A chain and flight conveyor flight bar detection system

Abstract

The utility model discloses a chain and grate machine grate plate detection system belongs to metallurgical mechanical equipment technical field, and its technical scheme main points include chain and grate machine main part, grate plate main part and chain and grate machine grate plate quality detection system, the grate plate main part sets up inside chain and grate machine main part, and the front end and the middle part of chain and grate machine main part are respectively bolted with front support and rear support, and the inboard of front support and rear support all bolted with a plurality of protection mechanism, chain and grate machine grate plate quality detection system includes the control module, and the input end unidirectional electric connection of data transmission module has image acquisition module, and through the full process design of multidimensional acquisition, intelligent analysis and data closed loop of chain and grate machine grate plate quality detection system, breaks through the limitation of traditional detection mode, and can gather grate plate image and temperature data in real time in the operation process of chain and grate machine without stopping, replaces the offline detection mode of manual entering high temperature, narrow space.

Description

Technical Field

[0001] This utility model relates to the field of metallurgical machinery and equipment technology, and in particular to a chain grate machine grate detection system. Background Technology

[0002] Chain grate machines are key equipment in the production of pellets in the metallurgical industry. As the core component that carries the pellets and participates in heat exchange and transportation, the grate plate works in harsh environments such as high temperature, dust, material erosion and mechanical vibration for a long time. It is prone to failures such as wear, deformation, cracks and even breakage. The condition of the grate plate directly affects the production efficiency, product quality and equipment operation safety of the pellets. Therefore, timely and accurate detection of the grate plate is crucial.

[0003] In existing technologies, the detection of chain grate plates mainly suffers from the following problems or deficiencies:

[0004] 1. Reliance on manual inspection is inefficient and unsafe: Traditional inspection methods often involve manual entry into the equipment after shutdown to visually observe or measure the condition of the grate using simple tools (such as calipers). Due to the narrow internal space of the chain grate machine and the long duration of high-temperature environment (it still needs to wait for cooling after shutdown), manual inspection is not only time-consuming and labor-intensive (a single inspection may take several hours or even days), which seriously affects the continuity of production, but also poses safety hazards such as burns and falls from heights.

[0005] 2. Low detection accuracy, prone to missed detection or misjudgment: Manual inspection is affected by subjective experience, visual fatigue and other factors, and has limited ability to identify defects such as fine cracks and local wear (such as wear at the edge of the grate or at the holes), which easily leads to missed detection; at the same time, the judgment of parameters such as deformation and wear depth relies on experience estimation and lacks quantitative data support, resulting in low detection accuracy and difficulty in meeting the needs of refined maintenance.

[0006] 3. Difficulty in achieving dynamic online detection: Existing technologies are mostly offline detection (requiring machine shutdown), which cannot monitor the status of the grate in real time during the operation of the chain grate machine. The faults of the grate are often dynamic, and offline detection cannot capture real-time defects during equipment operation (such as crack propagation caused by vibration), which may lead to delayed fault warnings, and thus trigger sudden equipment shutdown or more serious chain failures (such as the conveyor chain being blocked after the grate breaks).

[0007] 4. Lack of systematic data management and analysis capabilities: Traditional inspection records are mostly paper documents or simple spreadsheets, making it difficult to track and analyze the deterioration trend of the grate over a long period of time. It is also impossible to establish a life prediction model based on historical data, resulting in maintenance strategies that are mostly "repair after failure" or "regular overhaul", which easily leads to problems of over-maintenance (increasing costs) or under-maintenance (causing failures).

[0008] 5. Limitations of existing automated inspection technologies: In some scenarios, simple sensors (such as temperature sensors and vibration sensors) are introduced for indirect monitoring, but these technologies are difficult to directly locate specific defects in the grate (e.g., it is impossible to distinguish whether it is grate wear or failure of other components); a few machine vision-based inspection solutions suffer from poor image quality and low robustness of algorithm recognition due to the large amount of dust inside the chain grate machine and uneven lighting (high temperature radiation and equipment obstruction leading to complex lighting).

