Method for detecting the opening and closing of a valve, method for manufacturing coke, and system for detecting the opening and closing of a valve

Abstract

It can detect the open / closed state of a valve at low cost, even in dark conditions. [Solution] The valve opening / closing detection method includes the steps of: photographing the valve opening / closing device using a ToF camera; and inputting the image taken in the photographing step into a machine learning model to determine the opening / closing state of the valve.

Description

Technical Field

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[0003]

[0001] The present disclosure relates to a method for detecting the opening and closing of a valve, a method for manufacturing coke, and a valve opening and closing detection system.

Background Art

[0002] In a coke oven, the exhaust gas generated during the carbonization of coal flows through the riser pipe and the collecting valve into the dry main pipe. A top cover for opening and closing the riser pipe is provided on the riser pipe. The collecting valve can switch the connection between the riser pipe and the dry main pipe.

[0003] When charging coal into the carbonization chamber with a coal charging car in a coke oven, it is necessary to close the top cover and open the collecting valve. The operation of closing the top cover and the operation of opening the collecting valve can be performed by an opening and closing device provided on the coal charging car.

[0004] When charging coal into the carbonization chamber with a coal charging car, whether the opening and closing states of the top cover and the collecting valve are normal is usually determined by visual inspection by an operator.

[0005] As a determination method other than visual inspection by an operator, several methods can be considered. For example, a method of mounting a television camera on the coal charging car and monitoring the opening and closing states of the top cover and the collecting valve can be considered. Also, for example, Patent Document 1 discloses a method of detecting the opening and closing state of the top cover by connecting a chain sprocket mounted on the rotating shaft of the top cover and a chain sprocket installed at another location with a chain and attaching a striker that operates a limit switch to the chain.

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

[0007] Using a television camera to photograph the top cover and collecting valve is labor-intensive because it requires the operator to monitor the captured images. Furthermore, it is difficult to check the open / closed status at night due to the darkness of the images.

[0008] The method described in Patent Document 1 requires modification of the equipment for each riser pipe. Therefore, adopting this method presents the challenge of enormous investment costs.

[0009] The purpose of this disclosure is to provide a valve opening / closing detection method, a coke manufacturing method, and a valve opening / closing detection system that enable detection of the valve's open / closed state at low cost, even in dark conditions. [Means for solving the problem]

[0010] [1] A step of photographing the valve opening and closing mechanism using a ToF camera, The steps include inputting the image captured in the aforementioned shooting step into a machine learning model to determine the open / closed state of the valve, A method for detecting the opening and closing of a valve, including the following.

[0011] [2] The valve opening / closing detection method described in [1] above, wherein the learning model is machine-trained using images previously captured by the ToF camera as training data.

[0012] [3] The valve opening / closing detection method according to [1] or [2] above, wherein the step of taking a photograph involves photographing the valve and the valve opening / closing device such that the valve and the valve opening / closing device are included in the same image.

[0013] [4] The valve is a top cover installed in the riser pipe of a coke oven, the method for detecting the opening and closing of a valve according to any one of the above items [1] to [3].

[0014] [5] The valve opening / closing detection method according to any one of the above [1] to [4], wherein the valve opening / closing device is an opening / closing device for a collecting valve of a coke oven.

[0015] [6] The valve opening / closing detection method according to any one of the above items [1] to [5], wherein a reflector is installed on the opening / closing device of the collecting valve.

[0016] [7] The ToF camera is installed in a coal charging car used in a coke oven, and the valve opening / closing detection method described in any one of the above [1] to [6] is used.

[0017] [8] The valve opening / closing detection method according to any one of the above [1] to [7], wherein the step of making the determination limits the area in the image to which the opening / closing state of the valve is to be determined, and after averaging the multiple images that have been taken, the opening / closing state of the valve is determined.

[0018] [9] The valve opening / closing detection method according to any one of [1] to [8] above, wherein the ToF camera is housed in a camera case and cooled by injecting cooling air into the camera case.

[0019]

[10] A method for producing coke, comprising detecting the opening and closing of a valve using the valve opening and closing detection method described in any one of the above items [1] to [9], and charging coal into a carbonization chamber to produce coke.

[0020]

[11] A ToF camera that photographs the valve opening and closing mechanism, An information processing device that inputs images captured by the ToF camera into a machine learning model to determine the open / closed state of the valve, A valve opening / closing detection system equipped with the following features. [Effects of the Invention]

[0021] According to the valve opening / closing detection method, the coke manufacturing method, and the valve opening / closing detection system according to the present disclosure, the opening / closing state of a valve can be detected at low cost even in a dark state.

