Concentration kettle foam monitoring device based on AI imaging system

Abstract

The utility model provides a concentration kettle foam monitoring device based on an AI imaging system. According to the concentration kettle foam monitoring device based on the AI imaging system, a concentration kettle is installed at the top of a supporting bottom frame through a supporting frame, a sealing cover is installed at the top of the concentration kettle, an adjusting valve is installed at the top of the sealing cover, a feeding device is installed at the top of the adjusting valve, and a stirring device is installed at the top of the feeding device. An anti-explosion camera and a light supplementing device are installed on the top of the sealing cover, the top of the anti-explosion camera and the top of the light supplementing device are connected with a connector through a connecting line, and a network cable is installed at the other end of the connector. According to the concentration kettle foam monitoring device based on the AI imaging system, the foam liquid level is monitored in real time through the visual identification technology composed of the anti-explosion camera and the light supplementing device, accurate alarm is achieved in combination with the AI algorithm, the DCS system is linked through an industrial communication protocol to automatically control the defoaming agent adjusting valve, and the foam level is monitored in real time. The problems of low efficiency, poor reliability, insufficient automation and the like of a traditional method are solved.

Description

Technical Field

[0001] This utility model relates to the field of foam monitoring technology in concentration reactors, and in particular to a foam monitoring device for concentration reactors based on an AI imaging system. Background Technology

[0002] The main function of the concentration reactor is to increase the concentration of the adhesive solution by concentrating it, thereby reducing the amount of liquid phase entering the subsequent coagulation reactor. This process directly reduces the water-to-adhesive mixing ratio in the subsequent coagulation reactor, making the coagulation process in the later stages more efficient.

[0003] In chemical production processes, the liquid in the concentration vessel is prone to foaming due to high temperature, stirring, or chemical reactions. Excessive foam level may lead to material overflow, equipment contamination, or even safety accidents.

[0004] Traditional foam monitoring methods mainly rely on manual inspection or sensor detection, which have the following drawbacks: Low efficiency of manual inspection: It cannot monitor in real time, relies on experience judgment, and is prone to missed detection or misjudgment; Limitations of sensors: Contact sensors are easily damaged by corrosive media; Non-contact sensors such as ultrasonic and radar are greatly affected by ambient temperature, humidity and medium viscosity, and have insufficient accuracy.

[0005] Therefore, it is necessary to provide a foam monitoring device for concentration reactors based on AI imaging systems to solve the above-mentioned technical problems. Utility Model Content

[0006] This invention provides a foam monitoring device for concentration reactors based on an AI imaging system, which solves the problem of not being able to monitor the foam generated during chemical production in concentration reactors in a timely and accurate manner.

[0007] To solve the above-mentioned technical problems, the foam monitoring device for concentration reactor based on AI imaging system provided by this utility model includes: a supporting base frame;

[0008] A concentration vessel is mounted on top of a support base via a support frame. A sealing cover is installed on the top of the concentration vessel. A regulating valve is installed on the top of the sealing cover. A feeder is installed on the top of the regulating valve. An explosion-proof camera and a supplementary light are installed on the top of the sealing cover. The tops of the explosion-proof camera and the supplementary light are connected by a connecting wire and a connector. A network cable is installed at the other end of the connector.

[0009] The mounting bracket is installed on the top of the support base near one side. The mounting bracket contains a CD burner, a fiber optic transceiver, a central control room switch, an imaging computer, and a DCS controller. The structure of the DCS controller is connected via signal lines and regulating valves.

[0010] The feeder can add foam-eliminating agent into the concentration vessel in conjunction with the regulating valve. The monitoring and light-emitting ends of the explosion-proof camera and the supplementary light are located at the bottom of the inner wall of the sealed cover. The other end of the network cable is connected to the burner. The connection between the burner, fiber optic transceiver, central control room switch, imaging computer and DCS controller is based on the working principle.

[0011] Preferably, an operation screen is mounted on the front of the mounting bracket via a mounting base, and a liquid level sensor is mounted on the top of the sealing cover;

[0012] The liquid level sensor can monitor the height of the liquid level inside the concentration vessel, and the control panel can set the operating parameters of the equipment on the support frame.

[0013] Preferably, a discharge pipe is installed at the bottom of the concentration vessel, and a valve is fixedly connected to the other end of the discharge pipe.

[0014] Preferably, the support base includes a base plate, an adjusting bolt, and a contact block, wherein the adjusting bolt is used to install the contact block on the bottom of the base plate;

[0015] The stability of the base plate can be increased by adjusting the bolts.

