Conveyor Feedstock Mass Tracking via Image Segmentation
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Solution Overview
Problem
Existing systems for determining the mass flow of feedstock into metallurgical furnaces, such as electric arc furnaces, face inaccuracies due to the assumption that each charge stays together and progresses as a unit, which is not the case, especially with vibrating conveyors, leading to difficulties in modeling and predicting the feedstock arrival and mass distribution.
Innovation Solution
A method and system that involve taking successive digital images of the feedstock on a conveyor, computing the advancing distance and transversal height profiles, determining the effective density, and calculating the mass of feedstock discharged into the furnace using these parameters, allowing for precise tracking and prediction of feedstock arrival and optimizing furnace operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the system assumes each charge stays together and progresses as a unit on the conveyor, then the calculation system is simplified, but the measurement precision of feedstock mass flow deteriorates
Solution Approach 1:
The patent divides the feedstock charge into multiple sub-volumes along the conveyor direction. Instead of treating the entire charge as a single unit, the system segments it into discrete portions that can be individually tracked and measured. This segmentation allows for more accurate mass flow determination by accounting for the actual distribution and movement of different charge portions, resolving the contradiction between simplified calculations and precise measurement.
2Measurement precision
If successive digital images are taken and numerical processing is performed to compute advancing distance and density, then the measurement precision of feedstock mass flow is improved, but the device complexity increases
Solution Approach 1:
The patent replaces complex mechanical measurement systems with an optical-based image processing system. Instead of using mechanical sensors or physical measurement devices along the conveyor, the system uses digital cameras to capture images of the feedstock and employs numerical processing algorithms to extract advancing distance, height profiles, and density information. This substitution maintains high measurement precision while avoiding the complexity of mechanical measurement infrastructure.
Solution Approach 2:
The system creates digital copies (images) of the physical feedstock charge and performs measurements on these copies through numerical processing. By working with image data rather than directly measuring the physical material, the system achieves precise mass flow determination without requiring complex physical measurement devices. The digital copies allow for non-intrusive, contactless measurement that simplifies the overall system architecture.
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
This approach enables accurate tracking and prediction of feedstock mass flow, allowing for optimized furnace operation in terms of capacity, power consumption, and operating costs, even with vibrating conveyors, by dynamically adjusting parameters based on real-time data.
Implementation Method 1
taking successive digital images of the feedstock in a specific zone of the conveyor
Implementation Method 2
determining at least one transversal height profile of the sub-volume of feedstock
Data Source
AI summary
A method and a system for determining a mass of feedstock discharged by a conveyor during a first time interval Δt are disclosed. The method includes taking successive digital images of the feedstock in a specific zone of the conveyor being separated by a second time interval δt of smaller duration than the first time interval Δt, for each of the second time intervals δt: computing the advancing distance of a sub-volume of feedstock during the second time interval δt in the specific zone of the conveyor by numerical treatment of the two successive images associated with the second time interval δt; determining at least one transversal height profile of the sub-volume of feedstock; and determining an effective feedstock density for the sub-volume of feedstock. The method further includes computing the mass of feedstock discharged by the conveyor during the first time interval Δt into the metallurgical furnace on the basis of the advancing distance, the at least one transversal height profile and the effective feedstock density, computed or determined for each of the second time intervals δt.