A method and system for predicting and dynamically controlling the atmosphere isolation state of a double push plate kiln

Abstract

The present application belongs to the technical field of atmosphere control, and discloses a kind of double push plate kiln atmosphere isolation state prediction and dynamic regulation control method and system;Including: the grid coordinate system of push plate surface is constructed, and push plate surface is zoned;Identify abnormal temperature zone and abnormal height zone of bare area;Obtain the spatial center coordinates of each abnormal temperature zone and abnormal height zone, and form abnormal matching unit according to the Euclidean distance of abnormal temperature zone and abnormal height zone spatial center coordinates;Calculate the intersection and union ratio of abnormal matching unit;According to intersection and union ratio, abnormal matching unit is given spatial correlation degree grade;Confirm residual area judgment based on spatial correlation degree grade, and carry out atmosphere isolation state prediction;Obtain the push plate position of existing confirmation residual area, and carry out atmosphere regulation;The present application realizes the accurate locking of material residue on the push plate surface by analyzing the coupling relationship of abnormal temperature zone and abnormal height zone, and guarantees the sintering product quality and the stability of kiln operation.

Description

Technical Field

[0001] This invention relates to the field of atmosphere control technology, and more specifically, to a method and system for predicting and dynamically controlling the atmosphere isolation state of a double-pusher kiln. Background Technology

[0002] The double-pusher plate kiln is a core piece of equipment in high-temperature sintering processes in ceramics, metal powder metallurgy, and other fields. Its working principle involves using hydraulically driven intermittent pushers to move materials and complete sintering in specific atmospheres within each zone. Precise control of the atmosphere isolation is crucial for ensuring the sintering quality of the materials. Maintaining stable parameters such as pressure and gas composition is essential; otherwise, defects such as material oxidation, uneven composition, and cracking can easily occur, reducing the product qualification rate.

[0003] While existing technologies can achieve pusher synchronization and basic monitoring and control of atmosphere parameters through hydraulic encoders and pressure sensors, in actual high-temperature sintering processes, materials with a high proportion of fine powder are prone to overflow or scattering during sintering or transportation, forming fine powder residues on the pusher surface. This accumulation of dust residue is a major cause of deterioration in atmosphere isolation. The residue directly raises the local height of the pusher, widening or even eliminating the physical sealing gap between the pusher and the kiln body or sealing plate.

[0004] Existing technologies can only collect data that reflects the macroscopic movement of the pusher plate or the overall fluctuation of the atmosphere, and cannot directly obtain key physical information such as the spatial location, accumulation height, and local thermal anomalies caused by residual dust on the pusher plate surface. This deficiency prevents existing systems from accurately predicting and targeting dust residue, resulting in serious product quality defects and production interruptions.

[0005] In view of this, the present invention proposes a method and system for predicting and dynamically controlling the atmosphere isolation state of a double-pusher kiln to solve the above problems. Summary of the Invention

[0006] To overcome the aforementioned deficiencies of the prior art and achieve the above objectives, the present invention provides the following technical solution: a method for predicting and dynamically controlling the atmosphere isolation state of a double-pusher kiln, comprising:

[0007] A grid coordinate system is constructed for the surface of the push plate, and the surface of the push plate is divided into partitions, including a process placement area, a sealing and bonding area, and an exposed area.

[0008] Identify abnormal temperature and abnormal height zones in exposed areas;

[0009] Obtain the spatial center coordinates of each abnormal temperature zone and abnormal height zone, and form anomaly matching units based on the Euclidean distance between the spatial center coordinates of the abnormal temperature zone and abnormal height zone.

[0010] Calculate the crossover-union ratio of the anomalous matching units;

[0011] Assign spatial correlation levels to outlier matching units based on their intersection-union ratio;

[0012] The presence of a confirmed residual zone in the pusher plate is determined based on the spatial correlation level, and the atmosphere isolation state of the double pusher plate kiln is predicted based on the determination result of the confirmed residual zone in the pusher plate.

[0013] When it is determined that there is a pusher plate with a confirmed residual zone, the position of the pusher plate with the confirmed residual zone is obtained, and the atmosphere of the double pusher plate kiln is adjusted according to the position of the pusher plate with the confirmed residual zone.

[0014] Furthermore, the method for obtaining the abnormal temperature zone is as follows:

[0015] S201: Use a non-contact infrared thermal imager to scan the temperature of the exposed area of ​​the push plate, and spatially map and calibrate the temperature matrix obtained by the non-contact infrared thermal imager with the grid coordinate system to obtain a continuous temperature field data matrix of the entire exposed area.

[0016] S202: Each grid cell is used as the data carrier. The temperature value within the grid cell is obtained by the average temperature of the grid nodes of that grid cell. The coordinates of the grid cell are determined by the coordinates of the lower left grid node of that grid cell in the grid coordinate system.