Brief Description of the Drawings

[0022] [Figure 1] FIG. 1 is a schematic diagram showing an example of a valve opening / closing detection system 1 according to an embodiment of the present disclosure. [Figure 2] FIG. 2 is a flowchart showing an example of the operation of the valve opening / closing detection system according to an embodiment of the present disclosure. [Figure 3A] The result of determining the opening / closing state of the collecting valve by a comparative example. [Figure 3B] The result of determining the opening / closing state of the collecting valve by the valve opening / closing detection method according to the present disclosure. [Figure 4] Another example of the result of determining the opening / closing state of the collecting valve by the valve opening / closing detection method according to the present disclosure.

Modes for Carrying Out the Invention

[0023] Hereinafter, embodiments of the present disclosure will be described with reference to the drawings.

[0024] <000----107>FIG. 1 is a schematic diagram showing an example of a valve opening / closing detection system 1 according to an embodiment of the present disclosure.

[0025] The valve opening / closing detection system 1 is a system for detecting the opening / closing state of a valve in a coke oven. The valve may be any valve installed in the coke oven, but in this embodiment, the case where the valve is a top cover and a collecting valve will be described as an example.

[0026] As shown in Figure 1, the coke oven is equipped with a riser pipe 2 for discharging the exhaust gas generated during the carbonization of coal. A top cover 60 is installed above the riser pipe 2 to open and close the top of the riser pipe 2.

[0027] When coal is being charged into the carbonization chamber of a coke oven, the top cover 60 must be in the closed position. Furthermore, before coal is being charged into the carbonization chamber of the coke oven, the top cover 60 is in the open position.

[0028] In Figure 1, the top cover 60 is shown in the closed state by a solid line. The top cover 60 is shown in the open state by a dashed line. The top cover 60 can be opened or closed by rotating around the shaft 61. The top cover 60 functions as a "valve" to control the opening and closing state of the upper part of the riser pipe 2.

[0029] The exhaust gas discharged from the riser pipe 2 is discharged via the drymen piping 3. The collecting valve 70 can switch the connection between the riser pipe 2 and the drymen piping 3.

[0030] When coal is charged into the carbonization chamber of a coke oven, the collecting valve 70 must be in the open position. Furthermore, before coal is charged into the carbonization chamber of the coke oven, the collecting valve 70 is in the closed position.

[0031] In Figure 1, the collecting valve 70 is shown in the open state by a solid line. The collecting valve 70 is shown in the closed state by a dashed line.

[0032] The collecting valve 70 can be opened or closed by rotating around the shaft 73. An arm 71 is connected to the collecting valve 70. The coal charging car 10 can control the open or closed state of the collecting valve 70 by operating the arm 71.

[0033] The collecting valve 70 functions as a "valve" for switching the connection between the riser pipe 2 and the drymen pipe 3. The arm 71 functions as a "valve opening and closing device" for opening and closing the collecting valve 70.

[0034] A reflector 72 may be installed on the arm 71. The reflector 72 is a plate that reflects light. When the reflector 72 is installed on the arm 71, the reflector 72 moves in conjunction with the arm 71.

[0035] The valve opening / closing detection system 1 comprises a coal charging car 10, a ToF (Time Of Flight) camera 20, a control device 30, a cooling system 40, and an information processing device 50.

[0036] The coal charging car 10 is a mobile machine used in a coke oven. The coal charging car 10 can charge coal into the carbonization chamber of the coke oven. The coal charging car 10 may be equipped with levers that can operate the top cover 60 and the arm 71. The coal charging car 10 can control the open / closed state of the top cover 60 by using the levers. In addition, the coal charging car 10 can control the open / closed state of the collecting valve 70 by operating the arm 71 with the levers.

[0037] The ToF camera 20 is installed on the coal-charging car 10. The ToF camera 20 is a camera that measures distance using infrared light and generates an image corresponding to the distance information. Because the ToF camera 20 measures distance using infrared light, it can generate an image corresponding to the distance even in dark conditions.

[0038] The ToF camera 20 is positioned to photograph the top cover 60 and the arm 71 when the coal-charging car 10 is loading coal into the carbonization chamber. It is not essential that the ToF camera 20 can photograph both the top cover 60 and the arm 71; it is sufficient if it can photograph the arm 71.

