Reaction furnace based on intelligent flow sensing

Abstract

The utility model relates to the technical field of reaction furnaces, in particular to a reaction furnace based on intelligent flow sensing, which comprises a reaction furnace main body, a flow sensor, a flow sensor and a controller, the flow velocity detection unit is connected with the reaction furnace main body and comprises a fixed arm fixedly connected with the reaction furnace main body, a rotating arm hinged to the fixed arm and a connecting piece hinged to the rotating arm, and a high-speed camera used for collecting video information of the molten metal jet flow is arranged on the connecting piece; and the discharging unit comprises a discharging pipe and a discharging nozzle. According to the utility model, the high-speed camera is arranged at the discharging nozzle of the reaction furnace to carry out real-time video shooting on the molten metal ejected from the discharging nozzle, the main control development board processes the shot video in real time, the monitoring on the flow of the molten metal is completed in a non-contact manner, and the cost can be greatly reduced while the detection accuracy is ensured.

Description

Technical Field

[0001] This utility model relates to the field of reactor technology, and in particular to a reactor based on intelligent flow sensing. Background Technology

[0002] Molten metal is a high-temperature molten metal solution formed after metal ores have been smelted, including molten iron, molten steel, molten aluminum, and molten copper. Accurate measurement of molten metal flow rate is crucial to ensuring it meets product specifications, improving product quality, and increasing yield. However, the high temperature, strong corrosiveness, and high gloss of molten metal, along with the intermittent presence of high-concentration dust in the measurement environment, make real-time online accurate measurement of molten metal flow rate extremely difficult. The flow rate at the reactor nozzle is obtained by multiplying the molten jet velocity by the jet cross-sectional area; therefore, the task of molten metal flow rate measurement can be decomposed into online measurement of velocity and nozzle area. Due to the special characteristics of reactors—high temperature, high pressure, high corrosiveness, and high dust levels—the material requirements for contact instruments used for velocity and flow rate measurement are very high. Conventional contact instruments used at the reactor outlet for fluid velocity / flow rate measurement are not suitable for this harsh production environment.

[0003] Chinese Patent Publication No. CN104215281A discloses a differential pressure flow meter, including a junction box, a sensor protection box, and a flow throttle. The sensor protection box is installed below the junction box and is connected to the flow throttle. A differential pressure sensor and a pressure sensor are installed inside the sensor protection box. Exhaust valves are provided on both sides of the sensor protection box, and a positive pressure inlet and a negative pressure inlet are provided at the bottom of the sensor protection box. The positive pressure inlet and the negative pressure inlet are respectively connected to the flow throttle. It can be seen that the differential pressure flow meter is a contact instrument. When it is used to measure the flow rate of molten metal jet in a reactor, it has high material requirements and suffers from low detection accuracy and high cost. Utility Model Content

[0004] Therefore, this utility model provides a reaction furnace based on intelligent flow sensing to overcome the problems of low accuracy and high cost of contact instruments used in the prior art to measure the flow rate of molten metal jets in reaction furnaces.

[0005] To achieve the above objectives, this utility model provides a reactor based on intelligent flow sensing, comprising:

[0006] The main body of the reactor is used to smelt metal ore into high-temperature molten metal, and a pressure gauge is installed above it to detect the internal pressure of the reactor body.

[0007] The flow rate detection unit is connected to the main body of the reactor and includes a fixed arm fixedly connected to the main body of the reactor, a rotating arm hinged to the fixed arm, and a connecting member hinged to the rotating arm. The connecting member is equipped with a high-speed camera for acquiring video information of the molten metal jet.

[0008] The discharge unit includes a discharge pipe connected to the main body of the reactor for discharging the molten metal to a target location, and a discharge nozzle disposed at one end of the discharge pipe away from the main body of the reactor for spraying the molten metal to the target location.

[0009] The reactor body includes an outer shell, and the outer shell is axially provided with a hoop around its outer wall. The two ends of the outer shell are respectively provided with a first sealing element and a second sealing element. A plurality of fixing rods are provided between the first sealing element and the second sealing element, and the plurality of fixing rods pass through the hoop.

[0010] The rotating arm and the discharge nozzle are on the same horizontal plane, and the rotating arm rotates on the same horizontal plane.

[0011] The included angle formed by the fixed arm and the rotating arm on the side near the discharge nozzle is in the range of 90°-180°.

