar still suffers from limitations such as a limited number of scanning points, a rough material level surface, and low accuracy in volume calculation. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of existing radar measurement scanning points, such as small number of scanning points and low measurement accuracy, while adding thermal imaging scanning, so as to realize 3D images of the material surface and display the temperature distribution of the material surface.

[0005] The system comprises a millimeter-wave radar and its accessories, a 2D scanning turntable, a thermal imaging scanning system, and a control system. The millimeter-wave radar consists of a radar board, a single transmitting antenna, and a single receiving antenna, forming a single-transmit, single-receive radar system. The antenna utilizes an on-chip AOP antenna, saving space and significantly reducing the size of the circuit board. A focusing lens is designed outside the antenna, controlling the antenna beam angle within 1.5° to create a beam-like electromagnetic wave that illuminates in a designated direction. The lens and the millimeter-wave radar board are fixed together with metal studs to form a complete radar transceiver. Approximately 50mm outside the lens, a circular metal plate is designed at a 45° angle to the lens's radiating beam direction. The diameter of the metal plate is the same as the lens diameter. The metal plate is fixed to a servo motor that can rotate around its center point. In this design, the millimeter-wave beam, after being radiated through the lens, radiates at a 45° angle onto the flat metal plate, and is then deflected 90°, achieving 90° deflection control of the electromagnetic wave radiation direction.

[0006] The 2D scanning turntable consists of two servo motors. One motor, A, is connected to a metal plate and is responsible for rotating the metal plate to radiate the millimeter-wave beam to different positions in the vertical direction. The other motor, B, is responsible for supporting and rotating the millimeter-wave radar, its accessories, and the motor itself. The millimeter-wave radar plate, lens, metal plate, and servo motor A are arranged sequentially and fixed within a cylindrical housing made of a highly transparent plastic, such as polyethylene. The millimeter-wave radar plate and servo motor A are fixed to opposite ends of the cylinder, with cable exit ports provided.

[0007] The cylinder is fixed at both ends by metal brackets, which are placed on servo motor B. It is important to note that the center of servo motor B and the center of the rotating metal plate are aligned in a straight line. This ensures that the straight line formed by electromagnetic waves radiating to the material coincides with the center of servo motor B. Compared to servo motor A, servo motor B has a stronger load-bearing capacity.

[0008] The thermal imaging scanning system is embedded as an independent module on the outside of the cylindrical shell, on one side of the millimeter-wave radar circuit board. This balances the weight on both sides of the cylinder and does not interfere with the electromagnetic waves emitted by the millimeter-wave radar. The thermal imaging system does not require a servo motor to drive the scanning and can directly perform thermal imaging on a set area.

[0009] The control system is responsible for controlling the system's operation, data acquisition and analysis, data forwarding, and power supply. It employs a combination of industrial control computer and host computer software, and can also be remotely controlled, requiring only an additional power supply locally. In this system, the direction of electromagnetic wave radiation is controlled by rotating two servo motors. The position of the radar measurement point is synchronized with the rotation position of the servo motors, and the rotation speed of the motors is consistent with the speed at which radar data and thermal imaging data are acquired. This ensures that the results acquired and presented by the two devices in real time are synchronized after each measurement. Attached Figure Description

[0010] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0011] Figure 1 This is a system block diagram in an embodiment of the present invention;

[0012] Figure 2 This is a radar measurement signal transmission path diagram in an embodiment of the present invention;

[0013] Figure 3 This is a flowchart of the workflow in an embodiment of the present invention.

[0014] Explanation of reference numerals in the instruction manual:

[0015] 11. Servo motor B; 12. Metal support frame; 13. Millimeter-wave radar board with on-chip antenna; 14. Thermal imaging equipment; 15. Focusing lens; 16. Metal plate reflector; 17. Cylindrical plastic shell; 18. Servo motor A.

