Remote monitoring device for calcium carbide furnace production line

Abstract

The utility model belongs to the technical field of thermal imaging monitoring, and particularly relates to a remote monitoring device for a calcium carbide furnace production line. Comprising a base, a movable mechanism, a thermal imaging camera, a controller and a protective cover. The base is provided with a flange hole; the movable mechanism is used for rotating and moving the thermal imaging camera, and the movable mechanism is matched with the base; the thermal imaging camera is matched with the movable mechanism; the controller is electrically connected with the thermal imaging camera, and the controller is electrically connected with the movable mechanism. The protective cover wraps the thermal imaging camera, and the protective cover is made of a thermal insulation material. According to the scheme, the problem that the camera is easily damaged in a high-temperature environment is solved.

Description

Technical Field

[0001] This utility model belongs to the field of thermal imaging monitoring technology, specifically relating to a remote monitoring device for a calcium carbide furnace production line. Background Technology

[0002] This project addresses the shortcomings of remote monitoring in the calcium carbide furnace production process, as well as the significant safety hazards posed by high temperatures and carbon monoxide content in some areas. By researching intelligent control technologies for calcium carbide furnace production lines, this project establishes a data communication platform, collects image information, and introduces technologies such as intelligent recognition and accident early warning to construct an intelligent platform. This enables efficient and reliable storage of industrial big data from the calcium carbide furnace, improves the identification performance of abnormal operating conditions in the calcium carbide control system, and enhances the accuracy of fault diagnosis, thus propelling the calcium carbide production process towards intelligence and informatization.

[0003] Currently, a thermal imaging monitoring device with publication number CN221127381U includes a fixed bracket with multiple first buckles; a camera rotatably connected to the fixed bracket, and the camera has multiple second buckles and mounting holes; the mounting holes have grooves and movable fasteners located within the grooves; a safety rope, one end of which is detachably connected to a first buckle and the other end of which is detachably connected to a second buckle; and a handle, both ends of which can be inserted into corresponding mounting holes and secured by movable fasteners. This application allows for convenient disassembly of the camera. The multiple safety ropes prevent significant shaking during the initial drop, and the handle facilitates operation by maintenance personnel, especially after the safety ropes are removed, allowing for easy handling of the camera.

[0004] However, there is also a problem: the camera in this solution does not have high-temperature protection and is easily damaged by high ambient temperatures. Utility Model Content

[0005] This solution provides a remote monitoring device for a calcium carbide furnace production line to address the problem that high-temperature environments can easily damage cameras.

[0006] This solution provides a remote monitoring device for a calcium carbide furnace production line, including:

[0007] Base: The base is provided with flange holes;

[0008] Movable mechanism: The movable mechanism is used for rotating and moving the thermal imaging camera, and the movable mechanism cooperates with the base;

[0009] Thermal imaging camera: The thermal imaging camera cooperates with the moving mechanism;

[0010] Controller: The controller is electrically connected to the thermal imaging camera and also electrically connected to the moving mechanism;

[0011] Also includes:

[0012] Protective cover: The protective cover encloses the thermal imaging camera and is made of heat-insulating material.

[0013] The principle behind this solution is as follows: the controller, acting as the system's brain, receives data from the thermal imaging camera and analyzes the images according to a preset algorithm to determine if any anomalies exist. Simultaneously, it controls the movement of the active mechanisms to achieve automatic scanning and positioning. The base is secured with flange bolts, ensuring the device's stability in high-temperature and vibration environments and facilitating installation in various locations. The thermal imaging camera uses an infrared sensor to capture the surface temperature distribution of the calcium carbide furnace, generating a thermal image that is fed back to the controller in real time for data analysis. The protective cover is made of transparent, high-temperature resistant material, using physical insulation and heat reflection technology to reduce the impact of heat radiation on the camera.

[0014] The beneficial effects of this solution are as follows: 1. The remote monitoring feature allows operators to observe and control the system from a safe location away from hazardous sources, reducing the risk of direct contact with harmful substances. 2. The protective cover made of heat-insulating material effectively isolates the camera from the effects of high-temperature environments, reducing equipment failure rates caused by excessive temperatures and extending the overall system lifespan.

[0015] Furthermore, the active mechanism includes a rotating motor, a rotary motor, a fixed frame, and a rotating frame. The rotating frame is rotatably connected to the base, the rotating motor is fixedly connected to the base, and the shaft of the rotating motor is coaxially fixedly connected to the rotating frame.