[0016] Preferably, a drive assembly is mounted on the top of the sealing cap, a rotating shaft is mounted on the output end of the drive assembly, and a stirring rack is mounted on the bottom end of the rotating shaft.

[0017] Preferably, an installation ring is installed on the outer surface of the rotating shaft near the top end, and two cleaning rods are installed on the outer surface of the installation ring. Cleaning cotton is installed on the top of each of the two cleaning rods, and multiple spikes are installed on the bottom of one of the cleaning rods via an installation plate.

[0018] Compared with related technologies, the foam monitoring device for concentration reactors based on an AI imaging system provided by this utility model has the following beneficial effects:

[0019] This utility model provides a foam monitoring device for an enrichment vessel based on an AI imaging system. To improve the monitoring accuracy and achieve intelligent linkage, a CD burner, imaging computer, DCS controller, central control room switch, and fiber optic transceiver are first installed on a mounting bracket. An explosion-proof camera and supplementary lighting unit are connected to the CD burner via connecting cables, connectors, and network cables. The CD burner and fiber optic transceiver are connected via patch cords. The fiber optic transceiver is connected to the central control room switch via fiber optic cable. The central control room switch is connected to the imaging computer via a network cable. The imaging computer is connected to the DCS controller via an OPC communication line. Finally, the DCS controller and regulating valve are connected via signal lines. The explosion-proof camera is used to monitor the interior of the enrichment vessel. The foam is visually monitored, and during this process, the supplementary light source can supplement the light source needed for imaging. The monitored signal is processed by the recorder, fiber optic transceiver, central control room switch, imaging computer and DCS controller to accurately determine the specific situation of the foam inside the concentration tank. If the preset position is reached, the regulating valve can be controlled to release the defoamer in the feeder into the concentration tank to eliminate the foam. The foam level is monitored in real time by visual recognition technology composed of explosion-proof camera and supplementary light, and accurate alarm is achieved by combining AI algorithm. The defoamer regulating valve is automatically controlled by the DCS system through industrial communication protocol, which solves the problems of low efficiency, poor reliability and insufficient automation of traditional methods. Attached Figure Description

[0020] Figure 1 A schematic diagram of the structure of the first embodiment of the foam monitoring device for concentration reactor based on AI imaging system provided by this utility model;

[0021] Figure 2 A schematic diagram of the discharge pipe is provided for this utility model;

[0022] Figure 3 Provided for this utility model Figure 1 An enlarged view of point A shown;

[0023] Figure 4 A flowchart is provided for this utility model;

[0024] Figure 5 A schematic diagram of the second embodiment of the foam monitoring device for concentration reactor based on AI imaging system provided by this utility model;

[0025] Figure 6 A schematic diagram of the rotating shaft is provided for this utility model;

[0026] Figure 7 A schematic diagram of the drive component is provided for this utility model.

[0027] Numbered in the diagram: 1. Support frame, 101. Base plate, 102. Adjusting bolt, 103. Contact block, 2. Operation panel, 3. Mounting base, 4. Recorder, 5. Imaging computer, 6. Mounting bracket, 7. DCS controller, 8. Central control room switch, 9. Fiber optic transceiver, 10. Feeder, 11. Connecting cable, 12. Liquid level sensor, 13. Sealing cover, 14. Explosion-proof camera, 15. Concentration vessel, 16. Support frame, 17. Valve, 18. Discharge pipe, 19. Signal line, 20. Network cable, 21. Connector, 22. Filler light, 23. Adjusting valve, 24. Drive assembly, 241. Protective shell, 242. Angle sensor, 243. Drive component, 25. Cleaning cotton, 26. Cleaning rod, 27. Mounting ring, 28. Rotating shaft, 29. Stirring rack, 30. Spiked cone, 31. Mounting plate. Detailed Implementation

[0028] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0029] First Embodiment

[0030] Please refer to the following: Figure 1 , Figure 2 , Figure 3 , Figure 4 ,in, Figure 1 A schematic diagram of the structure of the first embodiment of the foam monitoring device for concentration reactor based on AI imaging system provided by this utility model; Figure 2 A schematic diagram of the discharge pipe is provided for this utility model; Figure 3 Provided for this utility model Figure 1 An enlarged view of point A shown; Figure 4 A flowchart is provided for this utility model. The foam monitoring device for the concentration vessel based on the AI ​​imaging system includes: a supporting base 1;

[0031] A concentration vessel 15 is mounted on top of a support base 1 via a support frame 16. A sealing cover 13 is mounted on top of the concentration vessel 15. A regulating valve 23 is mounted on top of the sealing cover 13. A feeder 10 is mounted on top of the regulating valve 23. An explosion-proof camera 14 and a supplementary light 22 are mounted on top of the sealing cover 13. The tops of the explosion-proof camera 14 and the supplementary light 22 are connected to a connector 21 via a connecting line 11. A network cable 20 is mounted on the other end of the connector 21.