[0039] The ToF camera 20 can detect the position of the top cover 60 by photographing the top cover 60. The ToF camera 20 can also detect the position of the collecting valve 70 by photographing the arm 71 connected to the collecting valve 70. As shown in Figure 1, for example, when the collecting valve 70 is in the open position, it is difficult for the ToF camera 20 to photograph the collecting valve 70. However, by photographing the arm 71 instead, the position of the collecting valve 70, which moves in conjunction with the arm 71, can be detected. The ToF camera 20 may also photograph the reflector 72 installed on the arm 71. Since the reflector 72 is easier to photograph than the arm 71, the ToF camera 20 can easily and accurately detect the position of the collecting valve 70 by photographing the reflector 72.

[0040] It is desirable that the ToF camera 20 be able to photograph the top cover 60 and the arm 71 so that they are included in the same image when the coal charging car 10 is loading coal into the carbonization chamber. If the top cover 60 and the arm 71 are photographed in the same image, it becomes possible to check the open / closed state of the top cover 60 and the open / closed state of the arm 71 in a single image.

[0041] The ToF camera 20 may be housed in a camera case. Housed in a camera case prevents dust from adhering to the lens of the ToF camera 20. In addition, cooling air may be injected into the camera case in which the ToF camera 20 is housed by a cooling system 40. When the ToF camera 20 is cooled by injecting cooling air into the camera case, the risk of damage to the ToF camera 20 due to radiant heat from the riser tube 2 can be reduced.

[0042] The control device 30 is a device that can control the movement and operation of the coal charging car 10. The control device 30 is installed on the coal charging car 10. The control device 30 can communicate with the information processing device 50. The control device 30 may control the movement and operation of the coal charging car 10 in response to commands from the information processing device 50.

[0043] The cooling equipment 40 is for cooling the ToF camera 20. The cooling equipment 40 is installed on the coal charging car 10. When the ToF camera 20 is housed in a camera case, the cooling equipment 40 can cool the ToF camera 20 by injecting cooling air into the camera case.

[0044] The cooling equipment 40 may include, for example, a compressor 41, an air dryer 42, and an air cooler 43. The configuration of the cooling equipment 40 is not limited to this, and may be any configuration capable of outputting cooling air.

[0045] The information processing device 50 is a general-purpose computer such as a workstation or personal computer. Alternatively, the information processing device 50 may be a dedicated computer configured to function as the information processing device 50 in the valve opening / closing detection system 1.

[0046] The information processing device 50 can communicate with the ToF camera 20 and the control device 30. When the information processing device 50 communicates with the ToF camera 20, it may communicate directly with the ToF camera 20 or communicate with the ToF camera 20 via the control device 30.

[0047] (Operation of the valve opening / closing detection system) Next, we will explain the operation of the valve opening / closing detection system 1.

[0048] When loading coal into the carbonization chamber, the coal charging car 10 moves to the vicinity of the riser pipe 2 and closes the top cover 60. The coal charging car 10 also opens the collecting valve 70 by operating the arm 71.

[0049] The ToF camera 20 captures images of the top cover 60 and the arm 71 connected to the collecting valve 70. The ToF camera 20 transmits the captured images to the information processing device 50.

[0050] When the information processing device 50 receives an image captured by the ToF camera 20, it inputs the received image into a machine learning model to determine whether the open / closed state of the top cover 60 and the collecting valve 70 is normal.

[0051] The learning model used to determine the open / closed state of the top cover 60 and the collecting valve 70 is a learning model that has been trained using images previously captured by the ToF camera 20 as training data.

[0052] The information processing device 50 determines that the opening and closing states of the top cover 60 and the collecting valve 70 are normal when the top cover 60 is closed and the collecting valve 70 is open.

[0053] The machine learning model may be stored in the information processing device 50, or it may be stored in an external device that can communicate with the information processing device 50.

[0054] In this way, by using a machine learning model trained with previously captured images as training data to determine the open / closed state of the top cover 60 and the collecting valve 70, the information processing device 50 can determine the open / closed state of the top cover 60 and the collecting valve 70 with high accuracy.

[0055] Furthermore, since the ToF camera 20 is installed on the coal-charging car 10 and moves with the coal-charging car 10, one ToF camera 20 can determine the open / closed state of the top cover 60 and the collecting valve 70 for multiple riser pipes 2. In other words, the open / closed state of the top cover 60 and the collecting valve 70 can be determined without installing a device for determining the open / closed state of the top cover 60 and the collecting valve 70 in each riser pipe 2. Therefore, the valve detection system 1 according to this embodiment can determine the open / closed state of the top cover 60 and the collecting valve 70 at low cost.

[0056] When the information processing device 50 determines that the opening and closing states of the top cover 60 and the collecting valve 70 are normal, it sends a command to the control device 30 installed in the coal charging car 10 to charge coal into the carbonization chamber.