[0017] S203: The temperature value of each grid cell is presented using pseudo-color encoding to form a surface temperature distribution map;

[0018] S204: Calculate the overall average temperature of the exposed area as a background baseline;

[0019] Set a temperature deviation threshold, traverse the entire temperature distribution map, and mark the grid cells that exceed the temperature deviation threshold as potential anomalies.

[0020] Connectivity analysis is performed on potential anomalies, and continuous regions formed by the aggregation of adjacent grid cells are identified as anomalous temperature zones.

[0021] Furthermore, the method for obtaining abnormal height regions is as follows:

[0022] S301: A laser profile measurement assembly consisting of a line laser projector and an industrial camera is used to obtain the height values ​​of each grid node in the exposed area of ​​the push plate.

[0023] S302: Take the average height value of all grid nodes in each grid cell as the height value of that grid cell, and generate a height matrix;

[0024] S303: Based on the height matrix, a height field is generated using pseudo-color encoding;

[0025] S304: Set a height threshold, perform connectivity analysis on grid cells with height values ​​greater than the height threshold, and determine the continuous region formed by the aggregation of adjacent grid cells as an abnormal height area.

[0026] Furthermore, the methods for composing anomaly matching units include:

[0027] S401: Extract the dedicated set of grid cells for each discrete abnormal temperature region and abnormal height region;

[0028] S402: For each abnormal temperature zone and abnormal height zone, the spatial center coordinates are obtained by averaging the coordinates of all grid cells in its grid cell set;

[0029] S403: Calculate the Euclidean distance between the spatial center coordinates of each abnormal temperature zone and all abnormal height zones, and match the abnormal height zone with the smallest Euclidean distance to form an abnormal matching unit.

[0030] Furthermore, methods for calculating the intersection-union ratio of anomalous matching units include:

[0031] Let set T be the set of mesh elements in the abnormal temperature region of the abnormal matching unit, and let set H be the set of mesh elements in the abnormal height region of the abnormal matching unit. Select the mesh elements that intersect set T and set H, and denote them as set I.

[0032] Count the total number of grid cells Nt in set T, the total number of grid cells Nh in set H, and the number of grid cells Ni in set I;

[0033] The intersection-union ratio (IoU) of the abnormal matching cells is obtained by dividing the number of grid cells in set I by the number of grid cells in the union of sets T and H.

[0034] Furthermore, methods for assigning spatial correlation levels to outlier matching units based on intersection-union ratios include:

[0035] Preset intersection-union ratio (IU) thresholds A1 and A2, where A1 is greater than A2;

[0036] Assign association labels based on the IoU value of a single abnormal matching unit;

[0037] If IoU ≥ A1, set the abnormal matching unit as strongly associated;

[0038] If A2≤IoU<A1, set the abnormal matching unit to medium association;

[0039] If IoU < A2, set the abnormal matching unit as a weak association.

[0040] Furthermore, the method for determining whether a confirmed residual zone exists in the pusher plate based on the spatial correlation level, and for predicting the atmosphere isolation state of a double-pusher kiln based on the determination result of the confirmed residual zone in the pusher plate, includes:

[0041] S501: For strongly correlated abnormal matching cells, obtain the union of the sets of grid cells in the abnormal temperature zone and abnormal height zone, and define the connected region covered by the grid cells in the union as the confirmed residual region.

[0042] S502: For a moderately correlated abnormal matching unit, obtain the total area and peak height of the grid cells in set H. After the next pusher advance cycle ends, obtain the total area and peak height of the grid cells in set H again.

[0043] Set area thresholds and peak height thresholds;

[0044] If either the total area of ​​the grid cells or the peak height shows an increasing trend, and the total area of ​​the grid cells is greater than the area threshold or the peak height is greater than the peak height threshold, then the union of the grid cell sets of the abnormal temperature zone and the abnormal height zone is obtained, and the connected region covered by the grid cells in the union is defined as the confirmed residual zone; otherwise, it is defined as the non-residual zone.

[0045] S503: For weakly correlated abnormal matching units and non-residual areas, only generate abnormal prompts and mark the abnormal areas, and perform abnormal investigation at the end of batch production;

[0046] S504: Test all pushers. If any pusher has a confirmed residual area, the predicted atmosphere isolation state is high-risk. Otherwise, it is low-risk.

[0047] Furthermore, the method for obtaining the location of the pusher plate where a confirmed residual zone exists, and for adjusting the atmosphere of the double-pusher kiln based on the location of the pusher plate where a confirmed residual zone exists, includes:

[0048] The location of the gas inlet in the sintering section is obtained, and the position of the pusher plate is collected in real time using the position encoder on the pusher plate;

[0049] When a pusher plate with a confirmed residual area is detected in the sintering section, a flow rate control command is immediately triggered. The gas supply port closest to the pusher plate is used as the control gas supply port. The opening of the gas supply valve corresponding to the control gas supply port is adjusted to reduce the flow rate of the nitrogen protective atmosphere at this point from the current set level to the preset ratio of the current set level.