[0016] One end of the fixed frame is fixedly connected to the rotating frame, and the other end is rotatably connected to the thermal imaging camera. The rotating motor is fixedly connected to the fixed frame, and the shaft of the rotating motor is fixedly coaxially connected to the thermal imaging camera.

[0017] When rotation is required, the controller starts the rotating motor, causing the rotating frame to rotate. The rotating frame drives the fixed frame to rotate, and the fixed frame drives the thermal imaging camera to rotate, thus realizing the rotation of the thermal imaging camera.

[0018] When the thermal imaging camera needs to rotate vertically, the controller activates the rotating motor, causing the camera to rotate to a set position for monitoring. This improves the monitoring range of the thermal imaging camera.

[0019] Furthermore, it also includes a scraper. The protective cover and the fixing frame are rotatably and sealingly connected. The scraper cooperates with the protective cover and is fixedly connected to the fixing frame. Because the protective cover has a heat insulation effect, a temperature difference easily occurs between the inside and outside. When the external ambient temperature is high, fogging will occur on the inner surface of the protective cover, causing the thermal imaging camera to malfunction. In this mechanism, when the protective cover fogs up, the operator only needs to rotate the protective cover, and the internal scraper will remove the fog from inside the protective cover, thus defogging. This mechanism eliminates the need to disassemble the protective cover for defogging, improving efficiency.

[0020] Furthermore, it also includes a protective ring, which is fixedly connected to the fixing frame. The protective ring is used to protect the rotating parts of the sealing cover and cooperates with the cover. The protective ring can protect the rotating parts of the column cover and prevent hot air or water mist from entering the interior of the cover.

[0021] Furthermore, it also includes a demisting mechanism, which includes a cylinder, a piston, a rack, and a gear. The cylinder is fixedly connected to a fixed frame, the piston is slidably and sealed to the cylinder, one end of the rack is fixedly connected to the piston, and the other end meshes with the gear. The gear is coaxially fixedly connected to a protective cover. The cylinder contains a working fluid with a boiling point of 60-80 degrees Celsius.

[0022] When the ambient temperature exceeds the set value, the inner wall of the protective cover may be covered by water mist. The working fluid inside the cylinder will vaporize, causing the piston to move upwards. This upward movement of the rack drives the gear upwards, which in turn rotates the protective cover. This causes the scraper to remove the water mist from the protective cover, ensuring the thermal imaging camera functions properly. This mechanism achieves automatic water mist removal, reducing labor costs.

[0023] Furthermore, the scraper is provided with an inclined groove, which is a groove with a certain inclination angle. The mounting frame is provided with absorbent cotton, and the inclined groove cooperates with the absorbent cotton. The inclined groove slopes downwards from the far end of the mounting frame towards the absorbent cotton. After the scraper removes the water mist, the water mist remains in the inclined groove. Under the action of gravity, the water droplets flow towards the absorbent cotton, where they are absorbed. The operator only needs to replace the absorbent cotton each time to ensure that the inside of the protective cover remains dry.

[0024] Furthermore, it also includes an infrared absorption spectrometer used to measure CO concentration, which is electrically connected to the controller. The controller acquires temperature image information from a thermal imaging camera and CO concentration data from the infrared absorption spectrometer. Based on preset safety thresholds, it determines whether there are any abnormal situations (such as overheating or high CO concentration). Once a potential hazard is detected, an alarm is immediately triggered and relevant personnel are notified to take appropriate measures.

[0025] Furthermore, it also includes a pressure switch and a buzzer. The pressure switch is fixedly connected to the cylinder body, and the buzzer is fixedly connected to the base. The pressure switch is electrically connected to the controller, and the controller is electrically connected to the buzzer. When the ambient temperature reaches the set point, the working fluid in the cylinder will vaporize, and the piston will move upward, causing the piston to press against the pressure switch. The pressure switch transmits an electrical signal to the controller, which then controls the buzzer to sound an alarm, alerting the operator to an abnormal ambient temperature. Attached Figure Description

[0026] Figure 1 This is a structural diagram of a remote monitoring device for a calcium carbide furnace production line without a protective cover.

[0027] Figure 2 This is a cross-sectional view of a remote monitoring device for a calcium carbide furnace production line.

[0028] Figure 3 This is a structural diagram of a scraper plate used in a remote monitoring device for a calcium carbide furnace production line.

[0029] Figure 4 This is a cross-sectional view of the demisting mechanism of a remote monitoring device for a calcium carbide furnace production line.