Claims

1. An intelligent monitoring system for 3D millimeter-wave imaging radar integrating thermal imaging, characterized in that: It includes a millimeter-wave radar and its accessories, a two-dimensional scanning turntable, a thermal imaging scanning system, and a control system. The millimeter-wave radar consists of a radar board, a single transmitting antenna, and a single receiving antenna, forming a single-transmit and single-receive radar system.

2. The intelligent monitoring system for a 3D millimeter-wave imaging radar fusion thermal imaging according to claim 1, characterized in that: The antenna is an on-chip AOP antenna, which does not occupy volume and can greatly reduce the size of the circuit board. A focusing lens is designed on the outside of the antenna, which can control the antenna wave velocity angle within 1.5°, thereby forming an electromagnetic wave similar to a beam of light, which shines in a specified direction. The lens and the millimeter-wave radar board are fixed together with metal studs to form a complete radar transceiver.

3. The intelligent monitoring system for a 3D millimeter-wave imaging radar fusion thermal imaging according to claim 2, characterized in that: A circular metal plate is designed about 50 mm outside the lens, forming a 45° angle with the direction of the lens's radiation beam. The diameter of the metal plate is the same as the diameter of the lens.

4. The intelligent monitoring system for a 3D millimeter-wave imaging radar fusion thermal imaging according to claim 3, characterized in that: The metal plate is fixed on a servo motor that can rotate around the center point of the metal plate. In this design structure, the millimeter wave beam is radiated by the lens and then radiates onto the flat metal plate at an angle of 45°. It can then be deflected by 90° and radiated outward, thus realizing 90° deflection control of the electromagnetic wave radiation direction.

5. The intelligent monitoring system for a 3D millimeter-wave imaging radar fusion thermal imaging according to claim 1, characterized in that: The two-dimensional scanning turntable consists of two servo motors. One motor, A, is connected to a metal plate and is responsible for rotating the metal plate to radiate the millimeter-wave beam to different positions in the vertical direction. The other motor, B, is responsible for supporting and rotating the millimeter-wave radar and its accessories, as well as the motor. That is, the millimeter-wave radar plate, lens, metal plate, and servo motor A are arranged in sequence and fixed in a cylindrical shell. The shell is made of a plastic with good wave transmission properties, such as polyethylene.

6. The intelligent monitoring system for a 3D millimeter-wave imaging radar fusion thermal imaging according to claim 5, characterized in that: The cylinder has a millimeter-wave radar plate and a servo motor A fixed at each end, with cable outlets provided. The cylinder is also fixed at both ends by metal brackets, which are placed on the servo motor B. It is important to note that the center of the servo motor B is aligned with the center of the rotating metal plate. This ensures that the straight line formed by the electromagnetic waves radiating to the material coincides with the center of the servo motor B. Compared to servo motor A, the servo motor has a stronger load-bearing capacity.

7. The intelligent monitoring system for a 3D millimeter-wave imaging radar fusion thermal imaging according to claim 1, characterized in that: The thermal imaging scanning system is embedded as an independent module on the outside of the cylindrical shell, on one side of the millimeter-wave radar circuit board. This balances the weight on both sides of the cylinder and does not interfere with the electromagnetic waves emitted by the millimeter-wave radar. The thermal imaging system does not require a servo motor to drive the scanning and can directly perform thermal imaging on a set area.

8. The intelligent monitoring system for a 3D millimeter-wave imaging radar fusion thermal imaging according to claim 1, characterized in that: The control system is responsible for controlling the system's operation, data acquisition and analysis, data forwarding, and power supply. It adopts a combination of industrial control computer and host computer software, or it can be remotely controlled. Only an additional power supply is needed locally. The control system controls the direction of electromagnetic wave radiation by controlling the rotation of two servo motors. The position of the radar measurement point is kept in sync with the rotation position of the servo motors. The rotation speed of the motors is consistent with the speed of acquiring radar data and thermal imaging data, which can ensure that the results acquired and presented by the two devices in real time are synchronized after each measurement.

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