[0032] Mounting bracket 6 is installed on the top of the support base 1 near one side. Inside the mounting bracket 6 are installed a CD burner 4, an optical transceiver 9, a central control room switch 8, an imaging computer 5, and a DCS controller 7. The structure of the DCS controller 7 is connected to the control valve 23 via signal line 19.

[0033] The feeder 10 can add foam-eliminating agent into the concentration vessel 15 in conjunction with the regulating valve 23. The monitoring and light-emitting ends of the explosion-proof camera 14 and the supplementary light device 22 are located at the bottom of the inner wall of the sealing cover 13. The other end of the network cable 20 is connected to the burner 4. The connection between the burner 4, the fiber optic transceiver 9, the central control room switch 8, the imaging computer 5 and the DCS controller 7 is based on the working principle.

[0034] The explosion-proof camera 14 is an image acquisition module, including a high-temperature explosion-proof camera and a multispectral light source, installed at the top sight glass of the concentration vessel to acquire images of foam inside the vessel; a data transmission module: the camera is connected to an industrial-grade recorder via a network cable, and then transmitted to the central control room switch via a fiber optic transceiver and fiber optic cable; an AI processing module: deployed on the central control room computer, including: an image preprocessing unit: performing noise reduction, enhancement, and ROI extraction on the image; an AI recognition unit: a foam level classification model based on a convolutional neural network for real-time identification of high-level foam; an alarm logic unit: triggering an alarm and generating a signal output when high-level foam is detected; and an execution module: transmitting the alarm signal to the DCS system via OPC communication, whereby the DCS controls the opening of the solenoid valve of the defoamer storage tank to automatically add defoamer. The method flow steps are: S1: acquire historical foam images, label normal and high-level states, and construct a training dataset; S2: train the CNN model and optimize the classification accuracy to 95%. The above steps are as follows: Step S3: Real-time image acquisition and transmission to the AI ​​processing module, outputting liquid level status; Step S4: When an alarm is triggered, a command is sent to the DCS via the OPC protocol to start the defoamer addition process; Camera type change: The high-temperature explosion-proof camera can be replaced with an industrial-grade camera with higher resolution and frame rate to obtain clearer and more real-time foam images, improving the accuracy of subsequent AI recognition. An infrared camera is used, which can capture invisible thermal radiation information for some concentration tank scenarios where foam characteristics are more obvious at specific temperatures, assisting in judging the foam status; Light source change: In addition to multi-spectral light sources, intelligent light sources with adjustable light intensity and color can be used. The parameters of the light source are dynamically adjusted according to different media and environmental conditions in the concentration tank to further enhance image contrast; A distributed light source layout is adopted, with multiple light sources set around the sight glass on the top of the concentration tank to reduce the influence of shadows and make the acquired images more uniform and comprehensive;In addition to fiber optic transmission, wireless transmission methods such as 5G and Wi-Fi 6 can be used in scenarios where real-time requirements are not extremely high and cabling is difficult. This improves system flexibility and scalability. Combined with edge computing devices, images can be preliminarily processed and compressed locally, reducing the amount of data transmitted and lowering network bandwidth requirements. Regarding transmission protocols, besides supporting RTSP streaming media transmission, compatibility with other common industrial transmission protocols such as HTTP and MQTT is also possible, facilitating integration with different systems. In the AI ​​processing module, the model structure has been changed. In addition to the convolutional neural network-based foam level classification model, recurrent neural networks or long short-term memory networks can be used to better model and predict foam changes with time-series characteristics. The processing flow has also changed. In the image preprocessing unit, in addition to denoising, enhancement, and ROI extraction, an image segmentation step can be added to more accurately segment the foam area from the background, improving the accuracy of subsequent recognition. Reinforcement learning algorithms are introduced to dynamically adjust the parameters of the AI ​​recognition unit and alarm logic unit based on different concentration vessel conditions and historical data, achieving adaptive foam monitoring.