[0009] In summary, existing technologies have significant shortcomings in terms of efficiency, accuracy, real-time performance, and intelligence in the detection of chain grate plates, and cannot meet the needs of modern metallurgical industry for efficient, safe, and low-cost production. There is an urgent need for a system that can achieve online, automated, and high-precision detection. Utility Model Content

[0010] The purpose of this utility model is to provide a chain grate machine grate inspection system that can solve the problems of low efficiency, poor safety, insufficient inspection accuracy, inability to perform online dynamic inspection, weak data management capabilities, and poor adaptability to automation solutions in the existing chain grate machine grate inspection process.

[0011] To achieve the above objectives, this utility model provides the following technical solution: a chain grate machine grate inspection system, comprising a chain grate machine body, a grate body, and a chain grate machine grate quality inspection system. The grate body is disposed inside the chain grate machine body. A front support and a rear support are respectively bolted to the front end and middle part of the chain grate machine body. Several protective mechanisms are bolted to the inner sides of the front support and the rear support.

[0012] The chain grate machine grate quality inspection system includes a central control module. The input end of the central control module is electrically connected to a data transmission module, and the input end of the data transmission module is electrically connected to an image acquisition module. The output end of the central control module is electrically connected to an image processing layer, and the output end of the image processing layer is electrically connected to a crack recognition layer. The output end of the crack recognition layer is electrically connected to a data recording layer and a status monitoring and alarm module.

[0013] Preferably, the image acquisition module includes a high-definition industrial camera, an infrared thermal imager, and a positioning camera. The high-definition industrial camera is located inside the protective mechanism, the infrared thermal imager is located inside the protective mechanisms on both sides of the rear, and the positioning camera is mounted on the side adjacent to the small shaft of the main body of the chain grate machine via an adjustable bracket, and the height of the camera lens is adapted to the height of the small shaft head and the license plate below it.

[0014] Preferably, the image processing layer includes an image acquisition module, an image preprocessing module, an image noise reduction module, and an image enhancement module.

[0015] Preferably, the crack identification layer includes a model building and training module and a real-time detection and judgment module.

[0016] Preferably, the data recording layer includes a recording module and a display module.

[0017] Preferably, the protective mechanism includes a heat-insulating protective shell, a miniature air compression structure is bolted to the top of the inner wall of the heat-insulating protective shell, and a first air supply pipe is connected to the bottom of the miniature air compression structure. A first air supply ring is connected to the bottom of the first air supply pipe, a connecting pipe is connected to the bottom of the first air supply ring, and a purging component is connected to the bottom of the connecting pipe. The purging component is located behind the lens of the high-definition industrial camera, and the first air supply ring is fitted onto the surface of the high-definition industrial camera.

[0018] Preferably, each of the two heat-insulating protective shells on both sides is provided with an integral cavity protective shell, and the infrared thermal imager is located inside the cavity protective shell. A connecting plate is slidably arranged inside the cavity protective shell, and the bottom of the connecting plate is bolted to the infrared thermal imager. Guide rods and threaded screws are respectively passed through both sides inside the connecting plate. A temperature sensor is bolted to the top of the inner wall of the cavity protective shell.

[0019] Preferably, the right side of the micro air compression structure is connected to a second air supply pipe, and the other end of the second air supply pipe is connected to a second jet ring. The second jet ring is located inside the cavity protective shell and is used in conjunction with an infrared thermal imager.

[0020] Compared with the prior art, the beneficial effects of this utility model are:

[0021] 1. The chain grate machine grate quality inspection system of this application breaks through the limitations of traditional inspection methods through a full-process design of multi-dimensional acquisition, intelligent analysis and data closed loop. It can collect grate images and temperature data in real time during the operation of the chain grate machine without stopping the machine, replacing the offline inspection mode of manual entry into high temperature and narrow space. The image acquisition module captures surface cracks, wear and other detailed defects, judges abnormalities such as grate not being reset through temperature distribution, and associates defects with specific shaft numbers. The data of these three types are optimized by the image processing layer and intelligently analyzed by the crack recognition layer to achieve accurate identification and quantitative evaluation of subtle defects. It solves the problems of missed detection, misjudgment and insufficient accuracy of manual inspection. Moreover, it can store the full life cycle inspection data and combine the real-time early warning of the status monitoring and alarm module to provide data-driven decision-making basis for maintenance: it avoids production losses caused by post-failure repair and reduces the excessive maintenance costs caused by regular overhaul, so as to achieve accurate maintenance of grate.