[0050] Throughout the entire control process, the protective atmosphere status is monitored in real time. If an atmosphere abnormality occurs after the flow rate decreases, corresponding compensation control is implemented.

[0051] After each push plate with a confirmed residual area is pushed forward, its position is re-acquired based on the real-time data of the push plate position encoder, and the corresponding control air supply port is dynamically updated.

[0052] When a switch in the air supply port is detected, the opening of the air supply valve of the previous air supply port is restored to the normal operating opening, and the flow rate reduction control of the previous air supply port is reapplied to the new air supply port.

[0053] Furthermore, compensation control includes:

[0054] Set the adjacent air inlets before and after the regulating air inlet as compensation air inlets;

[0055] If the pressure sensor detects insufficient pressure inside the kiln, the compensation air inlet continuously adjusts the opening of the air inlet valve in small increments of one percent of the full stroke until the pressure inside the kiln is restored to normal through real-time feedback from the pressure sensor.

[0056] If the atmosphere concentration sensor detects an abnormal atmosphere composition caused by the infiltration of outside air, the compensation air supply port will be adjusted in batches with a single adjustment step of one percent of the full stroke. The opening of the air supply valve will be increased in small increments. After each adjustment, the data of the pressure sensor and the atmosphere concentration sensor will be collected simultaneously until the air pressure inside the kiln reaches a slightly positive pressure range that is higher than the atmospheric pressure outside the kiln but lower than the upper limit of the normal working air pressure in the sintering section and the oxygen concentration returns to normal. This will block the infiltration of outside air by constructing a pressure difference barrier.

[0057] Throughout the process, the airflow velocity at the compensation and replenishment inlet is controlled to not exceed the preset low velocity threshold.

[0058] A predictive and dynamic control system for atmosphere isolation state in a double-pusher kiln, comprising the following steps:

[0059] Partitioning Module: Constructs a grid coordinate system for the push plate surface and partitions the push plate surface, including a process placement area, a sealing and bonding area, and an exposed area;

[0060] Anomaly detection module: Identifies abnormal temperature and height areas in exposed areas;

[0061] Anomaly matching module: Obtains the spatial center coordinates of each abnormal temperature zone and abnormal height zone, and forms anomaly matching units based on the Euclidean distance between the spatial center coordinates of the abnormal temperature zone and abnormal height zone;

[0062] Cross-Union Ratio (CURBR) Calculation Module: Calculates the CURBR of anomalous matching units;

[0063] Association Judgment Module: Assigns spatial association degree level to abnormal matching units based on intersection-union ratio;

[0064] Residue Judgment Module: Based on the spatial correlation level, it judges whether there is a confirmed residue area on the push plate, and predicts the atmosphere isolation state of the double push plate kiln based on the judgment result of the confirmed residue area on the push plate.

[0065] Atmosphere control module: When it is determined that there is a push plate with a confirmed residue zone, the position of the push plate with the confirmed residue zone is obtained, and the atmosphere of the double push plate kiln is controlled according to the position of the push plate with the confirmed residue zone.

[0066] The technical effects and advantages of the proposed method and system for predicting and dynamically controlling the atmosphere isolation state of a double-pusher kiln are as follows:

[0067] First, this invention achieves comprehensive capture and preliminary screening of material residue characteristics on the push plate surface through a dual-dimensional abnormal zone identification mechanism of temperature and height. It characterizes residue characteristics from two dimensions: thermal behavior and physical morphology. It captures potential residue risks through the temperature dimension and accurately represents the physical morphology of residues through the height dimension, thus making up for the technical defects of single temperature monitoring being prone to misjudging thermal fluctuations and single height monitoring being prone to misjudging push plate scratches.

[0068] Secondly, this invention constructs a progressive anomaly matching system based on spatial center matching, intersection-union ratio (IUGR) quantification, and correlation level classification. First, it uses Euclidean distance to initially pair anomaly temperature zones with anomaly height zones. Then, it calculates the IUGR to quantify the spatial overlap between the two, assigning spatial correlation levels based on preset thresholds, and performing hierarchical judgment on anomaly matching units. The IUGR can identify the spatial coupling relationship between the two, effectively avoiding the risk of misjudgment caused by analyzing only a single anomaly.

[0069] In summary, this invention, through dual-dimensional anomaly feature identification and progressive anomaly matching judgment, has the significant advantages of comprehensive feature capture and accurate residue identification. It is fully adapted to the special characteristics of the high temperature, high dust, and hidden residue risks in the sintering section of the double-pusher kiln, accurately pinpointing the material residue risks on the pusher surface, and effectively ensuring the quality of sintered products and the stability of kiln operation. Attached Figure Description

[0070] Figure 1 This is a flowchart of a method for predicting and dynamically controlling the atmosphere isolation state of a double-pusher kiln according to Embodiment 1 of the present invention;

[0071] Figure 2 This is a schematic diagram of the spatial correlation degree level acquisition method in Embodiment 1 of the present invention;

[0072] Figure 3 This is a block diagram of a double-pusher kiln atmosphere isolation state prediction and dynamic control system according to Embodiment 2 of the present invention. Detailed Implementation

[0073] 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.