[0030] The reference numerals in the accompanying drawings include: 1. Thermal imaging camera; 2. Protective ring; 3. Fixture; 4. Rotating frame; 5. Base; 6. Flange hole; 7. Protective cover; 8. Lens; 9. Cylinder; 10. Scraper; 11. Connecting rod; 12. Rack; 13. Piston; 14. Gear; 15. Absorbent cotton; 16. Inclined groove; 17. Press switch. Detailed Implementation

[0031] Based on the reaction conditions and electrical parameters within the furnace, the position and current of the electrodes are adjusted in real time to ensure stable reaction operation. Advanced control strategies, such as fuzzy control and adaptive control, are employed to improve the accuracy and response speed of electrode control. Simultaneously, an electrode fault diagnosis system is developed to monitor and provide early warnings for electrode breakage, overheating, and other faults in real time. A furnace temperature prediction model is established, combining furnace reaction kinetics and heat transfer principles to predict furnace temperature trends. Based on the prediction results, advanced control algorithms, such as model predictive control, are used to precisely control the furnace temperature. By adjusting parameters such as electrode current, raw material ratio, and furnace gas flow rate, stable furnace temperature control is achieved, improving the production quality and efficiency of calcium carbide.

[0032] Based on the production process requirements and raw material characteristics of the calcium carbide furnace, an optimization algorithm for raw material proportioning was studied. By real-time monitoring of the raw material composition and quality, combined with the reaction conditions inside the furnace, the raw material proportioning was adjusted, and the raw material feeding system was automatically controlled to ensure the calcium carbide furnace operates at full load. A comprehensive production process safety control system was developed to monitor and provide early warnings for various safety hazards during the calcium carbide furnace production process in real time. Parameters such as furnace pressure, temperature, and combustible gas concentration were monitored, and corresponding safety measures were taken promptly in case of abnormalities, including alarms, power cut-off, and activation of the emergency cooling system, to ensure the safe and reliable operation of the production process.

[0033] A data acquisition system is constructed to provide a remote monitoring device for a calcium carbide furnace production line, enabling real-time acquisition of various data during the calcium carbide furnace production process. The data acquisition system should possess high reliability, high accuracy, and high speed, and be able to adapt to the harsh environmental conditions of the calcium carbide furnace production site. A distributed data acquisition architecture is adopted, distributing data acquisition modules at various key locations on the production site to achieve comprehensive monitoring of the production process.

[0034] The collected data undergoes preprocessing, including data cleaning, filtering, and noise reduction, to improve data quality and usability. The preprocessed data is then stored in a database using efficient data storage technologies to ensure secure and reliable storage and fast retrieval.

[0035] We utilize data analytics and mining techniques to conduct in-depth analysis of production data stored in the database. Through data analysis, we uncover potential patterns and trends in the production process, providing support for optimized control and management decisions. By analyzing historical production data, we identify key factors affecting product quality and production efficiency, enabling targeted improvement measures.

[0036] As attached Figure 1 , Figure 2 As shown:

[0037] This solution provides a remote monitoring device for a calcium carbide furnace production line, including a central control room, a base 5, a moving mechanism, a thermal imaging camera 1, a controller, a protective cover 7, a scraper 10, a protective ring 2, a defogging mechanism, an infrared absorption spectrometer, a push switch 17, and a buzzer.

[0038] The calcium carbide furnace door opening and closing system has two operation modes: central control room DCS operation and local operation. Under normal circumstances, in remote mode, operators can remotely control the automatic opening and closing of the calcium carbide furnace inspection door via the central control room DCS. The opening, closing, and locking status of the inspection door are displayed on the DCS screen via a camera. When on-site installation, commissioning, or maintenance is required, the system switches to local operation mode, allowing operators to control the automatic opening and closing of the inspection door via buttons from a local control box.

[0039] The base 5 is bolted to the working platform of the calcium carbide furnace production line via flange holes 6, ensuring the stability of the device in a high-temperature and vibration environment. A rotating frame 4 is mounted above the base 5, and the rotating frame 4 is rotatably connected to the base 5 via bearings. A rotating motor is fixed inside the base 5, and its output shaft is coaxially connected to the rotating frame 4, driving the rotating frame 4 to rotate horizontally.

