State monitoring system and control method for mesh belt furnace for ceramic sintering

Abstract

The present invention relates to the technical field of mesh belt furnaces, and specifically to a state monitoring system and control method for a mesh belt furnace for ceramic sintering. The state monitoring system comprises an acquisition layer, an analysis layer and a regulation and control layer; the acquisition layer acquires image data of products conveyed in the mesh belt furnace, and then further segments the acquired product image data to obtain product images; the analysis layer synchronously receives the product images obtained by the segmentation processing in the acquisition layer and, on the basis of the product images, analyzes the sintering states of the products corresponding to each product image. The present invention acquires the image data of the products sintered in the mesh belt furnace, so as to provide foremost data for monitoring the operating state of the mesh belt furnace. Therefore, on the basis of analysis of acquired product image data, the qualification and overall quality of products output by the mesh belt furnace can be recognized and determined and, on the basis of the recognition and determination result, whether the operating state of the mesh belt furnace is normal is verified.

Description

A condition monitoring system and control method for a mesh belt furnace used in ceramic sintering Technical Field

[0001] This invention relates to the field of mesh belt furnace technology, and specifically to a condition monitoring system and control method for a mesh belt furnace used in ceramic sintering. Background Technology

[0002] The complete mesh belt furnace consists of three main parts: the furnace body, the mesh belt drive system, and the temperature control system. The furnace body comprises a feeding section, a pre-firing section, a sintering section, a slow cooling section, a water cooling section, and a discharge section. The mesh belt drive system consists of a high-temperature resistant mesh belt and a transmission device. The mesh belt speed is adjusted by a frequency converter and equipped with a digital display mesh belt speed measuring device; the mesh belt speed can be read directly. The temperature control system consists of thermocouples, a digital display intelligent PID controller, and a silicon controlled rectifier (SCR), forming a closed-loop control system that enables automatic and precise temperature control.

[0003] Currently, when mesh belt furnaces are used to produce metal ceramic products, their control often relies on a pre-set operating program to heat and sinter the products. During this process, due to the high ambient temperature, the products inside the mesh belt furnace in a sintering state cannot be manually observed. As a result, the quality of the products produced by the mesh belt furnace cannot be accurately distinguished from their appearance. Consequently, defects in the operation of the mesh belt furnace are often only discovered by workers when obvious defective products appear, leading to poor product quality and serious operational defects and malfunctions of the mesh belt furnace. Summary of the Invention

[0004] To address the aforementioned shortcomings of existing technologies, this invention provides a condition monitoring system and control method for a mesh belt furnace used in ceramic sintering, thus solving the technical problems mentioned in the background section.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] In a first aspect, a condition monitoring system for a mesh belt furnace for ceramic sintering includes: a data acquisition layer, an analysis layer, and a control layer;

[0007] The products conveyed in the mesh belt furnace have their image data acquired by the acquisition layer. The acquired product image data is further segmented to obtain product images. The analysis layer synchronously receives the product images obtained from the segmentation process in the acquisition layer. Based on the product images, it analyzes the sintering state of each group of product images. By applying the analyzed sintering state of each group of product images, it identifies the products corresponding to the sintering images that are not qualified and further obtains the corresponding positions of the products corresponding to the sintering images in the mesh belt furnace.

[0008] The control layer receives the analysis results of the sintering status of the products corresponding to each group of product images from the analysis layer, as well as the corresponding position of the products with unqualified sintering treatment images in the mesh belt furnace. Based on the analysis results, it evaluates the overall quality of the current products produced by the mesh belt furnace and controls the mesh belt furnace based on the received position in the mesh belt furnace.

[0009] The analysis layer includes an analysis module, an identification module, and a positioning module. The analysis module receives product images acquired from the acquisition layer and analyzes the sintering state of the product based on the product images. The identification module acquires the product sintering state analysis results from the analysis module and identifies products with unqualified sintering processes and their corresponding product images based on the product sintering state analysis results. The positioning module receives products with unqualified sintering processes and their corresponding product images identified by the identification module and uses the corresponding product images of the unqualified sintering processes to locate the products.

[0010] The product sintering state analysis logic in the analysis module is represented as follows:

[0011] Where: k is the product sintering state performance value; u is the product image; sim(α) v ,α center Tv represents the color-based similarity between the v-th sub-image in the product image and the central region of the product image; Tq represents the corresponding value of the q-th pixel in the v-th sub-image in the product image in the temperature mapping table; Tv represents the color-based similarity between the v-th sub-image in the product image and the central region of the product image. center For the v-th sub-image in the product image, the corresponding value of the center pixel in the temperature mapping table; (T MIN ,T MAX The threshold is composed of the maximum and minimum temperatures required for ceramic sintering.

