Tundish Water Model Flow Mapping With Ink-Diffusion Imaging
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Solution Overview
Problem
Current methods for obtaining fluid flow directions in tundish water models are limited by laser scattering and deviation caused by dams and weirs, and lack quantitative analysis through image processing in dyeing experiments.
Innovation Solution
A method involving building a tundish water model with a preset similarity ratio, conducting an ink diffusion experiment, frame-by-frame video processing, and using digital image processing to obtain velocity vector maps and fluid flow directions through grayscale gradients.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If PIV or LDA methods are used to obtain tundish flow field, then measurement precision is improved, but the method can only be applied to blank tundish or tundish with turbulence suppressor, and dams and weirs cause laser scattering and deviation
Solution Approach 1:
The patent creates a water model copy of the tundish that replicates the flow characteristics of the actual tundish. This allows the flow field to be studied in a controlled environment using dye injection and image processing, avoiding the limitations of direct laser measurement in complex tundish configurations with dams and weirs
Solution Approach 2:
The patent replaces the optical laser-based measurement systems (PIV/LDA) with a dye injection and optical imaging system. This substitution eliminates the laser scattering and deviation problems caused by dams and weirs, as the dye particles can be visualized through standard imaging techniques that are not affected by these structural elements
2Loss of information
If dyeing experiment of water model is conducted to reveal fluid flow, then flow visualization is improved, but current experiments are mostly qualitative discussions without quantitative analysis
Solution Approach 1:
The patent implements a feedback loop where the captured images of dye distribution are processed through image analysis algorithms that track dye particle positions over time. This feedback mechanism converts qualitative visual information into quantitative velocity and flow direction data, enabling precise measurement of fluid flow characteristics
Solution Approach 2:
The patent introduces image processing algorithms as an intermediary between the dye injection experiment and the final flow measurement results. These algorithms analyze the grayscale gradients in sequential images to calculate velocity vectors, transforming qualitative dye patterns into quantitative flow field data
3Measurement precision
If complex measurement systems like PIV or LDA are used, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent uses inexpensive dye materials and standard imaging equipment instead of expensive laser-based measurement systems. The dye is consumed in each experiment but provides sufficient data, and the imaging system is far less costly than PIV or LDA equipment while achieving comparable measurement precision through clever image processing
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
Accurately and efficiently obtains fluid flow directions in tundish water models, providing quantitative data under various conditions, and can be applied to other metallurgical vessels.
Implementation Method 1
carrying out an ink diffusion experiment in the tundish water model
Implementation Method 2
carrying out a binarization processing on the video of the ink diffusion process frame by frame to obtain binarized images; obtaining a time grayscale map based on grayscale values of the binarized images; obtaining a velocity vector map of the tundish water model based on grayscale gradients of the time grayscale map
Data Source
AI summary
A method and a system for obtaining fluid flow directions of a tundish water model are provided, and the method includes the following steps: building the tundish water model with a preset similarity ratio with a tundish prototype; carrying out an ink diffusion experiment in the tundish water model, and shooting a video of an ink diffusion process; carrying out a binarization processing on the video of the ink diffusion process frame by frame to obtain binarized images; obtaining a time grayscale map based on grayscale values of the binarized images; obtaining a velocity vector map of the tundish water model based on grayscale gradients of the time grayscale map; and obtaining a moving direction of the ink based on the velocity vector map, and obtaining a flowing direction of fluid in the tundish water model based on the moving direction.