[0022] 2. This application addresses the interference of the high-temperature, high-dust environment inside the chain grate machine on the detection equipment by setting up a protective mechanism. The protective mechanism integrates heat insulation, active cleaning, and adaptive temperature control to effectively block radiant and conductive heat inside the chain grate machine, preventing high temperatures from damaging the performance of precision equipment such as high-definition industrial cameras and infrared thermal imagers. It can also perform directional blowing on the lens of the high-definition industrial camera to prevent image blurring caused by dust adhesion. At the same time, when the ambient temperature exceeds the threshold, the infrared thermal imager automatically retracts to the low-temperature zone to avoid damage, and extends again to work after the temperature recovers, avoiding component aging caused by continuous high temperature. Attached Figure Description

[0023] Figure 1 This is an overall structural diagram of the chain grate machine grate detection system of this utility model;

[0024] Figure 2 This is a front view schematic diagram of the overall structure of this utility model;

[0025] Figure 3 This is a schematic diagram showing the connection between the rear support and the protective mechanism of this utility model;

[0026] Figure 4 This is a schematic diagram showing the connection between the protective mechanism and the cavity protective shell of this utility model;

[0027] Figure 5 This is a cross-sectional schematic diagram of the purging component of this utility model;

[0028] Figure 6 This is a flowchart illustrating the quality inspection system for the chain grate machine of this utility model.

[0029] In the diagram, 1. Main body of the chain grate machine; 2. Main body of the grate plate; 3. Front support; 4. Rear support; 5. Protective mechanism; 51. Heat insulation protective shell; 52. Miniature air compression structure; 53. First air supply pipe; 54. First air jet ring; 55. Connecting pipe; 56. Purge component; 6. Connecting plate; 7. Guide rod; 8. Lead screw; 9. Temperature sensor; 10. Second air supply pipe; 11. Second air jet ring. Detailed Implementation

[0030] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0031] Please see Figure 1-6 The present invention provides the following technical solution:

[0032] A chain grate machine grate inspection system includes a chain grate machine body 1, a grate plate body 2, and a chain grate machine grate plate quality inspection system. The grate plate body 2 is located inside the chain grate machine body 1. A front support 3 and a rear support 4 are respectively bolted to the front end and middle part of the chain grate machine body 1. Several protective mechanisms 5 are bolted to the inner side of both the front support 3 and the rear support 4.

[0033] The chain grate machine grate quality inspection system includes a central control module. The input end of the central control module is electrically connected to a data transmission module, and the input end of the data transmission module is electrically connected to an image acquisition module. The output end of the central control module is electrically connected to an image processing layer, and the output end of the image processing layer is electrically connected to a crack recognition layer. The output end of the crack recognition layer is electrically connected to a data recording layer and a status monitoring and alarm module.

[0034] In this embodiment, the chain grate quality inspection system overcomes the limitations of traditional inspection methods through a multi-dimensional acquisition, intelligent analysis, and data closed-loop design. It can acquire grate images and temperature data in real time during chain grate operation without stopping the machine, replacing the offline inspection mode that requires manual entry into high-temperature, confined spaces. The image acquisition module captures detailed defects such as surface cracks and wear, and the temperature distribution identifies anomalies such as grate misalignment, as well as correlated defects with specific shaft numbers. This data is optimized by the image processing layer and intelligently analyzed by the crack recognition layer, enabling accurate identification and quantitative assessment of subtle defects. This solves the problems of missed detections, misjudgments, and insufficient accuracy in manual inspection. Furthermore, it can store full lifecycle inspection data and, combined with real-time warnings from the status monitoring and alarm modules, provides data-driven decision-making for maintenance. This avoids production losses caused by post-failure repairs and reduces excessive maintenance costs associated with regular overhauls, achieving precise grate maintenance.