[0074] Example 1

[0075] See Figure 1 As shown, this embodiment provides a method for predicting and dynamically controlling the atmosphere isolation state of a double-pusher kiln, including:

[0076] Construct a grid coordinate system for the push plate surface and partition the push plate surface.

[0077] The specific method is as follows:

[0078] The origin of the grid coordinate system is set at the intersection of the front edge of the pusher plate along its advancing direction and the left edge of the pusher plate along its width direction. An X-axis is established along the advancing direction of the pusher plate and a Y-axis is established along the width direction of the pusher plate. Grid nodes are divided, and the grid accuracy is set to n×n (n can be 5mm). Coordinates are assigned to each node.

[0079] The surface of the push plate is divided into three zones: a process placement zone, a sealing and bonding zone, and an exposed zone. The process placement zone is where materials are placed, the sealing and bonding zone is where the push plate contacts the sealing plate, and the exposed zone is the area of ​​the push plate exposed to the atmosphere, excluding the process placement zone and the sealing and bonding zone.

[0080] Temperature data is collected from the exposed area of ​​the push plate to generate a surface temperature distribution map and identify abnormal temperature areas.

[0081] The method for obtaining the surface temperature distribution map is as follows:

[0082] S201: A non-contact infrared thermal imager is used to scan the temperature of the exposed area of ​​the push plate. The temperature matrix obtained by the non-contact infrared thermal imager is spatially mapped and calibrated with the grid coordinate system to obtain a continuous temperature field data matrix of the entire exposed area.

[0083] S202: Each grid cell is used as the data carrier. The temperature value within the grid cell is obtained by the average temperature of the grid nodes of that grid cell. The coordinates of the grid cell are determined by the coordinates of the lower left grid node of that grid cell in the grid coordinate system.

[0084] It should be noted that the grid node with the smallest X-coordinate and Y-coordinate in the grid cell is selected as the bottom left corner.

[0085] S203: The temperature value of each grid cell is presented using pseudo-color encoding, for example, 800-810℃ is blue, 810-820℃ is yellow, and above 820℃ is red, forming a surface temperature distribution map. This grid cell mapping rule based on the grid coordinate system is completely consistent with the subsequent height field.

[0086] S204: Calculate the overall average temperature of the exposed area as a background baseline;

[0087] Set a temperature deviation threshold, traverse the entire temperature distribution map, and mark the grid cells that exceed the temperature deviation threshold as potential anomalies.

[0088] Connectivity analysis is performed on potential anomalies, and continuous regions formed by the aggregation of adjacent grid cells are identified as anomalous temperature zones.

[0089] Material residue on the pusher plate surface will form a temperature gradient with the residue-free background area due to its own sintering reaction. This temperature difference can serve as a direct thermal basis for identifying the residue zone, exhibiting detectable thermal response characteristics before the residue has significantly accumulated or changed in height. The heat capacity, heat release mode, and gas evolution behavior of the material residue differ from those of the pusher plate itself, making it more temperature sensitive during heating and holding. Therefore, the temperature of the residue zone deviates significantly from that of the normal zone. Based on this principle, the temperature gradient can be regarded as a precursor signal of material residue. By accurately capturing local anomalies in the temperature field on the pusher plate surface, a reliable thermal basis can be provided for subsequent height detection, spatial correlation analysis, and dynamic atmosphere control.

[0090] The height of the exposed area of ​​the push plate is collected to generate a height field and abnormal height areas are identified.

[0091] The method for obtaining the abnormal height region is as follows:

[0092] S301: A laser profile measurement component consisting of a line laser projector and an industrial camera is used to obtain the height values ​​of each grid node in the exposed area of ​​the push plate, wherein the height values ​​are taken with the surface of the push plate as the zero point.

[0093] S302: Take the average height value of all grid nodes in each grid cell as the height value of that grid cell, and generate a height matrix that is completely consistent with the continuous temperature field data matrix in terms of coordinate system and grid accuracy.

[0094] S303: Based on the height matrix, a visual height field is generated using pseudo-color encoding. For example, the height range of 2.0-4.2mm is set to blue, 4.2-5.4mm to yellow, and above 5.4mm to red. The X / Y axis coordinates and height color correspondence legends are marked. The coordinate marking rules are strictly consistent with the temperature field distribution map, and the coordinates of the lower left corner vertex of the grid cell are used as the grid cell coordinates.

[0095] S304: Set a height threshold, perform connectivity analysis on grid cells with height values ​​greater than the height threshold, and determine the continuous region formed by the aggregation of adjacent grid cells as an abnormal height area.