[0040] One end of the fixed frame 3 is welded and fixed to the rotating frame 4, and the other end is rotatably connected to the thermal imaging camera 1 via a bearing. The rotary motor is fixed inside the fixed frame 3, and its output shaft is coaxially connected to the thermal imaging camera 1 to drive the thermal imaging camera 1 to rotate vertically. By controlling the rotary motor and the rotating motor through the controller, the thermal imaging camera 1 can achieve 360° horizontal scanning and ±90° vertical scanning, covering the key areas of the calcium carbide furnace production line.

[0041] The thermal imaging camera 1 uses the existing thermal imaging camera 1. The lens 8 of the thermal imaging camera 1 is located in front of the housing of the thermal imaging camera 1 and has the function of scanning thermal imaging images to determine whether the temperature inside the calcium carbide furnace production line exceeds the standard.

[0042] The protective cover 7 is made of high-temperature resistant transparent ceramic material, enclosing the thermal imaging camera 1 and rotatably connected to the mounting bracket 3 via a sealing ring. A protective ring 2 is provided on the outer edge of the protective cover 7, which is bolted to the mounting bracket 3 to seal the gaps at the rotation points of the protective cover 7, preventing the intrusion of external high-temperature gases or dust.

[0043] As attached Figure 3 , Figure 4 As shown:

[0044] The demisting mechanism includes a cylinder 9, a piston 13, a rack 12, and a gear 14. The cylinder 9 is filled with a Freon working fluid with a boiling point of 70°C. The cylinder 9 is welded and fixed to the mounting frame 3, and the scraper 10 is fixedly connected to the mounting frame 3 via a connecting rod 11. When the ambient temperature exceeds 70°C, the working fluid vaporizes, pushing the piston 13 upwards, causing the rack 12 to rise. The rack 12 meshes with the gear 14, driving the protective cover 7 to rotate. At this time, the scraper 10, fixed to the mounting frame 3, rotates relative to the protective cover 7, scraping away the mist from the inner wall of the protective cover 7. The inclined groove 16 of the scraper 10 guides condensate to absorbent cotton 15 on the mounting frame 3. The absorbent cotton 15 can be replaced periodically to keep it dry.

[0045] An infrared absorption spectrometer is mounted on the side of the mounting bracket 3 and connected to the controller via a cable to monitor CO concentration in real time. When the CO concentration exceeds a preset threshold or the thermal imaging camera 1 detects local overheating, the controller triggers a buzzer alarm. Additionally, a push-button switch 17 is located on the side wall of the cylinder 9. When the piston 13 moves upward to its limit position due to the vaporization of the working fluid, the push-button switch 17 sends a signal to the controller, and the buzzer simultaneously activates to indicate an abnormal ambient temperature.

[0046] The protective cover 7 can be manually rotated and removed for easy cleaning or replacement. The absorbent cotton 15 is fixed to the side of the mounting bracket 3 by clips and should be replaced monthly by the operator. The circuit interfaces of the buzzer and push-button switch 17 adopt a quick-connect design for easy replacement in case of failure.

[0047] The controller is connected to the central control room via an industrial Ethernet network. Temperature distribution images captured by thermal imaging camera 1 and CO concentration data from the infrared absorption spectrometer are transmitted to the central control platform in real time. Operators can remotely adjust the camera's scanning range through the platform interface and receive automatically pushed early warning information from the system, allowing them to take timely emergency measures.

[0048] As attached Figure 1-4 As shown:

[0049] The principle of this solution is as follows: the controller, acting as the system's brain, receives data from the thermal imaging camera 1 and analyzes the image according to a preset algorithm to determine if any anomalies exist. Simultaneously, it controls the movement of the active mechanism to achieve automatic scanning and positioning. The base 5 is secured with bolts via flange holes 6, ensuring the stability of the device in high-temperature and vibration environments and facilitating installation in various locations. The thermal imaging camera 1 uses an infrared sensor to capture the surface temperature distribution of the calcium carbide furnace, generating a thermal image that is fed back to the controller in real time for data analysis. The protective cover 7 is made of transparent, high-temperature resistant material, reducing the impact of heat radiation on the camera through physical insulation and heat reflection technology.

[0050] When the ambient temperature exceeds 70℃, the working fluid vaporizes, pushing the piston 13 upward, which in turn causes the rack 12 to rise. The rack 12 meshes with the gear 14, driving the protective cover 7 to rotate. At this time, the scraper 10, fixed on the mounting bracket 3, rotates relative to the protective cover 7, scraping away the mist on the inner wall of the protective cover 7. The inclined groove 16 of the scraper 10 guides the condensate to the absorbent cotton 15 on the mounting bracket 3. The absorbent cotton 15 can be replaced periodically to keep it dry.

