A kind of pellet rotary kiln hopper level image measuring device

Abstract

The utility model discloses a kind of pellet rotary kiln hopper level image measuring devices, including support, inside fixed connection servo motor of support, the end of support close to servo motor is fixedly connected backplate, one side of backplate is fixedly connected sliding table, the side of sliding table is provided with chute, the inside sliding connection of chute has sliding block, the bottom of sliding table is located above servo motor output end, the output end of servo motor is fixedly connected screw rod, screw rod extends to sliding table inside and is cooperated with sliding block thread, one end of sliding block is fixedly connected connecting plate, connecting plate is equipped with infrared thermal image detection device, the end of support away from servo motor is fixedly connected connecting piece, the lower end of connecting piece is connected with rotary kiln hopper bin and is fixedly connected, probe and probe rod are through connecting piece and make probe extend into rotary kiln hopper bin inside, servo motor and infrared thermal image detection device are electrically connected with PLC control system. Using this device can continuously, real-time monitor material image in hopper, and ensure probe safety, prolong probe service life.

Description

Technical Field

[0001] This utility model relates to the field of monitoring equipment technology, specifically to a pellet rotary kiln hopper material level image measurement device. Background Technology

[0002] The pellet rotary kiln is a large-scale, high-temperature equipment. During production, heated pellets fall into the hopper of the annular cooler. The accumulation height of the pellets in the hopper is crucial to the operation and control of the annular cooler and rotary kiln, and the production status needs to be adjusted according to the material level range.

[0003] Currently, commonly used material level detection methods in the market mainly include microwave level detectors and pressure sensors. Microwave detectors emit microwaves and detect the echoes, outputting a switch signal to determine the presence of material. Their advantages include high temperature resistance and non-contact measurement. However, their fundamental limitation is that they cannot perform continuous measurement, only provide point-level alarm functions, and cannot obtain the actual height change curve of the material level, thus failing to meet the needs of refined process control. Pressure sensors, on the other hand, calculate the material level by measuring the static pressure generated at the bottom of the silo due to material accumulation. The theoretical basis is that the material level is proportional to the static pressure. However, in practical applications, the bulk density of the material changes with factors such as the material level, material composition, and temperature. This non-linear relationship introduces significant measurement errors. Furthermore, the pipelines used for pressure sensing are easily clogged by dust, requiring frequent manual cleaning and maintenance, which not only increases maintenance costs but may also cause measurement failure due to blockage, resulting in low reliability.

[0004] Therefore, it is necessary to provide a pellet rotary kiln hopper level image measurement device to solve the above-mentioned technical problems. Utility Model Content

[0005] The purpose of this invention is to address the shortcomings of existing technologies by providing a pellet rotary kiln hopper level image measurement device.

[0006] To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0007] A pellet rotary kiln hopper level image measurement device includes a horizontally placed support, a servo motor fixedly connected inside the support, a back plate extending vertically upwards fixedly connected to one end of the support near the servo motor, a slide table fixedly connected to one side of the back plate near the servo motor, a groove formed on the side of the slide table away from the back plate, a slider slidably connected inside the groove, the bottom of the slide table being above the output end of the servo motor, a lead screw fixedly connected to the output end of the servo motor, the lead screw extending into the slide table, the slider threadedly engaging with the lead screw, the output end of the servo motor driving the lead screw to rotate along its own axis, thereby causing the slider to move along the groove, a connecting plate fixedly connected to one end of the slider extending out of the groove, the connecting plate mounting an infrared thermal imaging detection device, the infrared thermal imaging detection device including a probe and a probe rod fixedly connected above the probe, a connecting piece fixedly connected to one end of the support away from the servo motor, the lower end of the connecting piece communicating and fixedly connected to the rotary kiln hopper, the probe and probe rod passing through the connecting piece and extending the probe into the rotary kiln hopper, the servo motor and the infrared thermal imaging detection device both electrically connected to a PLC control system. It should be further explained that the PLC control system is used to control the start, stop and reverse rotation of the servo motor, and to receive and process the image data collected by the infrared thermal imaging detection device. When the infrared thermal imaging detection device detects that the temperature exceeds the set threshold, the PLC control system controls the servo motor to reverse, driving the slider and the infrared thermal imaging detection device connected to it to move upward along the slide groove, so that the probe exits the high temperature area.

[0008] Preferably, the connector is a pipe fitting with flanges installed at both the top and bottom ends, wherein the top end of the connector has a first flange and the bottom end has a second flange.

[0009] Preferably, a third flange communicating with the interior is installed on the outer surface of the rotary kiln hopper, and the third flange is fixedly connected to the second flange at the bottom of the connector by bolts.