[0012] The high-speed camera has a built-in image sensor, the effective photosensitive surface of which is parallel to the jet plane of the discharge nozzle.

[0013] The high-speed camera is a UVC high-speed camera.

[0014] The distance between the end of the fixed arm furthest from the reactor body and the discharge pipe is greater than the length of the rotating arm.

[0015] The sum of the lengths of the fixed arm and the rotating arm is greater than the sum of the lengths of the discharge pipe and the discharge nozzle.

[0016] It also includes a protective cover for the high-speed camera, which is placed between the high-speed camera and the discharge nozzle.

[0017] The protective shield is made of sapphire.

[0018] Compared with the prior art, the beneficial effect of this utility model is that a high-speed camera is installed at the discharge nozzle of the reactor to capture real-time video of the molten metal jetting out from it, and the main control development board processes the captured video in real time, completing the monitoring of the molten metal flow rate without contact, which can greatly reduce costs while ensuring detection accuracy.

[0019] Furthermore, the hoop and fixing rod reduce local stress concentration by constraining the radial deformation of the outer shell, ensuring its integrity under high-pressure conditions.

[0020] Furthermore, the UVC high-speed camera can operate without the need for special drivers and is compatible with products from different manufacturers. Users can simply connect the UVC high-speed camera to transmit images, improving ease of use.

[0021] Furthermore, the power supply module adopts an integrated DC voltage regulator module, which suppresses the output ripple to within ±1% through multi-level filtering and dynamic voltage compensation mechanisms, eliminating the risk of system downtime caused by input fluctuations or load changes, and ensuring stable system operation.

[0022] Furthermore, the rotating arm and the discharge nozzle are on the same horizontal plane, ensuring that the high-speed camera on the extension can directly face the core area of ​​the jet and capture complete video information of the jet.

[0023] Furthermore, the effective photosensitive surface of the image sensor built into the high-speed camera is parallel to the jet plane of the discharge nozzle, ensuring that no vertical velocity component is lost when the camera is shooting directly at the jet. This ensures that the real-time jet velocity obtained from the video information collected by the high-speed camera is consistent with the actual jet velocity, thus guaranteeing the accuracy of the jet velocity measured by the velocity detection unit. Attached Figure Description

[0024] Figure 1 This is a structural diagram of the reactor in an embodiment of the present invention;

[0025] Figure 2 for Figure 1 A magnified view of part A in the image;

[0026] Figure 3 This is another structural diagram of the reactor according to an embodiment of the present invention;

[0027] Figure 4 This is a top view of the reactor in an embodiment of the present invention.

[0028] Explanation of reference numerals in the attached figures:

[0029] 1-Furnace body, 2-Pressure gauge, 3-Fixed arm, 4-Rotating arm, 5-Connector, 6-High-speed camera, 7-Discharge pipe, 8-Discharge nozzle, 9-Main control development board, 10-Holding ring, 11-First seal, 12-Second seal, 13-Fixed rod, 14-Protective cover. Detailed Implementation

[0030] To make the objectives and advantages of this utility model clearer, the utility model will be further described below with reference to the embodiments; it should be understood that the specific embodiments described herein are only for explaining this utility model and are not intended to limit this utility model.

[0031] Preferred embodiments of the present invention will now be described with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are merely illustrative of the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0032] It should be noted that in the description of this utility model, the terms "upper", "lower", "left", "right", "inner", "outer", etc., indicating the direction or positional relationship are based on the direction or positional relationship shown in the drawings. This is only for the convenience of description and does not indicate or imply that the device or element must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation of this utility model.

[0033] Furthermore, it should be noted that, in the description of this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0034] Please see Figure 1 , Figure 2 , Figure 3 as well as Figure 4 The figures shown are a structural diagram, a partial enlarged view of A, another structural diagram, and a top view of the reactor based on intelligent flow sensing according to an embodiment of this utility model; the reactor based on intelligent flow sensing according to this utility model includes:

[0035] The main body of the reactor 1 is used to smelt metal ore into high-temperature molten metal, and a pressure gauge 2 is installed above it to detect the internal pressure of the main body of the reactor 1.