[0012] In this context, a smaller product sintering state value (k) indicates a better sintering state, and vice versa. The temperature mapping table is set based on the colors exhibited by sintered ceramics at different temperature states during historical mesh belt furnace sintering processes. The sub-images in the product image are obtained through product image segmentation, with no fewer than nine groups of sub-images, and each group of sub-images in the product image is of equal size. Table Find the average of the terms.

[0013] Furthermore, the acquisition layer includes a camera module, a segmentation module, and a storage module. The camera module is used to acquire image data of products transmitted in the mesh belt furnace. The segmentation module is used to receive the product image data acquired by the camera module, segment the product image data to extract all product images from the product image data, and the storage module is used to receive the product images extracted by the segmentation module and store the product images.

[0014] The mesh belt furnace consists of a conveyor station and a processing station. The conveyor station is used to transport products to the processing station for processing. The processing station consists of a pre-firing area, a sintering area, and a cooling area. The pre-firing and sintering areas are used to provide the temperature for sintering the products, and the cooling area is used to cool the products after sintering. The camera module is deployed in the sintering area of ​​the processing station. The conveyor station in the mesh belt furnace transports products at a constant speed, so that the products pass through the pre-firing area, sintering area, and cooling area of ​​the processing station in sequence. The camera module continuously collects product image data based on the time it takes for the products to travel from the conveyor station to the sintering area of ​​the processing station.

[0015] Furthermore, before each product is transferred from the conveyor station of the mesh belt furnace, each group of products is placed at a designated position on the surface of the conveyor station of the mesh belt furnace, ensuring that the placement posture of each group of products is consistent and that the horizontal and vertical distances of each group of products are equal. When the camera module acquires product image data, it uses the boundary of the conveyor station of the mesh belt furnace as the image data acquisition boundary, so that the foreground of the acquired product image data consists of products and the background consists of the surface of the conveyor station. When the segmentation module receives the product image data and segments the product image data to extract all product images, it first determines the product image coordinates in the product image data, constructs a closed shape based on the product image coordinates, and segments the product image data using the closed shape to obtain the image region corresponding to the closed shape.

[0016] Furthermore, the logic for determining the product image coordinates in the product image data is expressed as follows:

[0017] In the formula: (x, y) are any set of coordinates of adjacent products on the boundary of the conveying surface of the conveying station of the mesh belt furnace; (x0, y0) are any set of coordinates on the contour of the contact surface between the conveyed product and the conveying station on the conveying station of the mesh belt furnace; (m, n) are any set of coordinates on the long side of the contour of the product image data; (m0, n0) are the product image coordinates.

[0018] In this context, (x, y) and (x0, y0) use the same coordinate scale, and both the x and y coordinates of (x, y) and (x0, y0) are greater than zero. Similarly, (m, n) and (m0, n0) use the same coordinate scale, and both the x and y coordinates of (m, n) and (m0, n0) are greater than zero. When selecting (x, y), (x, y) falls on the long side of the transmission surface of the transmission station. The corresponding position of (x, y) is located in the product image data. The slope of (x, y) relative to (x0, y0) is equal to the slope of (m, n) relative to (m0, n0).

[0019] Furthermore, the (x0, y0) used in the product image coordinate determination logic are all contour corner points. After all the product image coordinates in the product image data are connected to each other, several sets of closed graphics are obtained. The image areas corresponding to these several sets of closed graphics are the product images.

[0020] Furthermore, each sub-image in each set of product images corresponds to a set of T images. center All T center When all conditions are met in equation (2), and the product sintering state performance value k < 1, the product corresponding to the product graphic is judged to be qualified; otherwise, it is judged to be unqualified.

[0021] After receiving the sintering failure product and the corresponding product image, the positioning module further obtains the closed shape corresponding to the product image, and then uses the position coordinates corresponding to the closed shape to obtain (x0, y0) corresponding to the position coordinates of the closed shape based on the product image coordinates. Based on (x0, y0), the unqualified sintering product is determined.