[0010] Preferably, a fourth flange is fixed above the first flange by bolts, and a probe rod sleeve communicating with the inside of the connector is fixed to the top surface of the fourth flange. A sealing sleeve is fixedly installed at the top of the probe rod sleeve, and the probe rod is inserted into the sealing sleeve and slides in contact with the inner wall of the sealing sleeve.

[0011] Compared with the prior art, this utility model has the following advantages:

[0012] 1. By acquiring real-time images of materials inside the hopper through an infrared thermal imaging detection device and combining them with image processing technology, the material level height can be measured continuously and non-contactly. The image measurement method is not affected by environmental factors such as material density and temperature fluctuations, and the measurement results are more stable and reliable.

[0013] 2. The probe is raised and lowered by a servo motor. In case of abnormal conditions such as water or gas supply failure or overheating, the probe can be automatically removed from the high-temperature area, effectively protecting the core detection components and extending the service life of the equipment. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the external structure of this utility model;

[0015] Figure 2 This is a schematic diagram of the internal structure of this utility model.

[0016] Figure 3 This is a schematic diagram of the structure of the probe of this utility model extending into the interior of the rotary kiln hopper for monitoring.

[0017] Among them, 1-bracket, 2-servo motor, 3-back plate, 4-slide table, 5-slider, 6-lead screw, 7-connecting plate, 8-probe, 9-probe rod, 10-connector, 11-first flange, 12-second flange, 13-third flange, 14-fourth flange, 15-probe rod sleeve, 16-sealing sleeve, 17-PLC control system, 18-rotary kiln hopper. Detailed Implementation

[0018] The present invention will be further illustrated below with reference to the accompanying drawings and specific embodiments. It should be understood that these embodiments are only for illustrating the present invention and not for limiting the scope of the present invention. After reading the present invention, any modifications of the present invention in various equivalent forms by those skilled in the art will fall within the scope defined by the appended claims.

[0019] In this utility model, unless otherwise explicitly specified and limited, the terms "installation", "setting", "connection", "fixed connection", etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; 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; they can refer to the internal connection of two components or the interaction between two components. Unless otherwise explicitly limited, those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0020] In this utility model, terms such as "upper", "lower", "bottom", and "top" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only used to facilitate the description of the structural relationship between the various components or elements of this utility model and do not specifically refer to any component or element in this utility model. They should not be construed as limiting this utility model.

[0021] like Figures 1 to 3As shown, a pellet rotary kiln hopper level image measurement device includes a horizontally placed support 1. A servo motor 2 is fixedly installed inside the support. A back plate 3 extending vertically upward is fixedly installed at one end of the support near the servo motor. A slide table 4 is fixedly installed on the side of the back plate near the servo motor. A slide groove is formed on the side of the slide table away from the back plate. A slider 5 is slidably connected inside the slide groove. The bottom of the slide table is located above the output end of the servo motor 2. A lead screw 6 is fixedly connected to the output end of the servo motor, extending into the slide table. The slider 5 is threadedly engaged with the lead screw 6. The output end of the servo motor 2 drives the lead screw to rotate along its own axis, thereby causing the slider to move along the slide groove. A connecting plate 7 is fixedly connected to one end of the slider extending out of the slide groove. An infrared thermal imaging detection device is installed on the connecting plate. The infrared thermal imaging detection device includes a probe 8 and a probe rod 9 fixedly connected above the probe. The support is welded to the end away from the servo motor. A connector 10 is provided, which is a pipe fitting with flanges installed at both the top and bottom. The top of the connector has a first flange 11 and the bottom has a second flange 12. A third flange 13, which communicates with the interior of the rotary kiln hopper, is installed on the outer surface of the hopper. The third flange is fixedly connected to the second flange at the bottom of the connector by bolts. A fourth flange 14 is fixedly connected to the top of the first flange by bolts. A probe rod sleeve 15, which communicates with the interior of the connector, is welded and fixed to the top surface of the fourth flange. A sealing sleeve 16 is installed at the top of the probe rod sleeve. The inner wall of the top of the probe rod sleeve has internal threads, and the outer wall of the sealing sleeve has external threads. The probe rod sleeve and the sealing sleeve are threadedly connected and fixed. The probe rod is inserted into the sealing sleeve and slides in contact with the inner wall of the sealing sleeve. The probe and the probe rod pass through the connector and extend the probe into the interior of the rotary kiln hopper. The servo motor and the infrared thermal imaging detection device are both electrically connected to the PLC control system 17.