[0036] The flow rate detection unit, which is connected to the reactor body 1, includes a fixed arm 3 fixedly connected to the reactor body 1, a rotating arm 4 hinged to the fixed arm 3, and a connecting member 5 hinged to the rotating arm 4. The connecting member 5 is equipped with a high-speed camera 6 for acquiring video information of the molten metal jet. In practice, the preferred embodiment of the high-speed camera 6 is a UVC high-speed camera 6, which allows it to operate without the need for special drivers and is compatible with products from different manufacturers. Users only need to connect the UVC high-speed camera 6 to transmit images.

[0037] The discharge unit includes a discharge pipe 7 connected to the reactor body 1 for discharging the molten metal to a target location, and a discharge nozzle 8 located at one end of the discharge pipe 7 away from the reactor body 1 for spraying the molten metal to the target location.

[0038] Specifically, the flow-based intelligent sensing reactor also includes a main control development board 9, which is used for command distribution and data processing, and is connected to the high-speed camera 6. A terminal visualization component and an audible-visual alarm component are also included, both of which can be connected to the main control development board 9. The terminal visualization component displays the jet status and flow data, while the audible-visual alarm component issues an alarm when abnormal flow occurs or the discharge nozzle 8 is blocked, reminding personnel to take action, and simultaneously displays the alarm information on the terminal visualization component.

[0039] In implementation, a high-speed camera 6 is installed at the discharge nozzle 8 of the reactor to capture real-time video of the molten metal jetting out from it. The main control development board 9 processes the captured video in real time, completing the monitoring of the molten metal flow rate without contact. This greatly reduces costs while ensuring detection accuracy.

[0040] Specifically, the flow-based intelligent sensing reactor also includes a power supply module, which powers the high-speed camera 6, the terminal visualization component, and the main control development board 9. To ensure stable system operation, the power supply module employs an integrated DC voltage regulator module, which uses multi-stage filtering and dynamic voltage compensation mechanisms to suppress output ripple to within ±1%, eliminating the risk of system downtime caused by input fluctuations or sudden load changes.

[0041] In implementation, the power supply module can be selected from DC switching power supply, lithium polymer battery pack, or redundant power supply. The preferred implementation is DC switching power supply. Those skilled in the art can make adaptive adjustments or replacements to the power supply type of the power supply module according to the actual application scenario or implementation environment.

[0042] The reactor body 1 includes an outer shell, and the outer shell is axially provided with a hoop 10 surrounding its outer wall. The two ends of the outer shell are respectively provided with a first sealing element 11 and a second sealing element 12. A plurality of fixing rods 13 are provided between the first sealing element 11 and the second sealing element 12. The plurality of fixing rods 13 pass through the hoop 10. The outer shell is reinforced by setting the hoop 10 and fixing rods 13 to prevent the outer shell from cracking due to excessive pressure.

[0043] In practice, the relative position of the rotating arm 4 and the discharge nozzle 8 is preferably on the same horizontal plane and the rotating arm 4 rotates on the same horizontal plane, so that the high-speed camera 6 can take pictures directly at the core area of ​​the jet. Those skilled in the art can make adaptive adjustments or replacements to the relative position of the rotating arm 4 and the discharge nozzle 8 according to the actual application scenario or implementation environment.

[0044] In practice, the angle formed by the fixed arm 3 and the rotating arm 4 near the discharge nozzle 8 is preferably in the range of 90°-180°. Those skilled in the art can make adaptive adjustments or replacements to the angle according to the actual application scenario or implementation environment.

[0045] In practice, the material of the protective cover 14 for protecting the high-speed camera 6, which is located between the high-speed camera 6 and the discharge nozzle 8, is preferably sapphire. Those skilled in the art can make adaptive adjustments to the material of the protective cover 14 or replace it with other high-temperature resistant materials according to the actual application scenario or implementation environment.

[0046] The high-speed camera 6 has a built-in image sensor, the effective photosensitive surface of which is parallel to the jet plane of the discharge nozzle 8. If the effective photosensitive surface of the image sensor is at an angle to the jet plane of the discharge nozzle 8, the actual jet velocity will be higher than the real-time jet velocity obtained from the video information acquired by the high-speed camera 6. When the effective photosensitive surface of the image sensor is parallel to the jet plane of the discharge nozzle 8, there will be no loss of velocity component in the vertical direction.

[0047] The high-speed camera 6 transmits the video information of the acquired jet to the main control development board 9, and sends the images to the terminal visualization component in multiple threads for data processing. According to the camera communication protocol, data is transmitted using USB 3.0.

