CN110487415B - Molten metal fluid data detection device, method and system - Google Patents
Molten metal fluid data detection device, method and system Download PDFInfo
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Abstract
The invention relates to the technical field of metallurgy detection, and discloses a device, a method and a system for detecting molten metal fluid volume data, which are used for synchronously detecting and being compatible with space temperature and speed distribution information of high-temperature molten metal fluids in different industries on line to obtain the volume data of the high-temperature molten metal fluids. The device of the invention comprises: a first functional component for acquiring infrared thermal images and visible light video of molten metal flow synchronization; the second functional component is used for carrying out regional positioning on the molten metal fluid in the infrared thermal image and calculating the molten metal fluid in the positioned region to obtain the temperature of the molten metal fluid; and the third functional component is used for decomposing a frame image from the visible light video, acquiring a flow velocity field of the molten metal fluid in a camera coordinate system according to the extracted image characteristics of the molten metal fluid, converting the flow velocity field in the camera coordinate system into a flow velocity field in a world coordinate system and calculating the flow velocity of the molten metal fluid.
Description
Technical Field
The invention relates to the technical field of metallurgy detection, in particular to a molten metal fluid data detection device, method and system.
Background
In the metallurgical industry, most metals are produced by smelting in a high temperature reaction furnace. The method comprises the steps of putting raw materials such as metal ores and coke into a high-temperature closed reaction furnace, and forming high-temperature molten metal fluid including molten iron, aluminum liquid, copper liquid and the like in a furnace hearth after complex oxidation reduction reaction. When the molten metal solution in the reaction furnace reaches a certain amount, it flows out from the tap at a high speed. The temperature, the flow velocity and other types of heterogeneous spatial information of the molten metal fluid reflect the operating conditions of the quality of the molten metal, the temperature and the pressure in the reaction furnace and the like, are important parameter bases for regulating and controlling the quality of the molten metal, calculating the opening plugging time of the reaction furnace and monitoring the wear state of the outflow opening, and are the keys for ensuring that the molten metal meets the specifications of subsequent products and improving the quality and the quality rate of the products. Therefore, accurate online detection of molten metal fluid state information is critical to the smelting process.
Because molten metal has the characteristics of high temperature, high flow speed, strong corrosivity, easy formation of an oxide layer and slag bonding on the surface and the like, the state information of molten metal fluid is difficult to accurately measure on line in real time. The existing information detection of the molten metal fluid mainly focuses on the detection of single information, and a device capable of synchronously and comprehensively detecting various types of heterogeneous spatial information of the molten metal fluid on line is lacked.
For the detection of the temperature of the high-temperature molten metal fluid, the existing detection devices may be classified into a contact type detection device and a non-contact type detection device according to whether the detection device is in contact with the molten fluid to be detected. The contact device comprises a thermocouple, a blackbody cavity and the like, and the non-contact device comprises an infrared thermometer, an infrared thermal imager and the like. When the thermocouple is used for measuring temperature, one thermocouple is consumed for measuring temperature every time due to the fact that the temperature of molten metal is very high, and certain danger is faced due to the fact that an operator needs to be close to high-temperature molten metal fluid during temperature measurement. The blackbody cavity device is easily corroded by the high-temperature molten metal fluid due to the fact that the blackbody cavity device needs to be in direct contact with the high-temperature molten metal fluid, and the service life of the blackbody cavity device is limited. The infrared thermometer can acquire the point source temperature of the molten metal fluid on line, and the thermal infrared imager can acquire the surface source temperature of the molten metal fluid on line, but the accuracy of the infrared temperature measurement result is poor due to the fact that the flow rate of the high-temperature molten metal fluid is high, and various substances such as an oxide layer and slag exist on the surface of the high-temperature molten metal fluid.
The existing detection device for the flow velocity of the high-temperature molten metal fluid is mainly divided into a contact type detection device and a non-contact type detection device, the contact type flow velocity detection device adopts a high-temperature resistant material to be in direct contact with the high-temperature molten fluid, and measurable data is generated to achieve the purpose of detecting the flow velocity of the high-temperature molten fluid in real time, however, the high-temperature fluid flowing at high speed gradually abrades and erodes the high-temperature resistant material, so that the repeatability of the device is poor, the service cycle is short, and not only is the service life and the service performance of the device affected under the severe environment of a large amount of dust and high temperature, so that the investment cost is high, the; the non-contact flow velocity detection device acquires an infrared image of the molten fluid in a non-invasive manner through the device, and performs characteristic tracking by using the characteristics of image intensity, but the image intensity is changed due to the existence of a large amount of dust on the outflow site of the reaction furnace, so that the accuracy of flow velocity detection is seriously influenced.
