Heat control system and method for a mesh belt furnace for ceramic sintering.

Abstract

This invention relates to a heat quantity control system and method for a mesh belt furnace for ceramic sintering, in the field of smart control technology. [Solution] The system includes a control terminal, a monitoring layer, an instruction layer, and an adjustment layer. The control terminal is the main control end of the system and issues execution commands. The monitoring layer extracts a contour image of the sintered ceramic from the simultaneously acquired image data of the mesh belt furnace sintered ceramic, divides and stores the image data of the mesh belt furnace sintered ceramic based on the contour image of the sintered ceramic, and the instruction layer further receives the divided image data of the mesh belt furnace sintered ceramic stored in the monitoring layer. The present invention improves the yield and control of costs of mesh belt furnace sintered ceramic by individually controlling the burners in the mesh belt furnace, and effectively improves the intelligence of the mesh belt furnace sintered ceramic during its operation.

Description

[Technical Field]

[0001] The present invention relates to the field of smart control, and more specifically to a heat quantity control system and method for a mesh belt furnace for ceramic sintering. [Background technology]

[0002] A mesh belt furnace is a common piece of equipment for sintering ceramics. It uses a mesh belt to transport the ceramic material at a constant speed, passing it through a preset high-temperature range to achieve uniform heating and sintering. Its advantages are clear: precise temperature control is possible, ensuring stable ceramic properties, and high production efficiency. It is applicable to the mass production of various ceramic products and is widely used in the ceramic processing field.

[0003] Chinese Patent Application No. 202310688592.X discloses a temperature control system for a semiconductor ceramic sintering furnace. This system includes an infrared camera, an image processing module, a data processing module, a temperature control module, a power control module, an execution module, an electric heating module, and a cooling module, wherein the infrared camera is positioned around the inside of each layer of the ceramic sintering furnace and is used to acquire ceramic video in real time and transmit it to the image processing module.

[0004] The infrared camera is further configured to acquire temperature values ​​in real time and transmit the acquired temperature values ​​to a data processing module. The image processing module is configured to perform frame division processing on the ceramic video acquired in real time, acquire the gradation value of the image pixel point Sij of each frame, label it as PSij, and transmit it to the data processing module. The data processing module performs difference value processing on the PSij between adjacent pixel points Sij, acquires the value R, sets the threshold limit value to K, analyzes and compares the threshold R and K, stores the pixel points Sij for which the threshold R is greater than K, performs fitting on the stored pixel points Sij, and if the fitting figure consists of one or more intersecting curves and the curves appear in the same image of multiple consecutive frames, it is determined that a crack exists in the ceramic, and the data processing module is configured to transmit an image anomaly signal to the temperature control module. The data processing module performs mean and mean squared error processing on the PSii, comprehensively analyzes it to obtain the image brightness value L, sets the image brightness standard value to H, and analyzes the image brightness value by comparing it with the reference value. If the image brightness value L ≠ H, the image brightness does not meet the standard, and the data processing module transmits an image anomaly signal to the temperature control module. The data processing module is further configured to process the temperature values ​​acquired in real time to obtain the temperature value TS of the ceramic sintering furnace for each layer, and transmit the temperature value TS to the temperature control module. The temperature control module is configured to perform decision-making and analysis processing of the temperature value TS in response to the image anomaly signal transmitted from the data processing module. A predetermined temperature range QS is set for the ceramic sintering furnace for each layer, and the temperature value TS and the predetermined temperature range QS are compared and analyzed.

[0005] The purpose of the above-mentioned prior art is to solve the problem that "at present, methods such as thermocouples and radiation thermometers are commonly used to detect the temperature of ceramic sintering furnaces. However, thermocouples are contact-type temperature measuring devices and can only measure temperature at a single point, and radiation thermometers can only reflect the projected temperature of the flame. Therefore, conventional technology does not allow for sufficiently accurate temperature detection inside the ceramic furnace, and the temperature cannot be controlled in real time."

[0006] However, in the case of ceramics sintered in a fuel gas heated mesh belt furnace, there is no independent control function for each burner in the mesh belt furnace. As a result, there are inevitably defective products among the ceramics sintered in a fuel gas heated mesh belt furnace, which affects the acceptance rate and cost of sintered products produced by this method.

[0007] Therefore, we provide a heat quantity control system for a mesh belt furnace used for ceramic sintering. [Overview of the project]

[0008] In response to the aforementioned drawbacks of the prior art, the present invention provides a heat quantity control system and method for a mesh belt furnace for ceramic sintering, thereby solving the technical problems described in the background art above.

[0009] To achieve the above objectives, the present invention employs the following technical means.