[0035] Specifically, such as Figure 2 , Figure 4 , Figure 6 As shown, the image acquisition module includes a high-definition industrial camera, an infrared thermal imager, and a positioning camera. The high-definition industrial camera is located inside the protective mechanism 5, the infrared thermal imager is located inside the protective mechanisms 5 on both sides of the rear, and the positioning camera is mounted on the side of the small shaft at the head of the chain grate machine body 1 via an adjustable bracket, and the height of the camera lens is adapted to the height of the small shaft head and the license plate below it.

[0036] Specifically, such as Figure 6 As shown, the image processing layer includes an image acquisition module, an image preprocessing module, an image noise reduction module, and an image enhancement module.

[0037] Specifically, such as Figure 6 As shown, the crack recognition layer includes a model building and training module and a real-time detection and judgment module.

[0038] Specifically, such as Figure 6 As shown, the data recording layer includes a recording module and a display module.

[0039] In this embodiment: a high-definition industrial camera is fixed inside the front support 3 and the rear support 4 via a protective mechanism 5, continuously capturing details of the grate surface. An infrared thermal imager is installed inside the rear protective mechanism 5 to collect images of the grate temperature field distribution. A positioning camera is aligned with the head shaft and number plate via an adjustable bracket, simultaneously recording the grate position information. The data collected by these three devices are summarized to provide multi-dimensional basis for subsequent defect identification and location. Through the collaborative work of the high-definition industrial camera and the infrared thermal imager, surface defects (such as cracks and wear) are captured, and the grate's fit status (such as not being reset) is determined through temperature distribution, achieving all-round detection. The positioning camera, in conjunction with the shaft number plate, accurately associates defects with the grate position, facilitating quick fault location by maintenance personnel. The image acquisition module receives the raw data from the image acquisition module, and the image preprocessing module performs image cropping (preserving the grate area) and geometric correction (eliminating shooting angle deviation). The image processing module performs image descaling (simplifying data) and image denoising (removing noise caused by dust and light interference) and image enhancement (highlighting the edge contours of features such as cracks and wear) to lay the foundation for subsequent recognition. The model building and training module uses a large number of annotated images of cracked grates (including samples under different lighting and dust conditions) to train a convolutional neural network, enabling it to learn the morphological features of cracks. The real-time detection and judgment module inputs the processed real-time images into the trained model, which quickly outputs a judgment result of "crack present" or "no crack," and annotates the location and shape of the crack. The recording module stores the crack recognition results (including location, size, and time) and infrared temperature data in the database. The display module performs statistical analysis on the data, generates reports such as defect incidence rate and deterioration trend, and displays them on a large screen for easy visualization, allowing maintenance personnel to formulate targeted maintenance plans based on the reports.

[0040] Specifically, such as Figure 4 , Figure 5 As shown, the protective mechanism 5 includes a heat-insulating protective shell 51. A miniature air compression structure 52 is bolted to the top of the inner wall of the heat-insulating protective shell 51. The bottom of the miniature air compression structure 52 is connected to a first air supply pipe 53. The bottom of the first air supply pipe 53 is connected to a first jet ring 54. The bottom of the first jet ring 54 is connected to a connecting pipe 55. The bottom of the connecting pipe 55 is connected to a purge member 56. The purge member 56 is located behind the lens of the high-definition industrial camera. The first jet ring 54 is fitted onto the surface of the high-definition industrial camera.

[0041] Specifically, such as Figure 4As shown, each of the two heat-insulating protective shells 51 on both sides is provided with an integral cavity protective shell, and the infrared thermal imager is located inside the cavity protective shell. A connecting plate 6 is slidably arranged inside the cavity protective shell, and the bottom of the connecting plate 6 is bolted to the infrared thermal imager. Guide rods 7 and threaded screws 8 are respectively threaded through both sides inside the connecting plate 6. A temperature sensor 9 is bolted to the top of the inner wall of the cavity protective shell.