[0057] The information processing device 50 displays an alarm if it determines that the open / closed state of the top cover 60 and the collecting valve 70 is not normal. The information processing device 50 may display the alarm on its own display or on the terminal device being operated by the operator.

[0058] The operation of the valve opening / closing detection system 1 according to this embodiment will be explained with reference to the flowchart shown in Figure 2.

[0059] Step S101: When loading coal into the carbonization chamber, the coal charging car 10 closes the top cover 60. The coal charging car 10 also opens the collecting valve 70 by operating the arm 71.

[0060] Step S102: When the coal-charging car 10 closes the top cover 60 and opens the collecting valve 70, the ToF camera 20 automatically photographs the top cover 60 and the arm 71 connected to the collecting valve 70.

[0061] Step S103: The information processing device 50 inputs the image captured by the ToF camera 20 into a machine learning model to determine whether the open / closed state of the top cover 60 and the collecting valve 70 is normal.

[0062] If the open / closed state of the top cover 60 and the collecting valve 70 is normal (Yes in step S103), the process proceeds to step S106. If the open / closed state of the top cover 60 and the collecting valve 70 is not normal (No in step S103), the process proceeds to step S104.

[0063] Step S104: If the information processing device 50 determines that the open / closed state of the top cover 60 and the collecting valve 70 is not normal, it displays an alarm.

[0064] Step S105: Upon receiving the alarm, the operator visually inspects, for example, the top cover 60 and the collecting valve 70, and takes necessary actions to restore the top cover 60 and the collecting valve 70 to their normal open / closed states. Once the top cover 60 and the collecting valve 70 are in their normal open / closed states, the process proceeds to step S106.

[0065] Step S106: When the information processing device 50 determines that the open / closed state of the top cover 60 and the collecting valve 70 is normal, it sends a command to the control device 30 of the coal charging car 10 to charge coal into the carbonization chamber and produce coke. At this time, the information processing device 50 may also determine that not only the open / closed state of the top cover 60 and the collecting valve 70, but also other conditions are normal before starting the coal charging.

[0066] (Examples) An operational test was conducted to determine the open / closed state of the collecting valve 70 using the valve open / closed detection method described herein. As a comparative example, an operational test was also conducted in which the open / closed state of the collecting valve 70 was determined by a threshold value. In both operational tests, 1268 images were taken using the ToF camera 20, and the open / closed state of the collecting valve 70 was determined based on the data from these 1268 images.

[0067] In the valve opening / closing detection method described herein, the 1268 captured data points were divided into four sets, three of which were used as training data to perform machine learning and generate a learning model, and the remaining set was used to determine the opening / closing state of the collecting valve 70.

[0068] In the comparative example where determination is made by a threshold, the open / closed state of the collecting valve 70 was determined by the following determination flow. 1: Select the area in the image captured by the ToF camera 20 that shows the reflector 72. 2: Set the range of depth values ​​when the collecting valve 70 is in the open state. 3. Count the number of pixels within the set depth range. 4. If the percentage of pixels within the threshold, defined as "percentage of pixels within the threshold = number of pixels within the threshold / number of pixels in the selected area," is greater than or equal to a reference value, the collecting valve 70 is determined to be in the open state. If it is less than the reference value, the collecting valve 70 is determined to be in the closed state. However, the reference value was set to 60%.

[0069] Figure 3A shows the results of determining the open / closed state of the collecting valve 70 using a comparative example that uses a threshold for determination. In the results shown in Figure 3A, the open / closed state of the collecting valve 70 was correctly determined 930 times, which is the sum of 438 times when the closed state image was judged as closed and 492 times when the open state image was judged as open. In other words, in the comparative example, only 930 out of 1268 times the determination was correct, resulting in a low accuracy rate of 73.34%.

[0070] Figure 3B shows the results of determining the open / closed state of the collecting valve 70 using the valve open / closed detection method according to this disclosure. In Figure 3B, the accuracy rate shown as Dataset 1 is the accuracy rate when a learning model is generated by machine learning using Datasets 2 to 4 as training data, and the open / closed state of the collecting valve 70 is determined using Dataset 1. The accuracy rates shown as Datasets 2 to 4 are also the accuracy rates when determined using the same method.

[0071] As shown in Figure 3B, the valve opening / closing detection method according to this disclosure achieved an average accuracy rate of 97.40%. This represents a significant improvement in judgment accuracy compared to the comparative example, which achieved an accuracy rate of 73.34%.