[0096] The temperature deviation threshold and height threshold are set by those skilled in the art based on their experience. For example, the temperature deviation threshold can be set by collecting the temperature matrix of the exposed area under normal sintering conditions with no residual pusher plate, statistically analyzing the distribution of the deviation of the grid temperature relative to the average temperature of the exposed area, and taking the 95th percentile of the deviation as the temperature deviation threshold; the height threshold can be set by collecting the height matrix of the exposed area under the condition that the pusher plate has been cleaned, statistically analyzing the distribution of the protrusion height of the grid height relative to the pusher plate reference surface, and taking the 95th percentile as the height threshold.

[0097] The separate identification of abnormal temperature and abnormal height zones enables comprehensive capture of residual characteristics from both thermal behavior and physical morphology dimensions. This effectively avoids the problem of misjudging thermal fluctuations as residues by single temperature monitoring and misjudging push plate scratches as residues by single height monitoring, laying a reliable data foundation for subsequent anomaly matching.

[0098] Obtain the spatial center coordinates of each abnormal temperature zone and abnormal height zone, and form anomaly matching units based on the Euclidean distance between the spatial center coordinates of the abnormal temperature zone and abnormal height zone.

[0099] Specific methods include:

[0100] S401: Extract the dedicated set of grid cells for each discrete abnormal temperature region and abnormal height region.

[0101] S402: For each abnormal temperature zone and abnormal height zone, the spatial center coordinates are obtained by averaging the coordinates of all grid cells in its grid cell set.

[0102] S403: Calculate the Euclidean distance between the spatial center coordinates of each abnormal temperature zone and all abnormal height zones, and match the abnormal height zone with the smallest Euclidean distance to form an abnormal matching unit.

[0103] Calculate the crossover-union ratio of the abnormal matching units.

[0104] Specific methods include:

[0105] Let set T be the set of mesh elements in the abnormal temperature region of the abnormal matching unit, and let set H be the set of mesh elements in the abnormal height region of the abnormal matching unit. Select the mesh elements that intersect set T and set H, and denote them as set I.

[0106] The total number of grid cells Nt in set T, the total number of grid cells Nh in set H, and the number of grid cells Ni in set I are counted, and then substituted into the formula to complete the calculation. The formula is:

[0107] ;

[0108] in, For intersection, union, and comparison.

[0109] The spatial correlation level of abnormal matching units is assigned based on the intersection-union ratio.

[0110] See Figure 2 As shown, the specific method is as follows:

[0111] Preset intersection-union ratio (IU) thresholds A1 (e.g., 80%) and A2 (e.g., 40%), where A1 is greater than A2;

[0112] If IoU≥A1, the spatial correlation level of the abnormal matching unit is set to strong correlation;

[0113] If A2≤IoU<A1, the spatial correlation level of the abnormal matching unit is set to medium correlation;

[0114] If IoU < A2, the spatial correlation level of the abnormal matching unit is set to weak correlation.

[0115] By calculating the crossover ratio, the spatial coupling relationship between temperature anomalies and altitude anomalies can be identified, and the true state of the remains can be characterized, effectively avoiding the risk of misjudgment caused by analyzing only a single anomaly.

[0116] The presence of a confirmed residual zone in the pusher plate is determined based on the spatial correlation level, and the atmosphere isolation state of the double pusher plate kiln is predicted based on the determination result of the confirmed residual zone in the pusher plate.

[0117] Specific methods include:

[0118] S501: For anomaly matching units with strong spatial correlation, obtain the union of the sets of grid cells in the anomalous temperature zone and anomalous height zone, and define the connected region covered by the grid cells in the union as the confirmed residual region.

[0119] S502: For abnormal matching units with medium spatial correlation, obtain the total area and peak height of the grid cells in set H. After the next push plate advance cycle ends, obtain the total area and peak height of the grid cells in set H again.

[0120] Set area thresholds and peak height thresholds;

[0121] If either the total area of ​​the grid cells or the peak height shows an increasing trend, and the total area of ​​the grid cells is greater than the area threshold or the peak height is greater than the peak height threshold, then the union of the grid cell sets of the abnormal temperature zone and the abnormal height zone is obtained, and the connected region covered by the grid cells in the union is defined as the confirmed residual zone; otherwise, it is defined as the non-residual zone.

[0122] The peak height is the maximum value of the height of all grid cells in set H.

[0123] S503: For abnormal matching units and non-residual areas with weak spatial correlation, only anomaly prompts are generated to mark the abnormal areas, and anomaly investigation is carried out at the end of batch production.

[0124] S504: Test all pushers. If any pusher has a confirmed residual area, the predicted atmosphere isolation state is high-risk. Otherwise, it is low-risk.

[0125] The area threshold and peak height threshold are set by those skilled in the art based on their experience. For example, the area threshold can be set to the area of ​​10 grid cells, and the peak height threshold can be set to twice the height threshold.

[0126] When it is determined that there is a pusher plate with a confirmed residual zone, the position of the pusher plate with the confirmed residual zone is obtained, and the atmosphere of the double pusher plate kiln is adjusted according to the position of the pusher plate with the confirmed residual zone.