[0042] In this embodiment: by setting up a protective mechanism 5, the heat-insulating protective shell 51 isolates external high temperatures and protects the high-definition industrial camera, while the miniature air compression structure 52 generates compressed air, which is sent to the first jet ring 54 and the purging component 56 through the first air supply pipe 53, continuously blowing the camera surface and lens from back to front to prevent dust adhesion. The combination of the heat-insulating protective shell 51 and compressed air purging effectively copes with high temperature and dust pollution, extends the camera's service life, solves the problem of frequent failures of existing equipment due to harsh environments, and ensures clear image capture by purging the lens, avoiding missed detections caused by dust obstruction. This ensures the stability of detection accuracy. The cavity protective shell provides basic protection for the infrared thermal imager, while the temperature sensor 9 monitors the temperature inside the shell. When the temperature exceeds the threshold, the external drive device (such as a motor) drives the lead screw 8 to rotate and drives the connecting plate 6 to retract the infrared thermal imager into the inner side of the shell (away from the high temperature area) along the guide rod 7. After the temperature recovers, the lead screw 8 rotates in the opposite direction to extend the thermal imager and continue to collect data. Through the retractable design combined with the temperature sensor 9, the infrared thermal imager can automatically avoid damage in high temperature environments, solving the performance degradation problem caused by continuous high temperature in traditional equipment.

[0043] Specifically, such as Figure 4 As shown, the right side of the miniature air compression structure 52 is connected to a second air supply pipe 10, and the other end of the second air supply pipe 10 is connected to a second jet ring 11. The second jet ring 11 is located inside the cavity protective shell, and the second jet ring 11 is used in conjunction with an infrared thermal imager.

[0044] In this embodiment: a portion of the compressed air generated by the micro air compression structure 52 is sent to the second jet ring 11 through the second air supply pipe 10 to blow away the surface of the infrared thermal imager inside the cavity protective shell, remove the attached dust, and achieve the effect of cooling and protecting the infrared thermal imager.

[0045] Working principle: When the main body 1 of the chain grate machine is running, a high-definition industrial camera captures images of the grate surface at a set frequency (e.g., 10 times per second) to capture surface defects such as cracks, wear, and deformation. Simultaneously, an infrared thermal imager acquires a pseudo-color image of the temperature field distribution of the grate, using temperature differences to determine if the grate has not been reset (unreset areas experience localized high temperatures due to abnormal heat dissipation). At the same time, a positioning camera adjacent to the small shaft at the machine head aligns with the shaft head and number plate via an adjustable bracket, acquiring position information to achieve precise correlation between defects and specific grate sections. While the high-definition industrial camera and infrared thermal imager are operating, the heat-insulating protective shell 51 and the cavity protective shell isolate the high internal temperature of the main body 1 of the chain grate machine, protecting the camera and thermal imager. The compressed air generated by the miniature air compression structure 52 is sent to the first jet ring 54 and the purging component 56 via the first air supply pipe 53, continuously purging the surface and lens of the high-definition industrial camera to prevent dust adhesion. Part of the compressed air is also supplied to the second jet ring 11 via the second air supply pipe 10 to purge the infrared thermal imager, preventing high-temperature damage. Simultaneously, the temperature sensor 9 inside the cavity protective shell monitors the ambient temperature in real time. When the temperature exceeds a threshold (e.g., 80℃), the external drive motor drives the lead screw 8 and the connecting plate 6, causing the infrared thermal imager to retract into the shell to avoid high temperatures. Once the temperature recovers, it extends again to continue working. (High-definition industrial camera, infrared thermal imager, positioning...) Image data captured by the camera is aggregated by a field switch and remotely transmitted to the central control module via a fiber optic transceiver array (first fiber optic transceiver → fiber optic → second fiber optic transceiver). This ensures stable and low-latency data transmission to the image processing layer. The image preprocessing module performs cropping (preserving the grate area), geometric correction (eliminating shooting angle deviations through four corner control points), and grayscale processing on the original image to simplify the data volume. The image noise reduction module uses filtering algorithms to remove noise caused by dust and uneven lighting, improving image clarity. The image enhancement module uses edge detection algorithms (such as the Sobel operator) to highlight the contour features of defects such as cracks and wear, providing clear feature basis for subsequent identification. The processed image is then input into a pre-trained convolutional neural network model in the crack recognition layer (the model is trained with a large number of labeled samples and can identify cracks of different shapes). The model identifies and determines whether there are cracks in the grate. At the same time, the status monitoring and alarm module analyzes and judges abnormal conditions such as missing or unreset grate. The recording module of the data recording layer stores defect information (type, location, time), temperature data, and shaft number association information into a database (such as MySQL) to form a full life cycle file of the grate. The display module performs statistical analysis on the stored data and generates reports such as defect incidence rate and deterioration trend, which are then visualized on a large screen to provide a basis for maintenance decisions.When the status monitoring and alarm module determines that the grate has abnormalities such as cracks, failure to reset, or missing parts, it immediately triggers multi-level alarms: on-site audible and visual alarms (flashing warning lights and sounding alarm), SMS notifications and emails to maintenance personnel, and simultaneous push of abnormal images and location information. Maintenance personnel, based on the precise location provided by the system (such as the shaft number) and the defect image, quickly locate the abnormal grate and perform repairs. Repair records are fed back to the database, forming a closed-loop management system.