[0010] In the first embodiment, a heat quantity control system for a ceramic sintering mesh belt furnace includes a control terminal, a monitoring layer, an indicator layer, and an adjustment layer, The control terminal is the main control terminal of the system and is used to issue execution commands. Image data of the sintered ceramic in the mesh belt furnace is collected by the monitoring layer, the monitoring layer extracts a contour image of the sintered ceramic from the collected image data, divides and stores the image data of the sintered ceramic based on the contour image, the indicator layer receives the divided image data of the sintered ceramic stored in the monitoring layer, analyzes the sintering heat distribution of the sintered ceramic based on the divided image data, associates the corresponding burner to be controlled based on the ceramic sintering heat distribution, the adjustment layer receives the burner to be controlled, controls the burner to be controlled and performs temperature adjustment in the mesh belt furnace. The indicator layer includes a receiving module, an analysis module, and a matching module. The receiving module is used to receive image data of the divided mesh belt furnace sintered ceramic stored in the monitoring layer. The analysis module is used to traverse the image data of the divided mesh belt furnace sintered ceramic and analyze the thermal distribution state of the sintered ceramic in the image data. The matching module receives the analysis results of the thermal distribution state of the sintered ceramic in the analysis module and is used to associate the burner to be controlled based on the analysis results. The analysis logic for the thermal distribution state of sintered ceramics in the aforementioned analysis module is expressed by the following equation:

number

[0011] Furthermore, the monitoring layer includes a camera module, an extraction module, and a splitting module. The camera module is used to acquire image data of the mesh belt furnace sintered ceramic. The extraction module receives the image data of the mesh belt furnace sintered ceramic acquired by the camera module and is used to extract a contour image of the sintered ceramic from the image data. The splitting module receives the image data of the mesh belt furnace sintered ceramic acquired by the camera module and the contour image of the sintered ceramic extracted by the extraction module. It uses the contour of the sintered ceramic in the contour image as a splitting path and performs a splitting process on the image data of the mesh belt furnace sintered ceramic to acquire local image data of the mesh belt furnace sintered ceramic corresponding to the position of the contour image of the sintered ceramic, and is used to store the image data of the local mesh belt furnace sintered ceramic. The mesh belt furnace is a fuel gas heated mesh belt furnace, and the burners on the top surface of the mesh belt furnace are uniformly distributed in an array, and the burners uniformly distributed in an array on the top surface of the mesh belt furnace are parallel to the surface of the conveyor belt of the mesh belt furnace, and a coordinate axis grid is set for the image data of the sintered ceramic inside the mesh belt furnace that is acquired by the camera module, and the coordinate axis grid is a two-dimensional coordinate axis grid, and the position of each group of burners on the top surface of the mesh belt furnace in the coordinate axis grid is known in a plan view, and the acquisition viewpoint when the camera module acquires image data of the sintered ceramic inside the mesh belt furnace is a plan view (overhead view).

[0012] Furthermore, during the operation phase of the mesh extraction module, after receiving image data of the mesh belt in-furnace sintered ceramic, contour pixels in the image data of the mesh belt in-furnace sintered ceramic are identified based on contour pixel identification logic, and a contour image of the sintered ceramic is constructed based on the contour pixels in the image data of the mesh belt in-furnace sintered ceramic. The contour pixel recognition logic for the image data of the mesh belt furnace-sintered ceramic is expressed by the following equation:

Number

[0013] Furthermore, each ceramic contour in the contour image of the sintered ceramic is a closed contour. After the contour image of the sintered ceramic is extracted by the extraction module, it is fed back to the segmentation module. The segmentation module operates to divide the image data of the sintered ceramic in the mesh belt furnace based on the contour image of the sintered ceramic, obtain the image data of the sintered ceramic in the local mesh belt furnace, and then further identify the burner distributed in the capture area by combining the image data of the sintered ceramic in the local mesh belt furnace as the capture area with the coordinate axis grid.

[0014] Furthermore, the divided image data of the sintered ceramic in the mesh belt furnace is the image data of the sintered ceramic in the local mesh belt furnace. The receiving module does not receive a unique image data of the divided mesh belt furnace sintered ceramics. The analysis module operates to receive one group of image data of the divided mesh belt furnace sintered ceramics each time. It then maps the coordinates of the burners distributed within the capture area in a plan view to the image data of the divided mesh belt furnace sintered ceramics, sets the burner's heat dissipation radius, draws a circle using the mapping coordinates of each group as the center and the burner's heat dissipation radius as the circle drawing radius, and the area in the image data of the divided mesh belt furnace sintered ceramics corresponding to the circle is the target area for performing the heat distribution state analysis of the sintered ceramics. Based on the analysis logic, the analysis is performed on the target area.

[0015] Furthermore, the average surface temperature T of the sintered ceramic s The formula for this calculation is:

number

[0016] Furthermore, the adjustment layer includes a logic module, a control module, and an identification module. The logic module receives the burner to be controlled that is matched in the instruction layer and is used to set the control logic of the burner to be controlled. The control module receives the control logic of the burner to be controlled set by the logic module and is used to control the operation of the burner to be controlled based on the control logic of the burner to be controlled. The identification module controls the re-operation of the camera module, and based on the image data of the sintered ceramic in the mesh belt furnace collected by the re-operation of the camera module, compares it with the image data of the sintered ceramic in the mesh belt furnace collected before controlling the burner to be controlled, identifies the difference between the two groups of image data, and controls the re-operation of the system based on the difference identification result. Here, the identification module monitors the operating state of the control module in the operating stage. After the operation of the control module ends, it executes an operation to control the re-operation of the camera module. When the identification module is controlling the operation of the camera module, the camera module continuously operates based on the operating frequency customized by the system-side user to continuously collect the image data of the sintered ceramic in the current mesh belt furnace, and compares the difference with the image data of the sintered ceramic in the mesh belt furnace collected before adjusting the burner to be controlled according to the following formula.