[0022] Furthermore, the control layer includes an evaluation module and a control module. The evaluation module is used to receive the unqualified sintered products located in the analysis layer and evaluate the overall quality of the products produced in the mesh belt furnace based on the unqualified sintered products. The control module is used to obtain the position information of the product image corresponding to the unqualified sintered products and to control the temperature of the sintering equipment to which the area corresponding to the product image position information belongs in the sintering station of the mesh belt furnace processing station.

[0023] The evaluation module includes evaluation logic. Based on this logic, the module assesses the overall quality of the products produced in the mesh belt furnace. Several sets of sintering equipment are evenly arranged at the sintering station within the mesh belt furnace's processing station. When the control module regulates the temperature of the sintering equipment, it follows the T-axis of the sub-image in the product image corresponding to the relative position of the sintering equipment on the product surface. center >T MAX If the temperature of the sintering equipment is lowered, it should not exceed T. MIN T center <T MIN Then adjust the sintering equipment temperature to increase, but not exceeding T. MAX .

[0024] Furthermore, the evaluation logic set in the evaluation module is expressed as follows:

[0025] In the formula: K is the comprehensive quality assessment result of the product produced in the mesh belt furnace; p is the set of product images participating in the qualification judgment; zk qLet be the defined value of the pass / fail judgment result k for the product corresponding to the q-th product image group; g is the total number of product images; w is the set of product images corresponding to products with a fail / fail judgment result; d(s r ,s r+1 Let be the distance between the r-th product image and the (r+1)-th product image;

[0026] in, Table The larger the value of K, the better the overall quality of the products produced in the mesh belt furnace, and vice versa. q The value can be 1 or 0. When the product image corresponds to a product qualification judgment result of qualified, zk q The value is 1, and the value is 0.

[0027] Furthermore, the analysis module is interconnected with an identification module and a positioning module via a wireless network, the analysis module is interconnected with a storage module via a wireless network, the storage module is interconnected with a segmentation module and a camera module via a wireless network, the positioning module is interconnected with an evaluation module via a wireless network, and the evaluation module is interconnected with a control module via a wireless network.

[0028] Secondly, a method for controlling the state of a mesh belt furnace for ceramic sintering includes the following steps:

[0029] Step 1: Collect product image data in the sintering area of ​​the mesh belt furnace processing station;

[0030] Step 2: Set up product image data segmentation logic, and perform segmentation processing on product image data based on the product image data segmentation logic to extract product images from all product image data;

[0031] Step 3: Obtain the product images obtained from segmentation and extraction, set the product sintering state analysis logic, perform sintering state analysis on each group of product images, and identify the products corresponding to unqualified product images;

[0032] Step 4: Locate the corresponding products for each group of non-conforming product images on the mesh belt furnace. Based on the positioning results and the identification results of the corresponding products for non-conforming product images, evaluate the quality of the sintered products produced in the mesh belt furnace.

[0033] Step 5: Set the control logic, obtain the analysis and recognition results of whether the product image corresponds to the product's qualification, and locate the product corresponding to the image of the unqualified product;

[0034] Step 6: For the product corresponding to the image of the non-conforming product located, deploy sintering equipment in the sintering area of ​​the corresponding processing station, and regulate the temperature of the sintering equipment based on the control logic.

[0035] Compared with known public technologies, the technical solution provided by this invention has the following beneficial effects:

[0036] This invention provides a status monitoring system for a mesh belt furnace used in ceramic sintering. During operation, the system collects image data of the products sintered on the mesh belt furnace, providing essential data for monitoring the furnace's operating status. Based on the analysis of the collected product image data, the system can identify and determine the qualification and overall quality of the products produced by the mesh belt furnace. Furthermore, the identification and determination results are used to verify whether the mesh belt furnace is operating normally. In cases of abnormal operation, the system can also accurately locate the problematic workstations and positions, thereby effectively improving the safety and stability of the mesh belt furnace operation and ensuring better product quality. Attached Figure Description

[0037] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are merely some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without any creative effort.

[0038] Figure 1 is a schematic diagram of a condition monitoring system for a mesh belt furnace used in ceramic sintering.

[0039] Figure 2 is a flowchart illustrating a method for controlling the state of a mesh belt furnace used in ceramic sintering.

[0040] Figure 3 is a schematic diagram of the logical concept for determining product image coordinates in product image data in this invention;

[0041] Figure 4 is a schematic diagram showing the mesh belt furnace station in this invention;

[0042] The labels in the diagram represent: 1. Sintered product; 2. Surface of the transfer station; 3. Product image data; 4. Product image. Detailed Implementation

[0043] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0044] The present invention will be further described below with reference to embodiments.

