Camera-Based Speed Measurement for Steel Casting Lines
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Solution Overview
Problem
Existing methods for measuring the movement characteristics of oblong products, such as speed and vibrations, in steel casting processes are often inaccurate due to high temperatures, wear issues with contact-based methods, and the complexity and cost of non-contact Doppler effect laser measurers, which also fail to account for horizontal and vertical movements caused by vibrations.
Innovation Solution
A device using a camera to acquire images of the product at successive instants and process them with mathematical algorithms based on the image correlation principle to determine spatial displacement, allowing for accurate measurement of speed and movement characteristics without contact, leveraging surface irregularities for enhanced reliability, and analyzing frequency components to diagnose anomalies in the casting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If contact-based measuring rolls are used to measure speed, then measurement can be performed, but accuracy deteriorates due to wear, heat dilation, and slipping at high temperatures
Solution Approach 1:
The patent replaces the mechanical contact-based measuring rolls with an optical measurement system using cameras and image correlation algorithms. This substitution eliminates direct mechanical contact between the measurement device and the hot metal product, thereby avoiding wear, heat dilation, and slipping issues that compromise accuracy and reliability in high-temperature environments.
Solution Approach 2:
The patent introduces light as an intermediary medium to transfer information about the product's movement. Instead of direct mechanical contact, the optical system captures images of the product surface, and the image correlation algorithm uses light-based patterns to calculate displacement and speed, enabling accurate measurement without physical contact.
2Measurement precision
If Doppler effect laser measurers are used for non-contact speed measurement, then contact issues are avoided, but device complexity and cost increase significantly
Solution Approach 1:
The patent creates optical copies (images) of the product surface at different time instances using standard cameras. Instead of using complex laser Doppler systems, the method captures visual information in the form of images and processes them through correlation algorithms to extract speed data, significantly simplifying the measurement system while maintaining non-contact capability.
Solution Approach 2:
The patent replaces the complex laser-based Doppler effect measurement system with a simpler optical imaging system using standard cameras and computational image correlation. This substitution reduces device complexity and cost while achieving comparable or superior measurement capabilities for industrial applications.
3Device complexity
If Doppler effect laser measurers are used, then non-contact measurement is achieved, but measurement reliability deteriorates due to inability to identify horizontal and vertical vibrations
Solution Approach 1:
The patent transitions from one-dimensional speed measurement to two-dimensional spatial displacement measurement by capturing images in multiple dimensions. The image correlation algorithm analyzes pixel displacement in both horizontal and vertical directions, enabling the system to distinguish between actual product movement and vibrations caused by mechanical systems, thereby improving measurement reliability.
4Reliability
If surface irregularities are present on the cast product, then contact measurement is affected, but optical image correlation measurement is enhanced
Solution Approach 1:
The patent converts the previously harmful surface irregularities (scale, roughness) into beneficial features for optical measurement. The image correlation algorithm uses these surface patterns as natural reference markers to track displacement, transforming what was once a source of measurement error into an enhancement of measurement precision and reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides accurate, reliable, and cost-effective measurement of speed and movement characteristics, including transverse movements, and quickly identifies potential issues like friction and lubrication problems, enabling effective diagnosis of casting process anomalies.
Implementation Method 1
products moving in a determinate direction of feed and emitting radiations, for example of the infrared type
Data Source
AI summary
A device to analyze and determine the movement characteristics of products moving in a determinate direction of feed (F) and emitting radiations, in particular products exiting from a casting line, comprises a camera to continuously acquire images of the product moving in the direction of feed (F) in at least two successive instants of time, and an electronic processing unit by means of which the comparison between at least two successive images acquired is carried out, using mathematical algorithms based on the image correlation principle, in order to determine the spatial displacement of the images and then the movement characteristics of the product moving in the direction of feed (F) are analyzed and determined.