Number

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number

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[0017] Furthermore, the control logic for the burner to be controlled, as set in the logic module, is as follows: Corresponds to the burner being controlled. The image data of the divided mesh belt furnace sintered ceramic is reflected in the T s The reference temperature for ceramic sintering is acquired and stored in the logic module, and the reference temperature and T s Compare the reference temperature T s If the reference temperature is higher than T, the valve opening of the burner being controlled will be widened and the damper opening will be widened, and the reference temperature will be T s If it is lower than this, the valve opening of the burner being controlled is narrowed, and the damper opening is narrowed. Here, the damper of the burner to be controlled is adjusted in priority to the valve, and during the adjustment process of the damper and valve of the burner to be controlled, the adjustment speed is kept constant, and the adjustment is terminated when the limit is reached.

[0018] Furthermore, the receiving module is interactively connected to the analysis module and the matching module via a wireless network, the receiving module is interactively connected to the division module via a wireless network, the division module is interactively connected to the extraction module and the camera module via a wireless network, the matching module is interactively connected to the logic module via a wireless network, and the logic module is interactively connected to the control module and the identification module via a wireless network.

[0019] In a second embodiment, a method for controlling the heat quantity of a mesh belt furnace for ceramic sintering is provided. The method is as follows: The steps include: acquiring image data of the mesh belt furnace-sintered ceramic, setting up contour image extraction logic, and extracting the contour image of the sintered ceramic from the image data of the mesh belt furnace-sintered ceramic based on the contour image extraction logic; The steps include: using the contour image of the sintered ceramic as a segmentation path, segmenting it within the image data of the mesh belt furnace sintered ceramic to acquire and store local mesh belt furnace sintered ceramic image data; The steps include acquiring stored image data of the local mesh belt furnace sintered ceramics and analyzing the thermal distribution state of the sintered ceramics in the image data of each group, The steps include setting grid coordinates on image data of sintered ceramics in a mesh belt furnace, identifying burners corresponding to each group of sintered ceramics based on the grid coordinates, and matching the burner group to be controlled by combining this with the results of the thermal distribution state analysis of the sintered ceramics in the image data, The steps include selecting burner-corresponding regions in image data of locally mesh belt furnace-sintered ceramics, and analyzing whether the regional temperature of each selected region satisfies the ceramic sintering reference temperature, The steps include: identifying burners in the group of burners to be controlled that do not meet the ceramic sintering reference temperature, setting control logic, and adjusting the identified burners based on the control logic; Includes.

[0020] The technical means of the present invention have the following beneficial effects compared to known prior art. The present invention provides a heat quantity control system and method for a mesh belt furnace for ceramic sintering. This system collects image data of the sintered ceramic inside the mesh belt furnace during operation, extracts contour images of the sintered ceramic, divides the image data of the sintered ceramic inside the mesh belt furnace based on the extracted contour images, sets a coordinate axis grid, identifies burners in the mesh belt furnace that correspond one-to-one with the divided images, analyzes the regions in the divided images that correspond one-to-one with the burners to determine which burners need to be controlled independently, and then independently controls the determined burners as control targets, thereby improving the yield and cost control of the mesh belt furnace sintered ceramic. Furthermore, by controlling the mesh belt furnace in this manner, the intelligence of the mesh belt furnace sintered ceramic during operation is effectively improved. Furthermore, during the execution of this method, the system is provided with additional operational logic support, ensuring stable system operation and bringing effective, real-time smart control to ceramic sintering using a mesh belt furnace. [Brief explanation of the drawing]

[0021] To more clearly illustrate embodiments of the present invention or technical concepts in the prior art, the drawings used in the description of embodiments or the prior art will be briefly described below. Clearly, the drawings in the following description are only a few embodiments of the present invention, and those skilled in the art can obtain other drawings based on these without any creative effort.

[0022] [Figure 1] This is a schematic diagram of the heat control system for a mesh belt furnace used in ceramic sintering. [Figure 2] This is a flowchart illustrating the heat quantity control method for a mesh belt furnace used in ceramic sintering. [Figure 3] This is a schematic diagram of the local structure of the mesh belt furnace according to the present invention. [Figure 4] This is a schematic diagram of the decision-making process for the final control of the burner in the present invention.

[0023] Explanation of the symbols 1. Top surface of the mesh belt furnace sintering chamber; 2. Burner; 3. Conveyor station of the mesh belt furnace; 4. Example of sintered ceramic; 5. Target area for performing thermal distribution state analysis of sintered ceramic. [Modes for carrying out the invention]

[0024] To further clarify the purpose, technical proposal, and advantages of the embodiments of the present invention, the technical proposal in the embodiments of the present invention will be described clearly and completely below with reference to the drawings of the embodiments. Clearly, the embodiments described are only some embodiments of the present invention, not all embodiments. All other embodiments obtained by those skilled in the art without creative work based on the embodiments of the present invention are within the scope of protection of the present invention.