[0127] Specific methods include:

[0128] The location of the gas inlet in the sintering section is obtained, and the position of the pusher plate is collected in real time using the position encoder on the pusher plate;

[0129] When a pusher plate with a confirmed residual zone is detected in the sintering section, a flow rate control command is immediately triggered. The gas supply port closest to the pusher plate is used as the control gas supply port. The opening of the gas supply valve corresponding to the control gas supply port is adjusted to reduce the flow rate of the nitrogen protective atmosphere at this point from the current set level to a preset ratio of the current set level. The preset ratio can be selected as 0.8.

[0130] Throughout the entire control process, the protective atmosphere status is monitored in real time. If an atmosphere abnormality occurs after the flow rate decreases, corresponding compensation control is implemented.

[0131] The compensation control includes:

[0132] Set the adjacent air inlets before and after the regulating air inlet as compensation air inlets;

[0133] If the pressure sensor detects insufficient pressure inside the kiln, the compensation air inlet continuously adjusts the opening of the air supply valve in small increments of one percent of the full stroke until the pressure inside the kiln is restored to normal through real-time feedback from the pressure sensor.

[0134] If the atmosphere concentration sensor detects an abnormal atmosphere composition caused by the infiltration of outside air, such as an increase in oxygen content detected by the oxygen content analyzer, the compensation air supply port will be adjusted in batches with a single adjustment step of one percent of the full stroke, gradually increasing the opening of the air supply valve. After each adjustment, data from the pressure sensor and the atmosphere concentration sensor will be collected simultaneously until the air pressure inside the kiln reaches a slightly positive pressure range that is higher than the atmospheric pressure outside the kiln but lower than the upper limit of the normal working air pressure in the sintering section, and the oxygen concentration returns to normal. This will block the infiltration of outside air by constructing a pressure difference barrier.

[0135] Throughout the process, the airflow velocity at the compensation air inlet is controlled to not exceed a preset low velocity threshold to avoid airflow disturbance of dust in the residual area. The low velocity threshold is set by a person skilled in the art based on their experience; for example, the low velocity threshold can be set to 0.5 times the conventional set velocity.

[0136] While maintaining the core logic of controlling the low flow rate of the gas injection port, ensure that the atmosphere isolation effect of the sintering section is not affected.

[0137] After each pusher plate with a confirmed residual area is pushed forward, its position is re-acquired based on real-time data from the pusher plate position encoder, and the corresponding control and replenishment air port is dynamically updated.

[0138] When a switch in the air supply port is detected, the opening of the air supply valve of the previous air supply port is restored to the normal operating opening, and the new air supply port is re-regulated.

[0139] By using the above-mentioned cyclic execution method, the deceleration and compensation air replenishment control can remain effective as the pusher advances, without being interrupted by changes in the pusher position.

[0140] Dust and uncured residue in the sintering section are easily lifted by high-speed airflow. Reducing the flow rate can prevent residual dust from spreading to other areas of the sintering section due to airflow disturbance and forming secondary accumulation. At the same time, the low-speed flow field will not disturb the high-temperature process environment and sintering state of the material in the sintering section, thus ensuring the stability of the sintering reaction.

[0141] Example 2

[0142] See Figure 3 As shown, this embodiment provides a prediction and dynamic control system for the atmosphere isolation state of a double-pusher kiln. The method for predicting and dynamically controlling the atmosphere isolation state of a double-pusher kiln includes:

[0143] Partitioning Module: Constructs a grid coordinate system for the push plate surface and partitions the push plate surface, including a process placement area, a sealing and bonding area, and an exposed area;

[0144] Anomaly detection module: Identifies abnormal temperature and height areas in exposed areas;

[0145] Anomaly matching module: Obtains the spatial center coordinates of each abnormal temperature zone and abnormal height zone, and forms anomaly matching units based on the Euclidean distance between the spatial center coordinates of the abnormal temperature zone and abnormal height zone;

[0146] Cross-Union Ratio (CURBR) Calculation Module: Calculates the CURBR of anomalous matching units;

[0147] Association Judgment Module: Assigns spatial association degree level to abnormal matching units based on intersection-union ratio;

[0148] Residue Judgment Module: Based on the spatial correlation level, it judges whether there is a confirmed residue area on the push plate, and predicts the atmosphere isolation state of the double push plate kiln based on the judgment result of the confirmed residue area on the push plate.

[0149] Atmosphere control module: When it is determined that there is a push plate with a confirmed residue zone, the position of the push plate with the confirmed residue zone is obtained, and the atmosphere of the double push plate kiln is controlled according to the position of the push plate with the confirmed residue zone.

[0150] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

[0151] In conclusion, the above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. 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.