[0022] The principle of a pellet rotary kiln hopper level image measurement device:

[0023] The pellet material in the rotary kiln hopper 18 undergoes high-temperature sintering and possesses significant thermal radiation characteristics. An infrared thermal imaging detector probe extends into the rotary kiln hopper to continuously and in real-time acquire infrared thermal images of the material inside. This image signal is transmitted to the PLC control system, which uses a built-in image processing algorithm to identify the contour lines of the material surface, thereby accurately calculating the real-time accumulation height of the material.

[0024] The PLC control system monitors the data from the infrared thermal imaging detection device in real time. When it detects abnormal conditions such as the temperature inside the rotary kiln hopper exceeding the preset safety threshold, the PLC control system will immediately issue a command to control the servo motor to rotate and quickly lift the infrared thermal imaging detection device upward, so that the probe is completely removed from the high-temperature hopper area, thereby effectively preventing the core optical and electronic components from being damaged due to overheating.

[0025] Method of using a pellet rotary kiln hopper level image measuring device:

[0026] First, install the device. Connect the second flange at the bottom of the connector to the third flange welded to the outer wall of the hopper and tighten with bolts. Connect the servo motor drive cable and the data and power cables of the infrared thermal imaging detector to the corresponding interfaces of the PLC control system and turn on the main power supply. Start the PLC control system. After the system self-checks, it controls the servo motor to rotate forward, driving the slider to move downward along the slide groove, driving the infrared thermal imaging detector to descend. Through the sliding of the probe rod within the sealing sleeve, the probe is smoothly delivered to the preset detection position in the hopper. Under normal production conditions, the infrared thermal imaging detector continuously scans the material in the hopper and transmits the image data to the PLC control system in real time. The control system processes the image data to obtain continuous material level information and uploads this signal to the monitoring system in the central control room to guide production operations. Once the PLC control system detects an anomaly, such as the temperature inside the kiln hopper exceeding the preset safety threshold, the PLC control system controls the servo motor to reverse, driving the infrared thermal imaging detector to rise rapidly along the slide groove until it reaches the preset safety position, completely removing the probe from the high-temperature environment.

[0027] The foregoing description illustrates and describes preferred embodiments of the present invention. As previously stated, it should be understood that the present invention is not limited to the forms disclosed herein and should not be construed as excluding other embodiments. It can be used in various other combinations, modifications, and environments, and can be altered within the scope of the inventive concept described herein through the foregoing teachings or related technical or knowledge. Any modifications and variations made by those skilled in the art that do not depart from the spirit and scope of the present invention should be within the protection scope of the appended claims.

Claims

1. A pellet rotary kiln hopper level image measuring device, characterized in that: The system includes a horizontally placed support, with a servo motor fixed inside. A back plate extending vertically upwards is fixed to one end of the support near the servo motor. A slide is fixed to the side of the back plate near the servo motor, and a groove is formed on the side of the slide away from the back plate. A slider is slidably connected inside the groove. The bottom of the slide is located above the output end of the servo motor. A lead screw is fixed to the output end of the servo motor, extending into the slide. The slider is threadedly engaged with the lead screw. The output end of the servo motor drives the lead screw to rotate along its own axis, thereby causing the slider to move along the groove. A connecting plate is fixed to one end of the slider extending out of the groove. An infrared thermal imaging detection device is mounted on the connecting plate. The infrared thermal imaging detection device includes a probe and a probe rod fixedly connected above the probe. A connecting piece is fixed to the end of the support away from the servo motor. The lower end of the connecting piece is connected and fixedly connected to the rotary kiln hopper. The probe and probe rod pass through the connecting piece, allowing the probe to extend into the rotary kiln hopper. Both the servo motor and the infrared thermal imaging detection device are electrically connected to a PLC control system.

2. The pellet rotary kiln hopper level image measuring device according to claim 1, characterized in that: The connector is a pipe fitting with flanges installed at both the top and bottom. The top of the connector has a first flange and the bottom has a second flange.

3. The pellet rotary kiln hopper level image measuring device according to claim 2, characterized in that: The outer surface of the rotary kiln hopper is equipped with a third flange that communicates with its interior. The third flange is fixedly connected to the second flange at the bottom of the connector by bolts.

4. The pellet rotary kiln hopper level image measuring device according to claim 2, characterized in that: A fourth flange is fixed above the first flange by bolts. A probe rod sleeve that communicates with the inside of the connector is fixed to the top surface of the fourth flange. A sealing sleeve is fixedly installed at the top of the probe rod sleeve. The probe rod is inserted into the sealing sleeve and slides in contact with the inner wall of the sealing sleeve.

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