[0025] The present invention will be further described below with reference to examples.

[0026] Example 1 This embodiment provides a heat quantity control system for a mesh belt furnace for ceramic sintering. As shown in Figure 1, the system includes a control terminal, a monitoring layer, an indicator layer, and an adjustment layer.

[0027] The control terminal is the main control terminal of the system and is used to issue execution commands. Image data of the sintered ceramic inside the mesh belt furnace is collected by the monitoring layer, which extracts a contour image of the sintered ceramic from the collected image data, divides and stores the image data of the sintered ceramic based on the contour image, the indicator layer receives the divided image data of the sintered ceramic stored in the monitoring layer, analyzes the sintering heat distribution of the sintered ceramic based on the divided image data, associates the corresponding burner to be controlled based on the ceramic sintering heat distribution, the adjustment layer receives the burner to be controlled, and controls the burner to perform temperature adjustment inside the mesh belt furnace.

[0028] The monitoring layer includes a camera module, an extraction module, and a splitting module. The camera module is used to acquire image data of the mesh belt furnace sintered ceramic. The extraction module receives the image data of the mesh belt furnace sintered ceramic acquired by the camera module and is used to extract a contour image of the sintered ceramic from the image data. The splitting module receives the image data of the mesh belt furnace sintered ceramic acquired by the camera module and the contour image of the sintered ceramic extracted by the extraction module. The splitting module uses the contour of the sintered ceramic in the contour image as a splitting path and performs a splitting process on the image data of the mesh belt furnace sintered ceramic to acquire local image data of the mesh belt furnace sintered ceramic corresponding to the position of the contour image of the sintered ceramic, and is used to store the image data of the local mesh belt furnace sintered ceramic. The mesh belt furnace is a fuel gas heated mesh belt furnace, and the burners on the top surface of the mesh belt furnace are uniformly distributed in an array, and the burners uniformly distributed in an array on the top surface of the mesh belt furnace are parallel to the surface of the conveyor belt of the mesh belt furnace, and a coordinate axis grid is set for the image data of the sintered ceramic inside the mesh belt furnace that is acquired by the camera module, and the coordinate axis grid is a two-dimensional coordinate axis grid, and the position of each group of burners on the top surface of the mesh belt furnace in the coordinate axis grid is known in a plan view, and the acquisition viewpoint when the camera module acquires image data of the sintered ceramic inside the mesh belt furnace is a plan view (overhead view).

[0029] During the operation phase of the mesh extraction module, after receiving image data of the mesh belt in-furnace sintered ceramic, contour pixels in the image data of the mesh belt in-furnace sintered ceramic are identified based on contour pixel identification logic, and a contour image of the sintered ceramic is constructed based on the contour pixels in the image data of the mesh belt in-furnace sintered ceramic. The contour pixel recognition logic for the image data of the mesh belt furnace-sintered ceramic is expressed by the following equation:

number

[0030] The indicator layer includes a receiving module, an analysis module, and a matching module. The receiving module is used to receive image data of the divided mesh belt furnace sintered ceramic stored in the monitoring layer. The analysis module is used to traverse the image data of the divided mesh belt furnace sintered ceramic and analyze the thermal distribution state of the sintered ceramic in the image data. The matching module receives the analysis results of the thermal distribution state of the sintered ceramic in the analysis module and is used to associate the burner to be controlled based on the analysis results. The analysis logic for the thermal distribution state of sintered ceramics in the aforementioned analysis module is expressed by the following equation:

number

[0031] Average surface temperature T of sintered ceramics s The formula for this calculation is:

number

[0032] The adjustment layer includes a logic module, a control module, and an identification module. The logic module receives the burner to be controlled that has been matched in the instruction layer and is used to set the control logic for the burner to be controlled. The control module receives the control logic for the burner to be controlled that has been set in the logic module and is used to control the operation of the burner to be controlled based on the control logic for the burner to be controlled. The identification module controls the re-operation of the camera module and, based on the image data of the mesh belt furnace sintered ceramic taken by the re-operation of the camera module, compares it with the image data of the mesh belt furnace sintered ceramic taken before controlling the burner to be controlled, identifies the difference between the two groups of image data, and triggers a re-operation of the system based on the difference identification result. In essence, "re-operation" here means returning the system to the initial operating stage that is suited to the current state of the sintered ceramic and executing the entire process of heat quantity control operation anew to correct any deviations that may have existed in the previous adjustment and ensure the yield of the sintered ceramic. Here, the identification module monitors the operating status of the control module during the operation phase, and after the control module has finished operating, it performs an operation to control the restart of the camera module. While the identification module is controlling the operation of the camera module, the camera module operates continuously based on an operating frequency customized by the system user to continuously acquire image data of the mesh belt furnace sintered ceramic, and compares the differences between the continuously acquired image data of the mesh belt furnace sintered ceramic and the image data of the mesh belt furnace sintered ceramic acquired before adjusting the burner to be controlled using the following formula.