[0045] Example 1:

[0046] This embodiment of a ceramic sintering mesh belt furnace condition monitoring system, as shown in Figure 1, includes: a data acquisition layer, an analysis layer, and a control layer;

[0047] The products conveyed in the mesh belt furnace have their image data acquired by the acquisition layer. The acquired product image data is further segmented to obtain product images. The analysis layer synchronously receives the product images obtained from the segmentation process in the acquisition layer. Based on the product images, it analyzes the sintering state of each group of product images. By applying the analyzed sintering state of each group of product images, it identifies the products corresponding to the sintering images that are not qualified and further obtains the corresponding positions of the products corresponding to the sintering images in the mesh belt furnace.

[0048] The acquisition layer includes a camera module, a segmentation module, and a storage module. The camera module is used to acquire image data of products transmitted in the mesh belt furnace. The segmentation module is used to receive the product image data acquired by the camera module, segment the product image data to extract all product images from the product image data, and the storage module is used to receive the product images extracted by the segmentation module and store the product images.

[0049] The mesh belt furnace consists of a conveyor station and a processing station. The conveyor station is used to transport products to the processing station for processing. The processing station consists of a pre-firing area, a sintering area, and a cooling area. The pre-firing area and sintering area are used to provide the temperature for sintering the products, and the cooling area is used to cool the products after sintering. The camera module is deployed in the sintering area of ​​the processing station. The conveyor station in the mesh belt furnace transports products at a constant speed, so that the products pass through the pre-firing area, sintering area, and cooling area of ​​the processing station in sequence. The camera module continuously collects product image data based on the time it takes for the products to travel from the conveyor station to the sintering area of ​​the processing station.

[0050] The control layer receives the analysis results of the sintering status of the products corresponding to each group of product images from the analysis layer, as well as the corresponding position of the products with unqualified sintering treatment images in the mesh belt furnace. Based on the analysis results, it evaluates the overall quality of the current products produced by the mesh belt furnace and controls the mesh belt furnace based on the received position in the mesh belt furnace.

[0051] The analysis layer includes an analysis module, an identification module, and a positioning module. The analysis module receives product images acquired from the acquisition layer and analyzes the sintering state of the product based on the product images. The identification module obtains the product sintering state analysis results from the analysis module and identifies products with unqualified sintering processes and their corresponding product images based on the product sintering state analysis results. The positioning module receives products with unqualified sintering processes and their corresponding product images identified by the identification module and uses the corresponding product images of the unqualified sintering processes to locate the products.

[0052] The product sintering state analysis logic in the analysis module is represented as follows:

[0053] Where: k is the product sintering state performance value; u is the product image; sim(α) v ,α center Tv represents the color-based similarity between the v-th sub-image in the product image and the central region of the product image; Tq represents the corresponding value of the q-th pixel in the v-th sub-image in the product image in the temperature mapping table; Tv represents the color-based similarity between the v-th sub-image in the product image and the central region of the product image. center For the v-th sub-image in the product image, the corresponding value of the center pixel in the temperature mapping table; (T MIN ,T MAX The threshold is composed of the maximum and minimum temperatures required for ceramic sintering.

[0054] Among them, the smaller the product sintering state performance value k, the better the product sintering state, and vice versa. The temperature mapping table is set based on the color of sintered ceramics at different temperature states during the historical mesh belt furnace sintering process. The sub-images in the product image are obtained by segmenting the product image, with no less than nine groups of sub-images in the product image, and each group of sub-images in the product image is of equal size. Table Find the average of the terms;

[0055] The control layer includes an evaluation module and a control module. The evaluation module is used to receive the unqualified sintered products located in the analysis layer and evaluate the overall quality of the products produced in the mesh belt furnace based on the unqualified sintered products. The control module is used to obtain the position information of the product image corresponding to the unqualified sintered products and to control the temperature of the sintering equipment to which the area corresponding to the product image position information belongs in the sintering station of the mesh belt furnace processing station.