[0051] The beneficial effects of this solution are as follows: 1. The remote monitoring feature allows operators to observe and control the equipment from a safe location away from hazardous sources, reducing the risk of direct contact with harmful substances. 2. The protective cover 7, made of heat-insulating material, effectively isolates the camera from the high-temperature environment, reducing equipment failure rates caused by excessive temperature and extending the overall system's service life. 3. Through the heat-insulating protective cover 7, automatic defogging mechanism, and multi-dimensional monitoring functions, this device effectively solves the problems of equipment damage and safety hazards caused by the high-temperature environment of the calcium carbide furnace, realizing remote intelligent monitoring and significantly improving production safety and operational efficiency.

[0052] The above descriptions are merely embodiments of this utility model, and common knowledge regarding specific structures and characteristics is not elaborated upon here. It should be noted that those skilled in the art can make various modifications and improvements without departing from the structure of this utility model, and these should also be considered within the scope of protection of this utility model. These modifications will not affect the effectiveness of the implementation of this utility model or the practicality of the patent. The scope of protection claimed in this application shall be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. A remote monitoring device for a calcium carbide furnace production line, comprising: Base (5): The base (5) is provided with flange holes (6); Motion mechanism: The motion mechanism is used for the rotation and movement of the thermal imaging camera (1), and the motion mechanism cooperates with the base (5); Thermal imaging camera (1): The thermal imaging camera (1) cooperates with the moving mechanism; Controller: The controller is electrically connected to the thermal imaging camera (1) and to the moving mechanism; Its characteristic is that it further includes: Protective cover (7): The protective cover (7) encloses the thermal imaging camera (1), and the protective cover (7) is made of heat-insulating material.

2. The remote monitoring device for a calcium carbide furnace production line according to claim 1, characterized in that, The active mechanism includes a rotating motor, a rotary motor, a fixed frame (3) and a rotating frame (4). The rotating frame (4) is rotatably connected to the base (5), the rotating motor is fixedly connected to the base (5), and the shaft of the rotating motor is coaxially fixedly connected to the rotating frame (4). One end of the fixed frame (3) is fixedly connected to the rotating frame (4), and the other end is rotatably connected to the thermal imaging camera (1). The rotating motor is fixedly connected to the fixed frame (3), and the shaft of the rotating motor is fixedly connected to the thermal imaging camera (1) on the same axis.

3. The remote monitoring device for a calcium carbide furnace production line according to claim 2, characterized in that, It also includes a scraper (10), the protective cover (7) and the fixed frame (3) are rotatably and sealedly connected, the scraper (10) cooperates with the protective cover (7), and the scraper (10) is fixedly connected to the fixed frame (3).

4. The remote monitoring device for a calcium carbide furnace production line according to claim 2, characterized in that, It also includes a protective ring (2), which is fixedly connected to the fixing frame (3). The protective ring (2) is used to protect the rotating part of the sealing cover (7), and the protective ring (2) cooperates with the cover (7).

5. The remote monitoring device for a calcium carbide furnace production line according to claim 3, characterized in that, It also includes a defogging mechanism, which includes a cylinder (9), a piston (13), a rack (12) and a gear (14). The cylinder (9) is fixedly connected to the fixed frame (3), the piston (13) is slidably sealed to the cylinder (9), one end of the rack (12) is fixedly connected to the piston (13), and the other end meshes with the gear (14). The gear (14) is coaxially fixedly connected to the protective cover (7). The cylinder (9) contains a working fluid with a boiling point of 60-80 degrees Celsius.

6. The remote monitoring device for a calcium carbide furnace production line according to claim 5, characterized in that, The scraper (10) is provided with an inclined groove (16), which is a groove with a certain inclination angle. The fixing frame (3) is provided with absorbent cotton (15), and the inclined groove (16) cooperates with the absorbent cotton (15).

7. The remote monitoring device for a calcium carbide furnace production line according to claim 1, characterized in that, It also includes an infrared absorption spectrometer, which is used to measure the concentration of CO, and the infrared absorption spectrometer is electrically connected to the controller.

8. The remote monitoring device for a calcium carbide furnace production line according to claim 5, characterized in that, It also includes a push switch (17) and a buzzer, wherein the push switch (17) is fixedly connected to the cylinder (9), the buzzer is fixedly connected to the base (5), the push switch (17) is electrically connected to the controller, and the controller is electrically connected to the buzzer.

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