number

number

number

number

number

[0033] The control logic for the burner to be controlled, as set in the logic module, is as follows: Corresponds to the burner being controlled. The image data of the divided mesh belt furnace sintered ceramic is reflected in the T s The reference temperature for ceramic sintering is acquired and stored in the logic module, and the reference temperature and T s Compare the reference temperature T s If the reference temperature is higher than T, the valve opening of the burner being controlled will be widened and the damper opening will be widened, and the reference temperature will be T s If it is lower than this, the valve opening of the burner being controlled is narrowed, and the damper opening is narrowed. Here, the damper of the burner to be controlled is adjusted in priority to the valve, and during the adjustment process of the damper and valve of the burner to be controlled, the adjustment speed is kept constant, and the adjustment is terminated when the limit is reached.

[0034] The receiving module is interactively connected to the analysis module and matching module via a wireless network, the receiving module is interactively connected to the division module via a wireless network, the division module is interactively connected to the extraction module and camera module via a wireless network, the matching module is interactively connected to the logic module via a wireless network, and the logic module is interactively connected to the control module and identification module via a wireless network.

[0035] In this embodiment, the camera module operates to collect image data of the mesh belt furnace sintered ceramic, the extraction module operates in a subsequent stage to receive the image data of the mesh belt furnace sintered ceramic collected by the camera module, extracts a contour image of the sintered ceramic from the mesh belt furnace sintered ceramic image data, the division module further receives the image data of the mesh belt furnace sintered ceramic collected by the camera module and the contour image of the sintered ceramic extracted by the extraction module, uses the contour of the sintered ceramic in the contour image of the sintered ceramic as a division path, performs division processing on the image data of the mesh belt furnace sintered ceramic, obtains local mesh belt furnace sintered ceramic image data at the position corresponding to the contour image of the sintered ceramic, stores the image data of the local mesh belt furnace sintered ceramic, the receiving module operates to receive the divided mesh belt furnace sintered ceramic image data stored in the monitoring layer, and further the division of the mesh by the analysis module The system traverses image data of the belt furnace sintered ceramic, analyzes the thermal distribution of the sintered ceramic in the image data, a matching module operates in the subsequent stage to receive the analysis results of the thermal distribution of the sintered ceramic in the analysis module, associates the target burner based on the analysis results, and finally the logic module receives the matched target burner in the indicator layer, sets the control logic for the target burner, the control module receives the control logic for the target burner set in the logic module, controls the operation of the target burner based on the control logic for the target burner, the identification module controls the restart of the camera module, and based on the image data of the mesh belt furnace sintered ceramic taken by the restart of the camera module, compares it with the image data of the mesh belt furnace sintered ceramic taken before controlling the target burner, identifies the differences between the two groups of image data, and triggers a system restart based on the difference identification result. The operation of the system in the above embodiment enables smart control effects in the ceramic sintering process in a fuel-gas heated net-belt furnace. This makes it possible to individually control each burner in the furnace, and based on this control, the state of the ceramic being sintered in the furnace is analyzed and the temperature is automatically and adaptively adjusted, thereby guaranteeing the yield of ceramic sintering in a fuel-gas heated net-belt furnace and reducing the overall cost of firing.

[0036] Referring to Figure 3, the top surface 1 of the sintering chamber of the mesh belt furnace, the burner 2, the mesh belt furnace transport station 3, and the example of sintered ceramic 4 are shown according to the reference numerals in Figure 3, and further examples of the application of the system in the above embodiment are illustrated.

[0037] Referring to Figure 4, the target region 5 for performing the thermal distribution state analysis of the sintered ceramic is indicated based on the symbols in the figure. Based on the arrows in the figure, it is shown as follows: The arrow pointing upwards indicates target region 5, where the thermal distribution state analysis of the sintered ceramic is to be performed. The arrows pointing to the lower right and lower left indicate areas corresponding to the burners that the system has identified and is controlling, and are displayed with shading. The downward arrow indicates the burner itself that has been identified and controlled by the system.

[0038] Example 2 In concrete implementation, this embodiment further describes the heat quantity control system for the ceramic sintering mesh belt furnace according to Embodiment 1, as shown in Figure 1. Each ceramic contour in the aforementioned sintered ceramic contour image is a closed contour. After the contour image of the sintered ceramic is extracted by the extraction module, it is fed back to the division module, which operates to divide the image data of the mesh belt furnace sintered ceramic based on the contour image of the sintered ceramic, and after obtaining image data of the local mesh belt furnace sintered ceramic, it further combines the image data of the local mesh belt furnace sintered ceramic as a capture region with a coordinate axis grid to identify the burners distributed within the capture region.

[0039] With the above configuration, the system can associate the sintered ceramic with the burner in the furnace based on a set coordinate axis network during operation. This allows the system to instantly determine corresponding objects based on the correspondence between the sintered ceramic image and the burner.