Claims

1. A method for predicting and dynamically controlling the atmosphere isolation state of a double-pusher kiln, characterized in that, include: A grid coordinate system is constructed for the surface of the push plate, and the surface of the push plate is divided into partitions, including a process placement area, a sealing and bonding area, and an exposed area. Identify abnormal temperature and abnormal height zones in exposed areas; Obtain the spatial center coordinates of each abnormal temperature zone and abnormal height zone, and form anomaly matching units based on the Euclidean distance between the spatial center coordinates of the abnormal temperature zone and abnormal height zone. Calculate the crossover-union ratio of the anomalous matching units; Assign spatial correlation levels to outlier matching units based on their intersection-union ratio; The presence of a confirmed residual zone in the pusher plate is determined based on the spatial correlation level, and the atmosphere isolation state of the double pusher plate kiln is predicted based on the determination result of the confirmed residual zone in the pusher plate. When it is determined that there is a pusher plate with a confirmed residual zone, the position of the pusher plate with the confirmed residual zone is obtained, and the atmosphere of the double pusher plate kiln is adjusted according to the position of the pusher plate with the confirmed residual zone.

2. The method for predicting and dynamically controlling the atmosphere isolation state of a double-pusher kiln according to claim 1, characterized in that, The method for obtaining the abnormal temperature zone is as follows: S201: Use a non-contact infrared thermal imager to scan the temperature of the exposed area of ​​the push plate, and spatially map and calibrate the temperature matrix obtained by the non-contact infrared thermal imager with the grid coordinate system to obtain a continuous temperature field data matrix of the entire exposed area. S202: Each grid cell is used as the data carrier. The temperature value within the grid cell is obtained by the average temperature of the grid nodes of that grid cell. The coordinates of the grid cell are determined by the coordinates of the lower left grid node of that grid cell in the grid coordinate system. S203: The temperature value of each grid cell is presented using pseudo-color encoding to form a surface temperature distribution map; S204: Calculate the overall average temperature of the exposed area as a background baseline; Set a temperature deviation threshold, traverse the entire temperature distribution map, and mark the grid cells that exceed the temperature deviation threshold as potential anomalies. Connectivity analysis is performed on potential anomalies, and continuous regions formed by the aggregation of adjacent grid cells are identified as anomalous temperature zones.

3. The method for predicting and dynamically controlling the atmosphere isolation state of a double-pusher kiln according to claim 1, characterized in that, The method for obtaining the abnormal height region is as follows: S301: A laser profile measurement assembly consisting of a line laser projector and an industrial camera is used to obtain the height values ​​of each grid node in the exposed area of ​​the push plate. S302: Take the average height value of all grid nodes in each grid cell as the height value of that grid cell, and generate a height matrix; S303: Based on the height matrix, a height field is generated using pseudo-color encoding; S304: Set a height threshold, perform connectivity analysis on grid cells with height values ​​greater than the height threshold, and determine the continuous region formed by the aggregation of adjacent grid cells as an abnormal height area.

4. The method for predicting and dynamically controlling the atmosphere isolation state of a double-pusher kiln according to claim 1, characterized in that, The method for composing the anomaly matching unit includes: S401: Extract the dedicated set of grid cells for each discrete abnormal temperature region and abnormal height region; S402: For each abnormal temperature zone and abnormal height zone, the spatial center coordinates are obtained by averaging the coordinates of all grid cells in its grid cell set; S403: Calculate the Euclidean distance between the spatial center coordinates of each abnormal temperature zone and all abnormal height zones, and match the abnormal height zone with the smallest Euclidean distance to form an abnormal matching unit.

5. The method for predicting and dynamically controlling the atmosphere isolation state of a double-pusher kiln according to claim 1, characterized in that, The method for calculating the cross-union ratio of abnormal matching units includes: Let set T be the set of mesh elements in the abnormal temperature region of the abnormal matching unit, and let set H be the set of mesh elements in the abnormal height region of the abnormal matching unit. Select the mesh elements that intersect set T and set H, and denote them as set I. Count the total number of grid cells Nt in set T, the total number of grid cells Nh in set H, and the number of grid cells Ni in set I; The intersection-union ratio (IoU) of the abnormal matching cells is obtained by dividing the number of grid cells in set I by the number of grid cells in the union of sets T and H.

6. The method for predicting and dynamically controlling the atmosphere isolation state of a double-pusher kiln according to claim 1, characterized in that, The method for assigning spatial correlation levels to outlier matching units based on intersection-union ratio includes: Preset intersection-union ratio (IU) thresholds A1 and A2, where A1 is greater than A2; If IoU≥A1, the spatial correlation level of the abnormal matching unit is set to strong correlation; If A2≤IoU<A1, the spatial correlation level of the abnormal matching unit is set to medium correlation; If IoU < A2, the spatial correlation level of the abnormal matching unit is set to weak correlation.