[0046] The above are merely preferred embodiments of the present utility model and are not intended to limit the present utility model. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A chain grate machine grate inspection system, comprising a chain grate machine body (1), a grate body (2), and a chain grate machine grate quality inspection system, characterized in that: The main body of the grate plate (2) is set inside the main body of the chain grate machine (1). The front end and the middle part of the main body of the chain grate machine (1) are respectively bolted with a front support (3) and a rear support (4). Several protective mechanisms (5) are bolted to the inner side of the front support (3) and the rear support (4). The chain grate machine grate quality inspection system includes a central control module. The input end of the central control module is electrically connected to a data transmission module, and the input end of the data transmission module is electrically connected to an image acquisition module. The output end of the central control module is electrically connected to an image processing layer, and the output end of the image processing layer is electrically connected to a crack recognition layer. The output end of the crack recognition layer is electrically connected to a data recording layer and a status monitoring and alarm module.

2. The chain grate machine grate detection system according to claim 1, characterized in that: The image acquisition module includes a high-definition industrial camera, an infrared thermal imager, and a positioning camera. The high-definition industrial camera is located inside the protective mechanism (5), the infrared thermal imager is located inside the protective mechanisms (5) on both sides of the rear, and the positioning camera is installed on the side of the small shaft of the main body (1) of the chain grate machine via an adjustable bracket, and the height of the camera lens is adapted to the height of the small shaft head and the license plate below it.

3. The chain grate machine grate detection system according to claim 1, characterized in that: The image processing layer includes an image acquisition module, an image preprocessing module, an image noise reduction module, and an image enhancement module.

4. The chain grate machine grate detection system according to claim 1, characterized in that: The crack identification layer includes a model building and training module and a real-time detection and judgment module.

5. The chain grate machine grate detection system according to claim 1, characterized in that: The data recording layer includes a recording module and a display module.

6. The chain grate machine grate detection system according to claim 2, characterized in that: The protective mechanism (5) includes a heat-insulating protective shell (51). A miniature air compression structure (52) is bolted to the top of the inner wall of the heat-insulating protective shell (51). The bottom of the miniature air compression structure (52) is connected to a first air supply pipe (53). The bottom of the first air supply pipe (53) is connected to a first jet ring (54). The bottom of the first jet ring (54) is connected to a connecting pipe (55). The bottom of the connecting pipe (55) is connected to a purge component (56). The purge component (56) is located behind the lens of the high-definition industrial camera. The first jet ring (54) is fitted onto the surface of the high-definition industrial camera.

7. The chain grate machine grate detection system according to claim 6, characterized in that: Two heat-insulating protective shells (51) on the rear sides are each provided with an integral cavity protective shell on their opposite sides, and the infrared thermal imager is located inside the cavity protective shell. A connecting plate (6) is slidably arranged inside the cavity protective shell, and the bottom of the connecting plate (6) is bolted to the infrared thermal imager. Guide rods (7) and threaded screws (8) are respectively passed through the two sides inside the connecting plate (6). A temperature sensor (9) is bolted to the top of the inner wall of the cavity protective shell.

8. The chain grate machine grate detection system according to claim 7, characterized in that: The right side of the micro air compression structure (52) is connected to a second air supply pipe (10), and the other end of the second air supply pipe (10) is connected to a second jet ring (11). The second jet ring (11) is located inside the cavity protective shell, and the second jet ring (11) is used in conjunction with an infrared thermal imager.

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