[0035] An operation screen 2 is mounted on the front of the mounting bracket 6 via the mounting base 3, and a liquid level sensor 12 is mounted on the top of the sealing cover 13.

[0036] The liquid level sensor 12 can monitor the height of the liquid level inside the concentration vessel 15, and the operation panel 2 can set the operating parameters of the equipment on the support base 1.

[0037] The bottom of the concentration vessel 15 is equipped with a discharge pipe 18, and the other end of the discharge pipe 18 is fixedly connected to a valve 17.

[0038] After valve 17 is opened, the liquid inside the concentration vessel 15 can be discharged by connecting it with discharge pipe 18.

[0039] The support base 1 includes a base plate 101, an adjusting bolt 102, and a contact block 103. The adjusting bolt 102 is used to install the contact block 103 on the bottom of the base plate 101.

[0040] The stability of the base plate 101 can be increased by adjusting the bolt 102.

[0041] The working principle of the foam monitoring device for concentration reactor based on AI imaging system provided by this utility model is as follows:

[0042] First, install the CD burner 4, imaging computer 5, DCS controller 7, central control room switch 8, and fiber optic transceiver 9 on the mounting bracket 6. Then, connect the explosion-proof camera 14 and the supplementary light unit 22 to the CD burner 4 via connecting cable 11, connector 21, and network cable 20. Connect the CD burner 4 and fiber optic transceiver 9 via patch cords. Connect the fiber optic transceiver 9 to the central control room switch 8 via fiber optic cable. Connect the central control room switch 8 to the imaging computer 5 via a network cable. Connect the imaging computer 5 to the DCS controller 7 via an OPC communication line. Finally, connect the signal line 19... The DCS controller 7 and the regulating valve 23 are connected. The explosion-proof camera 14 is used to visually monitor the foam inside the concentration vessel 15. During this process, the supplementary light device 22 can supplement the light source required for imaging. The monitored signal is processed by the recorder 4, fiber optic transceiver 9, central control room switch 8, imaging computer 5 and DCS controller 7 to accurately determine the specific situation of the foam inside the concentration vessel 15. If the preset position is reached, the regulating valve 23 can be controlled to release the defoamer in the feeder 10 into the concentration vessel 15 to eliminate the foam.

[0043] Compared with related technologies, the foam monitoring device for concentration reactors based on an AI imaging system provided by this utility model has the following beneficial effects:

[0044] To improve the monitoring accuracy of foam in the concentration reactor and achieve intelligent linkage, the CD burner 4, imaging computer 5, DCS controller 7, central control room switch 8, and fiber optic transceiver 9 are first installed on the mounting bracket 6. The explosion-proof camera 14 and the supplementary light 22 are connected to the CD burner 4 via connecting cable 11, connector 21, and network cable 20. The CD burner 4 and fiber optic transceiver 9 are connected via patch cord. The fiber optic transceiver 9 is connected to the central control room switch 8 via fiber optic cable. The central control room switch 8 is connected to the imaging computer 5 via network cable. The imaging computer 5 is connected to the DCS controller 7 via OPC communication line. Finally, the DCS controller 7 and the regulating valve 23 are connected via signal line 19. The explosion-proof camera 14 is used to monitor the foam inside the concentration reactor 15. During phase monitoring, the supplementary light device 22 can supplement the light source required for imaging. The monitored signal is processed by the recorder 4, fiber optic transceiver 9, central control room switch 8, imaging computer 5 and DCS controller 7 to accurately determine the specific situation of foam inside the concentration tank 15. If the preset position is reached, the regulating valve 23 can be controlled to release the defoamer in the feeder 10 into the concentration tank 15 to eliminate foam. The foam level is monitored in real time by visual recognition technology composed of explosion-proof camera 14 and supplementary light device 22. Combined with AI algorithm, accurate alarm is achieved. The defoamer regulating valve 23 is automatically controlled by the DCS system through industrial communication protocol, which solves the problems of low efficiency, poor reliability and insufficient automation of traditional methods.

[0045] Second Embodiment

[0046] Please refer to the following: Figures 5-6 - Figure 7 , Figure 5 A schematic diagram of the second embodiment of the foam monitoring device for concentration reactor based on AI imaging system provided by this utility model; Figure 6 A schematic diagram of the rotating shaft is provided for this utility model; Figure 7 This utility model provides a structural schematic diagram of the driving component. Based on the first embodiment of this application, which provides a foam monitoring device for a concentration vessel based on an AI imaging system, the second embodiment of this application proposes another foam monitoring device for a concentration vessel based on an AI imaging system. The second embodiment is merely a preferred embodiment of the first embodiment, and the implementation of the second embodiment will not affect the separate implementation of the first embodiment.