[0056] The evaluation module includes evaluation logic that assesses the overall quality of the products produced in the mesh belt furnace. Several sets of sintering equipment are evenly arranged at the sintering station within the mesh belt furnace's processing station. When the control module regulates the temperature of the sintering equipment, it follows the T-axis of the sub-image in the product image corresponding to the relative position of the sintering equipment on the product surface. center >T MAX If the temperature of the sintering equipment is lowered, it should not exceed T. MIN T center <T MIN Then adjust the sintering equipment temperature to increase, but not exceeding T. MAX ;

[0057] The analysis module is interconnected with the identification module and the positioning module via a wireless network. The analysis module is interconnected with the storage module via a wireless network. The storage module is interconnected with the segmentation module and the camera module via a wireless network. The positioning module is interconnected with the evaluation module via a wireless network. The evaluation module is interconnected with the control module via a wireless network.

[0058] In this embodiment, during system operation, the camera module acquires image data of the products transmitted in the mesh belt furnace. The segmentation module simultaneously receives the product image data acquired by the camera module and segments the product image data to extract all product images. The storage module receives the product images extracted by the segmentation module in real time and stores them. The analysis module further receives the product images acquired from the acquisition layer, analyzes the sintering state of the products based on the product images, and then the recognition module obtains the product sintering state analysis results from the analysis module. The results identify products that fail the sintering process and their corresponding images. The positioning module simultaneously receives the products that fail the sintering process and their corresponding images from the identification module. It then uses the corresponding images of the products that fail the sintering process to locate the products. Finally, the evaluation module receives the non-conforming sintered products located in the analysis layer and evaluates the overall quality of the products produced in the mesh belt furnace based on the non-conforming sintered products. The control module obtains the position information of the corresponding product images of the non-conforming sintered products and adjusts the temperature of the sintering equipment to which the corresponding product image position information belongs in the sintering station of the mesh belt furnace.

[0059] The system described in the above embodiments provides a relatively reliable safety monitoring of the operating status of the mesh belt furnace for ceramic sintering, ensuring the long-term stable operation of the mesh belt furnace and the quality of the products produced by the mesh belt furnace.

[0060] Referring to Figure 3, the markings in the figure further illustrate how product image data is determined based on product image coordinates, and then further extracted.

[0061] As shown in Figure 4, this figure illustrates the structural distribution of the mesh belt furnace referred to in the above embodiment.

[0062] Example 2:

[0063] At the implementation level, based on Example 1, this example further describes the condition monitoring system for a mesh belt furnace for ceramic sintering in Example 1 with reference to Figure 1:

[0064] Before each product is transferred from the conveyor station of the mesh belt furnace, each group of products is placed at a designated position on the surface of the conveyor station, ensuring that the placement posture of each group of products is consistent and that the horizontal and vertical distances of each group of products are equal. When the camera module acquires product image data, it uses the boundary of the conveyor station of the mesh belt furnace as the image data acquisition boundary, so that the foreground of the acquired product image data consists of the product and the background consists of the surface of the conveyor station. When the segmentation module receives the product image data and segments it to extract all product images, it first determines the product image coordinates in the product image data, constructs a closed shape based on the product image coordinates, and segments the product image data using the closed shape to obtain the image region corresponding to the closed shape.

[0065] The above settings further define the operating logic of the camera module and impose logical constraints on the process of segmenting and extracting product images from product image data.

[0066] As shown in Figure 1, the logic for determining the product image coordinates in the product image data is as follows:

[0067] In the formula: (x, y) are any set of coordinates of adjacent products on the boundary of the conveying surface of the conveying station of the mesh belt furnace; (x0, y0) are any set of coordinates on the contour of the contact surface between the conveyed product and the conveying station on the conveying station of the mesh belt furnace; (m, n) are any set of coordinates on the long side of the contour of the product image data; (m0, n0) are the product image coordinates.

[0068] Where (x, y) and (x0, y0) use the same coordinate scale, and the vertical and horizontal coordinates of (x, y) and (x0, y0) are both greater than zero; (m, n) and (m0, n0) use the same coordinate scale, and the vertical and horizontal coordinates of (m, n) and (m0, n0) are both greater than zero; when (x, y) is selected, (x, y) falls on the long side of the transmission surface of the transmission station, and the corresponding position of (x, y) is in the product image data; the slope of (x, y) relative to (x0, y0) is equal to the slope of (m, n) relative to (m0, n0);

[0069] In the logic for determining product image coordinates, (x0, y0) are all contour corner points. After all product image coordinates in the product image data are connected to each other, several sets of closed graphics are obtained. The image areas corresponding to these sets of closed graphics are the product images.

[0070] The above settings provide a specified logic for determining the coordinates of the product image in the product image data.