[0040] The image data of the divided mesh belt furnace sintered ceramic is image data of the local mesh belt furnace sintered ceramic. The receiving module does not receive a unique image data of the divided mesh belt furnace sintered ceramics. The analysis module operates to receive one group of image data of the divided mesh belt furnace sintered ceramics each time. It then maps the coordinates of the burners distributed within the capture area in a plan view to the image data of the divided mesh belt furnace sintered ceramics, sets the burner's heat dissipation radius, draws a circle using the mapping coordinates of each group as the center and the burner's heat dissipation radius as the circle drawing radius, and the area in the image data of the divided mesh belt furnace sintered ceramics corresponding to the circle is the target area for performing the heat distribution state analysis of the sintered ceramics. Based on the analysis logic, the analysis is performed on the target area.

[0041] In this embodiment, the above configuration provides further operational data support to the system according to Embodiment 1, ensuring stable operation of the system of Embodiment 1. Furthermore, based on the above, the source code and specific logic of "Target Region 5 for performing state analysis of sintered ceramic heat distribution" are described in more detail.

[0042] Example 3: In concrete implementation, this embodiment further explains the heat quantity control method for the ceramic sintering mesh belt furnace according to Embodiment 1, as shown in Figure 2. The method for controlling the heat output of a mesh belt furnace for ceramic sintering is: The steps include: acquiring image data of the mesh belt furnace-sintered ceramic, setting up contour image extraction logic, and extracting the contour image of the sintered ceramic from the image data of the mesh belt furnace-sintered ceramic based on the contour image extraction logic; The steps include: using the contour image of the sintered ceramic as a segmentation path, segmenting it within the image data of the mesh belt furnace sintered ceramic to acquire and store local mesh belt furnace sintered ceramic image data; The steps include acquiring stored image data of the local mesh belt furnace sintered ceramics and analyzing the thermal distribution state of the sintered ceramics in the image data of each group, The process involves setting grid coordinates on image data of sintered ceramics in a mesh belt furnace, identifying the burner corresponding to each group of sintered ceramics based on the grid coordinates, and matching (identifying) the group of burners to be controlled by combining this with the results of the thermal distribution state analysis of the sintered ceramics in the image data. The steps include selecting burner-corresponding regions in image data of locally mesh belt furnace-sintered ceramics, and analyzing whether the regional temperature of each selected region satisfies the ceramic sintering reference temperature, The steps include: identifying burners in the group of burners to be controlled that do not meet the ceramic sintering reference temperature, setting control logic, and adjusting the identified burners based on the control logic; Includes.

[0043] In summary, in the above embodiment, the system collects image data of the sintered ceramic in the mesh belt furnace during operation, extracts contour images of the sintered ceramic, divides the image data of the sintered ceramic in the mesh belt furnace based on the extracted contour images, sets a coordinate axis grid, identifies burners in the mesh belt furnace that correspond one-to-one with the divided images, analyzes the regions in the divided images that correspond one-to-one with the burners to determine which burners need to be controlled independently, and then independently controls the determined burners as control targets, thereby improving the yield and cost control of the mesh belt furnace sintered ceramic. Furthermore, by controlling the mesh belt furnace in this way, the intelligence of the mesh belt furnace sintered ceramic during operation is effectively improved. In addition, during the execution of this method, the system is provided with further operational logic support, ensuring stable operation of the system and bringing effective and real-time smart control to ceramic sintering by the mesh belt furnace.

[0044] The above embodiments are merely for illustrating the technical concepts of the present invention and are not intended to limit them. While the present invention has been described in detail with reference to the above embodiments, those skilled in the art can still modify the technical concepts described in each of the above embodiments or make equivalent substitutions to some of the technical features therein, and should understand that such modifications or substitutions do not depart from the spirit and scope of the technical concepts of each embodiment of the present invention in any way that the essence of the corresponding technical concepts remains within that spirit and scope.

Claims

1. A heat quantity control system for a ceramic sintering mesh belt furnace, comprising a control terminal, a monitoring layer, an indicator layer, and an adjustment layer, The control terminal is the main control terminal of the system and is used to issue execution commands. Image data of the sintered ceramic in the mesh belt furnace is collected by the monitoring layer, the monitoring layer extracts a contour image of the sintered ceramic from the collected image data, divides and stores the image data of the sintered ceramic based on the contour image, the indicator layer receives the divided image data of the sintered ceramic stored in the monitoring layer, analyzes the sintering heat distribution of the sintered ceramic based on the divided image data, associates the corresponding burner to be controlled based on the ceramic sintering heat distribution, the adjustment layer receives the burner to be controlled, controls the burner to be controlled and performs temperature adjustment in the mesh belt furnace. The indicator layer includes a receiving module, an analysis module, and a matching module. The receiving module is used to receive image data of the divided mesh belt furnace sintered ceramic stored in the monitoring layer. The analysis module is used to traverse the image data of the divided mesh belt furnace sintered ceramic and analyze the thermal distribution state of the sintered ceramic in the image data. The matching module receives the analysis results of the thermal distribution state of the sintered ceramic in the analysis module and is used to associate the burner to be controlled based on the analysis results. The analysis logic for the thermal distribution state of sintered ceramics in the aforementioned analysis module is expressed by the following equation: [Math 1] In the formula, Q is the surface heat of the sintered ceramic, k is the thermal conductivity of the sintered ceramic raw material, A is the total surface area of ​​the sintered ceramic, and T ｓ is the average surface temperature of the sintered ceramic, and T ０ is the reference ambient temperature, α is the thermal diffusivity of the sintered ceramic, t is the time to collect image data for calculating the surface heat Q of the sintered ceramic, and L is the maximum diameter of the top surface of the sintered ceramic. The time t at which image data is acquired to calculate the surface heat Q of the sintered ceramic is 1, and the reference ambient temperature T ０ This is the current ambient temperature inside the mesh belt furnace, and the average surface temperature T of the sintered ceramic. ｓ The system is characterized in that it is determined based on image data of the sintered ceramic in a divided mesh belt furnace, corresponding to the sintered ceramic.