[0047] Specifically, the difference between the foam monitoring device for the concentration vessel based on the AI ​​imaging system provided in the second embodiment of this application is that a drive assembly 24 is installed on the top of the sealing cover 13, a rotating shaft 28 is installed at the output end of the drive assembly 24, and a stirring rack 29 is installed at the bottom end of the rotating shaft 28.

[0048] The stirring rack 29 can stir the liquid.

[0049] A mounting ring 27 is installed on the outer surface of the rotating shaft 28 near the top. Two cleaning rods 26 are installed on the outer surface of the mounting ring 27. Cleaning cotton 25 is installed on the top of each of the two cleaning rods 26. Multiple spikes 30 are installed on the bottom of one of the cleaning rods 26 through the mounting plate 31.

[0050] The cleaning cotton 25 comes into contact with the explosion-proof camera 14 and the fill light 22.

[0051] Compared with related technologies, the foam monitoring device for concentration reactors based on an AI imaging system provided by this utility model has the following beneficial effects:

[0052] To improve foam elimination and facilitate cleaning of the imaging equipment, a drive assembly 24 is installed on the top of the sealing cover 13. A rotating shaft 28 with a stirring rack 29 is then installed at the output end of the drive assembly 24. Two cleaning rods 26 are mounted on the outer surface of the rotating shaft 28 via mounting rings 27. The cleaning cotton 25 on the top of the cleaning rods 26 contacts the bottom of the supplementary light unit 22 and the explosion-proof camera 14. During the rotation of the cleaning rods 26, the cleaning cotton 25 cleans the supplementary light unit 22 and the explosion-proof camera 14. Meanwhile, the spiked cone 30 installed at the bottom of the cleaning rods 26 via the mounting plate 31 assists in puncturing the foam inside the concentration vessel 15 during the rotation of the cleaning rods 26, improving the foam elimination effect. Simultaneously, the cleaning cotton 25 cleans the supplementary light unit 22 and the explosion-proof camera 14, increasing the accuracy of the imaging acquisition.

[0053] The above description is merely an embodiment of this utility model and does not limit the patent scope of this utility model. Any equivalent structural or procedural transformations made based on the content of this utility model specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this utility model.

Claims

1. A foam monitoring device for a concentration vessel based on an AI imaging system, characterized in that, include: Support frame; A concentration vessel is mounted on top of a support base via a support frame. A sealing cover is installed on the top of the concentration vessel. A regulating valve is installed on the top of the sealing cover. A feeder is installed on the top of the regulating valve. An explosion-proof camera and a supplementary light are installed on the top of the sealing cover. The tops of the explosion-proof camera and the supplementary light are connected by a connecting wire and a connector. A network cable is installed at the other end of the connector. The mounting bracket is installed on the top of the support base near one side. The mounting bracket contains a CD burner, a fiber optic transceiver, a central control room switch, an imaging computer, and a DCS controller. The structure of the DCS controller is connected via signal lines and regulating valves.

2. The foam monitoring device for the concentration vessel based on an AI imaging system according to claim 1, characterized in that, An operation panel is mounted on the front of the mounting bracket via a mounting base, and a liquid level sensor is mounted on the top of the sealing cover.

3. The foam monitoring device for the concentration vessel based on an AI imaging system according to claim 1, characterized in that, The bottom of the concentration vessel is equipped with a discharge pipe, and a valve is fixedly connected to the other end of the discharge pipe.

4. The foam monitoring device for the concentration vessel based on an AI imaging system according to claim 1, characterized in that, The support frame includes a base plate, an adjusting bolt, and a contact block. The adjusting bolt is used to install the contact block at the bottom of the base plate.

5. The foam monitoring device for the concentration vessel based on an AI imaging system according to claim 1, characterized in that, A drive assembly is mounted on the top of the sealing cap, a rotating shaft is mounted on the output end of the drive assembly, and a stirring rack is mounted on the bottom end of the rotating shaft.

6. The foam monitoring device for the concentration vessel based on an AI imaging system according to claim 5, characterized in that, An installation ring is installed on the outer surface of the rotating shaft near the top. Two cleaning rods are installed on the outer surface of the installation ring. Cleaning cotton is installed on the top of each of the two cleaning rods. Multiple spikes are installed on the bottom of one of the cleaning rods via an installation plate.

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