[0071] As shown in Figure 1, each product image group has a corresponding T-image. center All T centerWhen all conditions are met in equation (2), and the product sintering state performance value k < 1, the product corresponding to the product graphic is judged to be qualified; otherwise, it is judged to be unqualified.

[0072] After receiving the sintering failure product and the corresponding product image, the positioning module further obtains the closed shape corresponding to the product image, and then uses the position coordinates corresponding to the closed shape to obtain (x0, y0) corresponding to the position coordinates of the closed shape based on the product image coordinates. Based on (x0, y0), the unqualified sintering product is determined.

[0073] The above settings further define the logic for determining the qualification of products corresponding to product images in the analysis layer of the system, and provide necessary operational data support for the operation of the subsequent control layer in the system.

[0074] As shown in Figure 1, the evaluation logic set in the evaluation module is represented as follows:

[0075] In the formula: K is the comprehensive quality assessment result of the product produced in the mesh belt furnace; p is the set of product images participating in the qualification judgment; zk q Let be the defined value of the pass / fail judgment result k for the product corresponding to the q-th product image group; g is the total number of product images; w is the set of product images corresponding to products with a fail / fail judgment result; d(s r ,s r+1 Let be the distance between the r-th product image and the (r+1)-th product image;

[0076] in, Table The larger the value of K, the better the overall quality of the products produced in the mesh belt furnace, and vice versa. q The value can be 1 or 0. When the product image corresponds to a product qualification judgment result of qualified, zk q The value is 1, and the value is 0.

[0077] By setting the above logical formula, the logic of the evaluation module in the system for evaluating the overall quality of the products produced in the furnace is further limited.

[0078] Example 3:

[0079] At the implementation level, based on Example 1, this example further describes the condition monitoring system for a mesh belt furnace for ceramic sintering in Example 1 with reference to Figure 2:

[0080] A method for controlling the state of a mesh belt furnace for ceramic sintering includes the following steps:

[0081] Step 1: Collect product image data in the sintering area of ​​the mesh belt furnace processing station;

[0082] Step 2: Set up product image data segmentation logic, and perform segmentation processing on product image data based on the product image data segmentation logic to extract product images from all product image data;

[0083] Step 3: Obtain the product images obtained from segmentation and extraction, set the product sintering state analysis logic, perform sintering state analysis on each group of product images, and identify the products corresponding to unqualified product images;

[0084] Step 4: Locate the corresponding products for each group of non-conforming product images on the mesh belt furnace. Based on the positioning results and the identification results of the corresponding products for non-conforming product images, evaluate the quality of the sintered products produced in the mesh belt furnace.

[0085] Step 5: Set the control logic, obtain the analysis and recognition results of whether the product image corresponds to the product's qualification, and locate the product corresponding to the image of the unqualified product;

[0086] Step 6: For the product corresponding to the image of the non-conforming product located, deploy sintering equipment in the sintering area of ​​the corresponding processing station, and regulate the temperature of the sintering equipment based on the control logic.

[0087] In summary, during operation, the system in the above embodiments collects image data of the products sintered on the mesh belt furnace, providing essential data for monitoring the furnace's operating status. Based on the analysis of the collected product image data, the system can identify and determine the qualification and overall quality of the products produced by the mesh belt furnace. Furthermore, the identification and determination results are used to verify whether the mesh belt furnace is operating normally. In cases of abnormal operation, the system can also accurately locate the workstations and positions with abnormal problems, thereby effectively improving the safety and stability of the mesh belt furnace operation and ensuring better product quality.