[0072] Typically, in a coke oven, the process of charging coal into the carbonization chamber is performed more than 100 times a day. In this case, the method according to the comparative example would result in approximately 30 false detections of the open / closed state of the collecting valve 70 per day. However, the valve open / closed detection method according to the present disclosure can significantly reduce the frequency of false detections.

[0073] Figure 4 shows the results when, in the valve opening / closing detection method according to this disclosure, in order to further improve the accuracy rate, the area to be determined for determining the opening / closing state of the collecting valve 70 in the image captured by the ToF camera 20 is limited to a narrow range, and after averaging multiple captured images, machine learning using training data and determination of the opening / closing state of the collecting valve 70 are performed. With this method, the average accuracy rate was improved to 99.68%.

[0074] As described above, the valve opening / closing detection method according to this embodiment includes the steps of: photographing the valve opening / closing device using a ToF camera 20; and inputting the image taken in the photographing step into a machine learning model to determine the valve's open / closed state. Thus, because the valve opening / closing detection method according to this embodiment uses a ToF camera 20 for photography, it can take images even in dark conditions. Furthermore, since one ToF camera 20 can determine the open / closed state of the top cover 60 and the collecting valve 70 for multiple riser pipes 2, the open / closed state of the top cover 60 and the collecting valve 70 can be determined at low cost. Therefore, the valve opening / closing detection method according to this embodiment can detect the valve's open / closed state at low cost even in dark conditions.

[0075] Furthermore, since the valve opening / closing detection method according to this embodiment uses a ToF camera 20 installed on the coal charging car 10 to take photographs, the operator does not need to visually check the opening / closing status of the top cover 60 and the collecting valve 70, thereby reducing the workload on the operator.

[0076] This disclosure is not limited to the embodiments described above. For example, multiple blocks described in the block diagram may be combined, or a single block may be divided. Instead of executing multiple steps described in the flowchart in chronological order as described, they may be executed in parallel or in a different order, depending on the processing capacity of the device performing each step, or as necessary. Other modifications are possible without departing from the spirit of this disclosure.

[0077] For example, in this embodiment, the case in which the ToF camera 20 photographs the top cover 60 and the arm 71 was described as an example, but the ToF camera 20 may also photograph valves other than the top cover 60, or valve opening / closing devices other than the arm 71. [Explanation of symbols]

[0078] 1. Valve Open / Close Detection System 2 Ascending tube 3. Drymen Piping 10 Coal loading car 20 ToF Cameras 30 Control device 40 Cooling equipment 41 Compressor 42 Air Dryer 43 Air cooler 50 Information Processing Devices 60 Top cover (valve) 61 axis 70 Collecting valve (valve) 71. Arm (valve opening and closing device) 72 Reflector 73 axes

Claims

1. The steps include: photographing the valve opening and closing mechanism using a ToF camera, The steps include inputting the image captured in the aforementioned shooting step into a machine learning model to determine the open / closed state of the valve, A method for detecting the opening and closing of a valve, including the following.

2. The valve opening / closing detection method according to claim 1, wherein the learning model is machine-trained using images previously captured by the ToF camera as training data.

3. The valve opening / closing detection method according to claim 1, wherein the step of taking a photograph involves photographing the valve and the valve opening / closing device such that the valve and the valve opening / closing device are included in the same image.

4. The valve is a top cover installed in the riser pipe of a coke oven, as described in claim 3, for detecting the opening and closing of a valve.

5. The valve opening / closing detection method according to claim 1, wherein the valve opening / closing device is an opening / closing device for a collecting valve of a coke oven.

6. The valve opening / closing detection method according to claim 5, wherein a reflector is installed on the opening / closing device of the collecting valve.

7. The ToF camera is installed in a coal charging car used in a coke oven, as described in claim 1, for detecting the opening and closing of a valve.

8. The valve opening / closing detection method according to claim 1, wherein the determination step involves limiting the area in the image to be used for determining the opening / closing state of the valve, averaging the captured images, and then determining the opening / closing state of the valve.

9. The valve opening / closing detection method according to claim 1, wherein the ToF camera is housed in a camera case and is cooled by injecting cooling air into the camera case.

10. A method for producing coke, comprising detecting the opening and closing of a valve using the valve opening and closing detection method described in any one of claims 1 to 9, and charging coal into a carbonization chamber to produce coke.

11. A ToF camera to photograph the valve opening and closing mechanism, An information processing device that inputs images captured by the ToF camera into a machine learning model to determine the open / closed state of the valve, A valve opening / closing detection system equipped with the following features.

Images