7. The method for predicting and dynamically controlling the atmosphere isolation state of a double-pusher kiln according to claim 1, characterized in that, The method for determining whether a confirmed residual zone exists in the pusher plate based on the spatial correlation level, and predicting the atmosphere isolation state of the double pusher plate kiln based on the determination result of the confirmed residual zone of the pusher plate, includes: S501: For anomaly matching units with strong spatial correlation, obtain the union of the sets of grid cells in the anomalous temperature zone and the anomalous height zone, and define the connected region covered by the grid cells in the union as the confirmed residual region. S502: For abnormal matching units with medium spatial correlation, obtain the total area and peak height of the grid cells in set H. After the next push plate advance cycle ends, obtain the total area and peak height of the grid cells in set H again. Set area threshold and peak height threshold; If either the total area of ​​the grid cells or the peak height shows an increasing trend, and the total area of ​​the grid cells is greater than the area threshold or the peak height is greater than the peak height threshold, then the union of the grid cell sets of the abnormal temperature zone and the abnormal height zone is obtained, and the connected region covered by the grid cells in the union is defined as the confirmed residual zone; otherwise, it is defined as the non-residual zone. S503: For abnormal matching units and non-residual areas with weak spatial correlation, only an anomaly prompt is generated, and an anomaly investigation is carried out at the end of batch production. S504: Test all pushers. If any pusher has a confirmed residual area, the predicted atmosphere isolation state is high-risk. Otherwise, it is low-risk.

8. The method for predicting and dynamically controlling the atmosphere isolation state of a double-pusher kiln according to claim 1, characterized in that, The method for obtaining the position of the pusher plate where a confirmed residual zone exists, and for adjusting the atmosphere of the double-pusher kiln based on the position of the pusher plate where a confirmed residual zone exists, includes: The location of the gas inlet in the sintering section is obtained, and the position of the pusher plate is collected in real time using the position encoder on the pusher plate; When a pusher plate with a confirmed residual area is detected in the sintering section, a flow rate control command is immediately triggered. The gas supply port closest to the pusher plate is used as the control gas supply port. The opening of the gas supply valve corresponding to the control gas supply port is adjusted to reduce the flow rate of the nitrogen protective atmosphere at this point from the current set level to the preset ratio of the current set level. Throughout the entire control process, the protective atmosphere status is monitored in real time. If an atmosphere abnormality occurs after the flow rate decreases, corresponding compensation control is implemented. After each push plate with a confirmed residual area is pushed forward, its position is re-acquired based on the real-time data of the push plate position encoder, and the corresponding control air supply port is dynamically updated. When a switch in the air supply port is detected, the opening of the air supply valve of the previous air supply port is restored to the normal operating opening, and the flow rate reduction control of the previous air supply port is reapplied to the new air supply port.

9. The method for predicting and dynamically controlling the atmosphere isolation state of a double-pusher kiln according to claim 8, characterized in that, The compensation control includes: Set the adjacent air inlets before and after the regulating air inlet as compensation air inlets; If the pressure sensor detects insufficient pressure inside the kiln, the compensation air inlet continuously adjusts the opening of the air inlet valve in small increments of one percent of the full stroke until the pressure inside the kiln is restored to normal through real-time feedback from the pressure sensor. If the atmosphere concentration sensor detects an abnormal atmosphere composition caused by the infiltration of outside air, the compensation air supply port will be adjusted in batches with a single adjustment step of one percent of the full stroke. The opening of the air supply valve will be increased in small increments. After each adjustment, the data of the pressure sensor and the atmosphere concentration sensor will be collected simultaneously until the air pressure inside the kiln reaches a slightly positive pressure range that is higher than the atmospheric pressure outside the kiln but lower than the upper limit of the normal working air pressure in the sintering section and the oxygen concentration returns to normal. This will block the infiltration of outside air by constructing a pressure difference barrier. Throughout the process, the airflow velocity at the compensation and replenishment inlet is controlled to not exceed the preset low velocity threshold.

10. A predictive and dynamic control system for atmosphere isolation state in a double-pusher kiln, implementing the method for predicting and dynamic control of atmosphere isolation state in a double-pusher kiln as described in any one of claims 1-9, characterized in that, include: Partitioning Module: Constructs a grid coordinate system for the push plate surface and partitions the push plate surface, including a process placement area, a sealing and bonding area, and an exposed area; Anomaly detection module: Identifies abnormal temperature and height areas in exposed areas; Anomaly matching module: Obtains the spatial center coordinates of each abnormal temperature zone and abnormal height zone, and forms anomaly matching units based on the Euclidean distance between the spatial center coordinates of the abnormal temperature zone and abnormal height zone; Cross-Union Ratio (CURBR) Calculation Module: Calculates the CURBR of anomalous matching units; Association Judgment Module: Assigns spatial association degree level to abnormal matching units based on intersection-union ratio; Residue Judgment Module: Based on the spatial correlation level, it judges whether there is a confirmed residue area on the push plate, and predicts the atmosphere isolation state of the double push plate kiln based on the judgment result of the confirmed residue area on the push plate. Atmosphere control module: When it is determined that there is a push plate with a confirmed residue zone, the position of the push plate with the confirmed residue zone is obtained, and the atmosphere of the double push plate kiln is controlled according to the position of the push plate with the confirmed residue zone.

Images