2. The monitoring layer includes a camera module, an extraction module, and a splitting module. The camera module is used to acquire image data of the mesh belt furnace sintered ceramic. The extraction module receives the image data of the mesh belt furnace sintered ceramic acquired by the camera module and is used to extract a contour image of the sintered ceramic from the image data. The splitting module receives the image data of the mesh belt furnace sintered ceramic acquired by the camera module and the contour image of the sintered ceramic extracted by the extraction module. The splitting module uses the contour of the sintered ceramic in the contour image as a splitting path and performs a splitting process on the image data of the mesh belt furnace sintered ceramic to acquire local image data of the mesh belt furnace sintered ceramic corresponding to the position of the contour image of the sintered ceramic, and is used to store the image data of the local mesh belt furnace sintered ceramic. The mesh belt furnace is a fuel gas heated mesh belt furnace, the burners on the top surface of the mesh belt furnace are uniformly distributed in an array, the burners uniformly distributed in an array on the top surface of the mesh belt furnace are parallel to the surface of the conveyor belt of the mesh belt furnace, a coordinate axis grid is set for image data of the sintered ceramic inside the mesh belt furnace acquired by a camera module, the coordinate axis grid is a two-dimensional coordinate axis grid, the positions of each group of burners on the top surface of the mesh belt furnace in the coordinate axis grid are all known in plan view, and the acquisition viewpoint is a plan view when the camera module acquires image data of the sintered ceramic inside the mesh belt furnace, as described in claim 1.

3. During the operation phase of the extraction module, after receiving image data of the mesh belt furnace-sintered ceramic, contour pixels in the image data of the mesh belt furnace-sintered ceramic are identified based on contour pixel identification logic, and a contour image of the sintered ceramic is constructed based on the contour pixels in the image data of the mesh belt furnace-sintered ceramic. The contour pixel recognition logic for the image data of the mesh belt furnace-sintered ceramic is expressed by the following equation: [Math 2] In the formula, P （ｘ，ｙ） is the pixel value of pixel (x, y) in the image data of mesh belt furnace sintered ceramic, x and y are the row and column numbers of pixel (x, y), X is the contour pixel determination value, and P ｎｏｒｒ This is the pixel value of the contour pixel, Here, the pixel value P of the contour pixel. ｎｏｒｒ The system according to claim 2, characterized in that the system is customized by the user on the system side, and when X = 1, the pixel corresponding to the pixel value is a contour pixel, and when X = 1, the pixel corresponding to the pixel value is a non-contour pixel, and based on the above formula, it is determined whether each pixel in the image data of the mesh belt furnace sintered ceramic is a contour pixel and a set of contour pixels in the image data of the mesh belt furnace sintered ceramic is obtained.

4. Each ceramic contour in the aforementioned sintered ceramic contour image is a closed contour. The system according to claim 1, characterized in that, after the contour image of the sintered ceramic is extracted by the extraction module, it is fed back to the division module, the division module operates to divide the image data of the mesh belt furnace sintered ceramic based on the contour image of the sintered ceramic, obtains image data of the local mesh belt furnace sintered ceramic, and then combines the image data of the local mesh belt furnace sintered ceramic as a capture region with a coordinate axis grid to identify burners distributed within the capture region.

5. The image data of the divided mesh belt furnace sintered ceramic is image data of the local mesh belt furnace sintered ceramic. The system according to any one of claims 1 to 4, characterized in that the receiving module receives image data of divided mesh belt furnace sintered ceramics, the analysis module operates to receive image data of one group of divided mesh belt furnace sintered ceramics each time, further maps the coordinates on the coordinate axis grid of burners distributed within the capture area in a plan view to the image data of divided mesh belt furnace sintered ceramics, sets the heat dissipation radius of the burners, draws a circle with the mapping coordinates of each group as the center and the heat dissipation radius of the burners as the circle drawing radius, the area in the image data of divided mesh belt furnace sintered ceramics corresponding to the circle is the target area for performing a heat distribution state analysis of the sintered ceramics, and a heat distribution state analysis is performed on the target area based on the analysis logic.