[0088] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions will not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A condition monitoring system for a mesh belt furnace used in ceramic sintering, characterized in that, include: Data acquisition layer, analysis layer, and control layer; The products conveyed in the mesh belt furnace have their image data acquired by the acquisition layer. The acquired product image data is further segmented to obtain product images. The analysis layer synchronously receives the product images obtained from the segmentation process in the acquisition layer. Based on the product images, it analyzes the sintering state of each group of product images. By applying the analyzed sintering state of each group of product images, it identifies the products corresponding to the sintering images that are not qualified and further obtains the corresponding positions of the products corresponding to the sintering images in the mesh belt furnace. The control layer receives the analysis results of the sintering status of the products corresponding to each group of product images from the analysis layer, and the corresponding position of the products corresponding to the images of products that have failed the sintering process in the mesh belt furnace. Based on the analysis results, it evaluates the overall quality of the products currently produced by the mesh belt furnace, and controls the mesh belt furnace based on the received position in the mesh belt furnace. The analysis layer includes an analysis module, an identification module, and a positioning module. The analysis module receives product images acquired from the acquisition layer and analyzes the sintering state of the product based on the product images. The identification module acquires the product sintering state analysis results from the analysis module and identifies products with unqualified sintering processes and their corresponding product images based on the product sintering state analysis results. The positioning module receives products with unqualified sintering processes and their corresponding product images identified by the identification module and uses the corresponding product images of the unqualified sintering processes to locate the products. The product sintering state analysis logic in the analysis module is represented as follows: Where: k is the product sintering state performance value; u is the product image; sim(α) v ,α center The similarity of the v-th sub-image in the product image to the central region of the product image is based on color level; T q T represents the value of the q-th pixel in the v-th sub-image of the product image in the temperature mapping table; center For the v-th sub-image in the product image, the corresponding value of the center pixel in the temperature mapping table; (T MIN ,T MAX The threshold is composed of the maximum and minimum temperatures required for ceramic sintering. In this context, a smaller product sintering state value (k) indicates a better sintering state, and vice versa. The temperature mapping table is set based on the colors exhibited by sintered ceramics at different temperature states during historical mesh belt furnace sintering processes. The sub-images in the product image are obtained through product image segmentation, with no fewer than nine groups of sub-images, and each group of sub-images in the product image is of equal size. Table Find the average of the terms.

2. The ceramic sintering mesh belt furnace condition monitoring system according to claim 1, characterized in that, The acquisition layer includes a camera module, a segmentation module, and a storage module. The camera module is used to acquire image data of products transmitted in the mesh belt furnace. The segmentation module is used to receive the product image data acquired by the camera module, segment the product image data to extract all product images from the product image data, and the storage module is used to receive the product images extracted by the segmentation module and store the product images. The mesh belt furnace consists of a conveyor station and a processing station. The conveyor station is used to transport products to the processing station for processing. The processing station consists of a pre-firing area, a sintering area, and a cooling area. The pre-firing and sintering areas are used to provide the temperature for sintering the products, and the cooling area is used to cool the products after sintering. The camera module is deployed in the sintering area of ​​the processing station. The conveyor station in the mesh belt furnace transports products at a constant speed, so that the products pass through the pre-firing area, sintering area, and cooling area of ​​the processing station in sequence. The camera module continuously collects product image data based on the time it takes for the products to travel from the conveyor station to the sintering area of ​​the processing station.

3. The ceramic sintering mesh belt furnace condition monitoring system according to claim 2, characterized in that, Before each product is transferred from the conveyor station of the mesh belt furnace, each group of products is placed at a designated position on the surface of the conveyor station, ensuring that the placement posture of each group of products is consistent and that the horizontal and vertical distances of each group of products are equal. When the camera module acquires product image data, it uses the boundary of the conveyor station of the mesh belt furnace as the image data acquisition boundary, so that the foreground of the acquired product image data consists of the product and the background consists of the surface of the conveyor station. When the segmentation module receives the product image data and segments it to extract all product images, it first determines the product image coordinates in the product image data, constructs a closed shape based on the product image coordinates, and segments the product image data using the closed shape to obtain the image region corresponding to the closed shape.

4. The ceramic sintering mesh belt furnace condition monitoring system according to claim 3, characterized in that, The logic for determining the product image coordinates in the product image data is as follows: In the formula: (x, y) are any set of coordinates of adjacent products on the boundary of the conveying surface of the conveying station of the mesh belt furnace; (x0, y0) are any set of coordinates on the contour of the contact surface between the conveyed product and the conveying station on the conveying station of the mesh belt furnace; (m, n) are any set of coordinates on the long side of the contour of the product image data; (m0, n0) are the product image coordinates. In this context, (x, y) and (x0, y0) use the same coordinate scale, and both the x and y coordinates of (x, y) and (x0, y0) are greater than zero. Similarly, (m, n) and (m0, n0) use the same coordinate scale, and both the x and y coordinates of (m, n) and (m0, n0) are greater than zero. When selecting (x, y), (x, y) falls on the long side of the transmission surface of the transmission station. The corresponding position of (x, y) is located in the product image data. The slope of (x, y) relative to (x0, y0) is equal to the slope of (m, n) relative to (m0, n0).

