Thermal Imaging of Coal Piles for Early Heat Generation Detection
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Solution Overview
Problem
Existing methods for detecting heat generation in coal and steelmaking dust piles are inefficient, requiring manual insertion of thermocouples and limited to partial temperature assessments, missing narrow-range heat generation and lacking comprehensive, timely detection.
Innovation Solution
A management system utilizing an imaging unit to capture heat distribution images of coal and steelmaking dust piles from a vantage point, combined with threshold information to determine heat generation, and a determining unit to assess and respond to potential ignition risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If thermocouples are inserted into the coal pile to measure temperature, then temperature measurement capability is provided, but manual intervention is required and only partial temperatures can be assessed
Solution Approach 1:
The patent replaces the mechanical thermocouple insertion method with an infrared imaging system that uses optical sensors to detect thermal radiation from the coal pile surface. The infrared camera captures heat distribution images without physical contact, eliminating the need for manual thermocouple insertion and retrieval while providing comprehensive temperature assessment across the entire pile surface.
Solution Approach 2:
The patent creates a thermal image copy of the coal pile's heat distribution pattern. The infrared camera captures and processes thermal radiation to generate visual representations of temperature distribution, allowing operators to assess the entire pile's thermal state from a distance without direct contact or manual measurement at multiple points.
2Measurement precision
If thermocouples are inserted into the coal pile, then temperature measurement is possible, but detection of narrow-range heat generation is missed and work for insertion and retrieval increases
Solution Approach 1:
The patent divides the coal pile surface into multiple detectable regions using an infrared camera with adjustable fields of view. The imaging system captures heat distribution across different zones and time points, ensuring comprehensive coverage of the entire pile surface. This segmented approach to thermal imaging detects heat generation at multiple locations simultaneously, preventing omission of narrow-range thermal events.
Solution Approach 2:
The patent implements continuous or repeated infrared thermal imaging of the coal pile over time. By capturing heat distribution images at multiple time points and processing them to identify temperature changes, the system continuously monitors for heat generation events. This continuous observation ensures that transient or localized heating events are detected, improving reliability compared to discrete thermocouple measurements.
3Area of stationary object
If infrared thermometers scan the surface layer of coal piles, then overall heat generation image can be obtained, but comprehensive heat generation assessment takes too much time
Solution Approach 1:
The patent transitions from one-dimensional point-by-point temperature scanning to two-dimensional thermal image capture. The infrared camera captures the entire coal pile surface in a single frame, providing comprehensive spatial coverage instantaneously. This dimensional change from linear scanning to areal imaging dramatically reduces assessment time while maintaining complete surface coverage.
Solution Approach 2:
The patent pre-processes and stores heat distribution images and their corresponding timestamp information for efficient retrieval and analysis. By organizing thermal data in advance with metadata including capture timing and location information, the system enables rapid assessment when needed, reducing the time required for heat generation evaluation compared to real-time scanning.
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
Enables comprehensive, rapid detection of heat distribution across entire piles, allowing for targeted responses to prevent ignition without manual intervention and ensuring thorough heat generation detection.
Implementation Method 1
an imaging unit, a threshold information acquiring unit, and a determining unit. The imaging unit is configured to perform imaging of heat distribution image information indicating a heat distribution image of a surface layer of a pile of the coal and/or steelmaking dust
Data Source
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AI summary
To provide a management system, a management apparatus, a management method, and a management program capable of readily determining a heat distribution of a pile of coal and/or steelmaking dust. An aspect of the present invention provides a management system of coal and/or steelmaking dust being managed outdoors. The management system includes an imaging unit, a threshold information acquiring unit, and a determining unit. The imaging unit is configured to perform imaging of heat distribution image information indicating a heat distribution image of a surface layer of a pile of the coal and/or steelmaking dust from a position where imaging of an entire surface layer of the pile can be performed. The threshold information acquiring unit is configured to acquire threshold information indicating a threshold of a temperature of the surface layer of the pile. The determining unit is configured to determine heat generation of the pile based on the heat distribution image information and the threshold information.