6. The surface average temperature T of the sintered ceramic ｓ The formula for this calculation is: [Math 3] where m is the total amount of pixels in the image data of the divided mesh belt furnace sintered ceramic corresponding to the sintered ceramic, and h ｊ is the gradation value of the j-th pixel, and r is the ratio of the temperature to the gradation value Here, the ratio r of temperature to grayscale value is a priori known parameter, the matching module is set with a determination threshold for the burner to be controlled, the matching module operates to receive the analysis results of the heat distribution state of each set of sintered ceramic, and determines the analysis results that satisfy the threshold based on a comparison of the analysis results with the determination threshold for the burner to be controlled. The system according to claim 1, characterized in that the burner to be controlled is located in a target region for performing thermal distribution state analysis of sintered ceramics corresponding to analysis results that satisfy a threshold.

7. The adjustment layer includes a logic module, a control module, and an identification module. The logic module receives the burner to be controlled that has been matched in the instruction layer and is used to set the control logic of the burner to be controlled. The control module receives the control logic of the burner to be controlled that has been set in the logic module and is used to control the operation of the burner to be controlled based on the control logic of the burner to be controlled. The identification module controls the re-operation of the camera module and, based on the image data of the mesh belt in-furnace sintered ceramic taken by the re-operation of the camera module, compares it with the image data of the mesh belt in-furnace sintered ceramic taken before controlling the burner to be controlled, identifies the difference between the two groups of image data, and is used to trigger a re-operation of the system based on the difference identification result. Here, the identification module monitors the operating status of the control module during the operation phase, and after the control module has finished operating, it performs an operation to control the restart of the camera module. While the identification module is controlling the operation of the camera module, the camera module operates continuously based on an operating frequency customized by the system user to continuously acquire image data of the mesh belt furnace sintered ceramic, and compares the differences between the continuously acquired image data of the mesh belt furnace sintered ceramic and the image data of the mesh belt furnace sintered ceramic acquired before adjusting the burner to be controlled using the following formula. [Math 4] During the ceremony, [Math 5] This represents the difference between the two sets of images, R ａ , R ｂ These are the values ​​in the R channel of image a and image b, and G ａ G ｂ This is the value in the G channel of image a and image b, and B ａ , B ｂ These are the values ​​in the B channel of image a and image b, [Math 6] ω is the trigger judgment value, １ , ω ２ , ω ３ This represents the weight, and max(•) takes the maximum value within the parentheses. Here, the trigger judgment value [Number 7] The system-side user customizes the weight ω １ , ω ２ , ω ３ All of them are greater than zero and the sum of the three sets of weights is 1. [Number 8] The system according to claim 1, characterized in that, if the condition is met, the identification module triggers a restart of the system.

8. The control logic for the burner to be controlled, configured in the aforementioned logic module, is as follows: Corresponds to the burner being controlled. The image data of the divided mesh belt furnace sintered ceramic is reflected in the T ｓ The reference temperature for ceramic sintering is acquired and stored in the logic module, and the reference temperature and T ｓ Compare the reference temperature T ｓ If the reference temperature is higher than T, the valve opening of the burner to be controlled will be widened and the damper opening will be widened, and the reference temperature will be T ｓ If it is lower than this, the valve opening of the burner being controlled is narrowed, and the damper opening is narrowed. The system according to claim 7, characterized in that the damper of the burner to be controlled is adjusted in priority to the valve, the adjustment speed is kept constant during the adjustment process of the damper of the burner to be controlled and the valve, and the adjustment is terminated when a limit is reached.

9. The system according to claim 1, characterized in that the receiving module is interactively connected to an analysis module and a matching module via a wireless network, the receiving module is interactively connected to a division module via a wireless network, the division module is interactively connected to an extraction module and a camera module via a wireless network, the matching module is interactively connected to a logic module via a wireless network, and the logic module is interactively connected to a control module and an identification module via a wireless network.

10. A method for controlling the heat quantity of a mesh belt furnace for ceramic sintering, The above method is a method to be implemented for a heat quantity control system for a ceramic sintering mesh belt furnace according to any one of claims 1 to 4 or 6 to 9, The steps include: acquiring image data of the mesh belt furnace-sintered ceramic, setting up contour image extraction logic, and extracting the contour image of the sintered ceramic from the image data of the mesh belt furnace-sintered ceramic based on the contour image extraction logic; The steps include: using the contour image of the sintered ceramic as a segmentation path, segmenting it within the image data of the mesh belt furnace sintered ceramic to acquire and store local mesh belt furnace sintered ceramic image data; The steps include acquiring stored image data of the local mesh belt furnace sintered ceramics and analyzing the thermal distribution state of the sintered ceramics in the image data of each group, The steps include setting grid coordinates on image data of sintered ceramics in a mesh belt furnace, identifying burners corresponding to each group of sintered ceramics based on the grid coordinates, and matching the burner group to be controlled by combining this with the results of the thermal distribution state analysis of the sintered ceramics in the image data, The steps include selecting burner-corresponding regions in image data of locally mesh belt furnace-sintered ceramics, and analyzing whether the regional temperature of each selected region satisfies the ceramic sintering reference temperature, The steps include: identifying burners in the group of burners to be controlled that do not meet the ceramic sintering reference temperature, setting control logic, and adjusting the identified burners based on the control logic; The system according to claim 1, characterized by including

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