5. The ceramic sintering mesh belt furnace condition monitoring system according to claim 4, characterized in that, In the logic for determining product image coordinates, (x0, y0) are all contour corner points. After all product image coordinates in the product image data are connected to each other, several sets of closed graphics are obtained. The image regions corresponding to these several sets of closed graphics are the product images.

6. The ceramic sintering mesh belt furnace condition monitoring system according to claim 5, characterized in that, Each product image group contains a sub-image that corresponds to a set of T. center All T center When all conditions are met in equation (2), and the product sintering state performance value k < 1, the product corresponding to the product graphic is judged to be qualified; otherwise, it is judged to be unqualified. After receiving the sintering failure product and the corresponding product image, the positioning module further obtains the closed shape corresponding to the product image, and then uses the position coordinates corresponding to the closed shape to obtain (x0, y0) corresponding to the position coordinates of the closed shape based on the product image coordinates. Based on (x0, y0), the unqualified sintering product is determined.

7. The ceramic sintering mesh belt furnace condition monitoring system according to claim 1, characterized in that, The control layer includes an evaluation module and a control module. The evaluation module is used to receive the unqualified sintered products located in the analysis layer and evaluate the overall quality of the products produced in the mesh belt furnace based on the unqualified sintered products. The control module is used to obtain the position information of the product image corresponding to the unqualified sintered products and to control the temperature of the sintering equipment to which the area corresponding to the product image position information belongs in the sintering station of the mesh belt furnace processing station. The evaluation module includes evaluation logic. Based on this logic, the module assesses the overall quality of the products produced in the mesh belt furnace. Several sets of sintering equipment are evenly arranged at the sintering station within the mesh belt furnace's processing station. When the control module regulates the temperature of the sintering equipment, it follows the T-axis of the sub-image in the product image corresponding to the relative position of the sintering equipment on the product surface. center >T MAX If the temperature of the sintering equipment is lowered, it should not exceed T. MIN T center <T MIN Then adjust the sintering equipment temperature to increase, but not exceeding T. MAX .

8. The ceramic sintering mesh belt furnace condition monitoring system according to claim 7, characterized in that, The evaluation logic set in the evaluation module is expressed as follows: In the formula: K is the comprehensive quality assessment result of the product produced in the mesh belt furnace; p is the set of product images participating in the qualification judgment; zk q Let d(s) be the defined value of the pass / fail judgment result k for the product corresponding to the q-th product image group; g is the total number of product images; w is the set of product images corresponding to products with a fail / fail judgment result; d(s) r ,s r+1 Let be the distance between the r-th product image and the (r+1)-th product image; in, Table The larger the value of K, the better the overall quality of the products produced in the mesh belt furnace, and vice versa. q The value can be 1 or 0. When the product image corresponds to a product qualification judgment result of qualified, zk q The value is 1, and the value is 0.

9. The condition monitoring system for a mesh belt furnace for ceramic sintering according to claim 1, characterized in that, The analysis module is interconnected with the identification module and the positioning module via a wireless network. The analysis module is interconnected with the storage module via a wireless network. The storage module is interconnected with the segmentation module and the camera module via a wireless network. The positioning module is interconnected with the evaluation module via a wireless network. The evaluation module is interconnected with the control module via a wireless network.

10. A method for controlling the state of a mesh belt furnace for ceramic sintering, wherein the method is an implementation method of the state monitoring system for a mesh belt furnace for ceramic sintering as described in any one of claims 1-9, characterized in that, Includes the following steps: Step 1: Collect product image data in the sintering area of ​​the mesh belt furnace processing station; Step 2: Set up product image data segmentation logic, and perform segmentation processing on product image data based on the product image data segmentation logic to extract product images from all product image data; Step 3: Obtain the product images obtained from segmentation and extraction, set the product sintering state analysis logic, perform sintering state analysis on each group of product images, and identify the products corresponding to unqualified product images; Step 4: Locate the corresponding products for each group of non-conforming product images on the mesh belt furnace. Based on the positioning results and the identification results of the corresponding products for non-conforming product images, evaluate the quality of the sintered products produced in the mesh belt furnace. Step 5: Set the control logic, obtain the analysis and recognition results of whether the product image corresponds to the product's qualification, and locate the product corresponding to the image of the unqualified product; Step 6: For the product corresponding to the image of the non-conforming product located, deploy sintering equipment in the sintering area of ​​the corresponding processing station, and regulate the temperature of the sintering equipment based on the control logic.

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