[0048] The terminal visualization components include a display for showing the jet status and flow data, and a keyboard and mouse for users to issue start or stop commands.

[0049] The distance between the end of the fixed arm 3 furthest from the reactor body 1 and the discharge pipe 7 is greater than the arm length of the rotating arm 4.

[0050] The sum of the lengths of the fixed arm 3 and the rotating arm 4 is greater than the sum of the lengths of the discharge pipe 7 and the discharge nozzle 8.

[0051] Working Principle: The flow velocity detection unit uses a high-speed camera 6 to acquire video information of the jet stream from the discharge nozzle 8 of the reactor body 1. It tracks the video information and uses an optical flow velocimetry algorithm to calculate the jet velocity in real time based on the acquired video information, thus monitoring the flow velocity of the discharge nozzle 8 of the reactor body 1 in real time. Simultaneously, the main control development board 9 analyzes the jet trajectory in the image to obtain the real-time cross-sectional area of ​​the jet. The flow rate of the discharge nozzle 8 of the reactor body 1 is obtained by multiplying the jet velocity by the jet cross-sectional area. The flow velocity detection unit monitors the flow velocity in real time and, based on empirical values, provides graded alarms for excessively high or low flow velocities, as well as sudden changes in flow velocity, serving as a warning to on-site operators. The real-time measurement data is also uploaded to a display screen as parameters for on-site operation.

[0052] The technical solution of this utility model has been described above with reference to the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the protection scope of this utility model is obviously not limited to these specific embodiments. Without departing from the principle of this utility model, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will all fall within the protection scope of this utility model.

Claims

1. A flow intelligence based reaction furnace, characterized in that, The application relates to a reaction furnace body for smelting metal ore into high-temperature molten metal, a pressure gauge arranged above the reaction furnace body for detecting the pressure inside the reaction furnace body, a flow rate detection unit connected with the reaction furnace body, a fixed arm fixedly connected with the reaction furnace body, a rotating arm hingedly connected with the fixed arm, a connecting piece hingedly connected with the rotating arm, a high-speed camera arranged on the connecting piece for collecting video information of a molten metal jet, a discharge unit connected with the reaction furnace body and comprising a discharge pipe for outputting the molten metal to a target position and a discharge nozzle arranged at one end of the discharge pipe away from the reaction furnace body and used for spraying the molten metal to the target position. The reaction furnace body comprises an outer shell, the outer shell is axially provided with a hoop around the outer wall of the outer shell, the two ends of the outer shell are respectively provided with a first sealing piece and a second sealing piece, a plurality of fixing rods are arranged between the first sealing piece and the second sealing piece, and the plurality of fixing rods penetrate through the hoop. The rotating arm is located in the same horizontal plane as the discharge nozzle, and the rotating arm rotates in the same horizontal plane. The included angle between the fixed arm and the rotating arm near the side of the discharge nozzle is 90-180 degrees.

2. The flow intelligence based perception enabled reactor as claimed in claim 1, wherein, The high-speed camera is internally provided with an image sensor, and the effective photosensitive surface of the image sensor is parallel to the jet plane of the discharge nozzle.

3. The flow intelligence based perception enabled reactor as claimed in claim 1, wherein, The high-speed camera is a UVC high-speed camera.

4. The flow intelligence based reaction furnace as claimed in claim 3, wherein, The distance between the end of the fixed arm away from the reaction furnace body and the discharge pipe is greater than the arm length of the rotating arm.

5. The flow intelligence based reaction furnace as claimed in claim 4, wherein, The sum of the lengths of the fixed arm and the rotating arm is greater than the sum of the lengths of the discharge pipe and the discharge nozzle.

6. The flow intelligence based perception enabled reactor as claimed in claim 1, wherein, The application further comprises a protective cover arranged between the high-speed camera and the discharge nozzle and used for protecting the high-speed camera.

7. The flow intelligence based perception enabled reactor as claimed in claim 1, wherein, The material of the protective cover is sapphire.

8. The flow intelligence based perception enabled reactor as claimed in claim 1, wherein, ​ 9. The flow intelligence based perception enabled reactor as claimed in claim 1, wherein, ​ 10. The flow intelligence based reaction furnace as claimed in claim 9, wherein, ​

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