On the background of high-quality development of a metallurgical process, new requirements are provided for detection of the metallurgical process, complex relationships among multiple types of heterogeneous spatial information are expected to be described, and online acquisition of the multiple types of heterogeneous spatial information is more expected. In order to comprehensively and vividly describe various types of heterogeneous spatial information such as temperature, flow velocity and the like of high-temperature molten metal fluid, the invention provides a concept of molten metal fluid volume data, and structural data formed by various types of heterogeneous spatial information such as temperature, flow velocity and the like and coupling relations thereof are defined as volume data, and the minimum composition unit of the volume data is a voxel with spatial geometric attributes, such as a temperature field, a flow velocity field and the like of the high-temperature molten metal fluid.
CN104748793A discloses a real-time combined measuring device for the temperature and the flow rate of a melt in an aluminum electrolysis cell and a measuring method thereof, and the real-time measuring device for the temperature and the flow rate comprises a distributed measuring probe transparent protection device, an infrared detection sensor, a user interface module and a temperature and speed measuring module. During detection, the device needs to be immersed into a melt in an aluminum electrolysis cell, an infrared image of the melt is obtained through an infrared detection sensor, a temperature detection module of the device detects the melt in the aluminum electrolysis cell at about 950 ℃ by adopting a colorimetric temperature measurement method, and a flow rate detection module of the device calculates the flow rate of the melt in the aluminum electrolysis cell according to the processing results of the infrared images at different moments.
However, the above patent only deals with melts with single physical properties, and when the physical properties of the molten metal are different, the temperature measurement results will have large deviation. The patent considers the melt flow in the aluminum electrolysis cell as simple rigid body movement, neglects the motion in the fluid and adds the influence of random noise, and after time t, the same area as the characteristic area is difficult to find on the image, thus leading to poor flow velocity detection effect of the patent. In addition, the patent belongs to a contact type detection device, is easy to wear and has a limited service life.
CN 201251439Y discloses a water depth flow velocity temperature measuring device. This patent specifically discloses a perpendicular continuous measurement device of measuring depth of water, velocity of flow, temperature, and the device comprises instrument box, motor drive mechanism, linear motion mechanism and measuring mechanism etc. can realize the continuous accurate measurement of the velocity of water and the temperature of the different degree of depth. However, this patent is a contact type detection device, and is faced to low temperature water flow, and is easily damaged when detecting high temperature molten fluid. And the core sensors such as the temperature sensor, the flow rate sensor and the like of the patent are difficult to be applied to high-temperature molten fluid.
Disclosure of Invention
The invention aims to disclose a device, a method and a system for detecting the volume data of molten metal fluid, which are used for synchronously detecting and being compatible with the space temperature and speed distribution information of high-temperature molten metal fluid in different industries on line to obtain the volume data of the high-temperature molten metal fluid.
To achieve the above object, the present invention discloses a method for detecting molten metal fluid volume data, comprising:
acquiring a synchronous infrared thermal image and a visible light video of the molten metal fluid;
carrying out regional positioning on the molten metal fluid in the infrared thermal image, and calculating the molten metal fluid in the positioned region to obtain the temperature of the molten metal fluid;
decomposing a frame image from the visible light video, acquiring a flow velocity field of the molten metal fluid in a camera coordinate system according to the extracted image characteristics of the molten metal fluid, converting the flow velocity field in the camera coordinate system into a flow velocity field in a world coordinate system, and calculating the flow velocity of the molten metal fluid;
correlating the resulting synchronized temperature and flow rate of the molten metal fluid into the molten metal fluid volume data.
To achieve the above object, the present invention also discloses a molten metal fluid data detecting apparatus, comprising:
a first functional component for acquiring infrared thermal images and visible light video of molten metal flow synchronization;
the second functional component is used for carrying out regional positioning on the molten metal fluid in the infrared thermal image and calculating the molten metal fluid in the positioned region to obtain the temperature of the molten metal fluid;
and the third functional component is used for decomposing a frame image from the visible light video, acquiring a flow velocity field of the molten metal fluid in a camera coordinate system according to the extracted image characteristics of the molten metal fluid, converting the flow velocity field in the camera coordinate system into a flow velocity field in a world coordinate system and calculating the flow velocity of the molten metal fluid.
Preferably, the apparatus of the present invention further comprises: a fourth functional component for correlating the resulting synchronized temperature and flow rate of the molten metal fluid into molten metal fluid volume data.
To achieve the above object, the present invention further discloses a molten metal fluid data detecting system, which includes at least one molten metal fluid data detecting device as described above. Optionally, the molten metal fluid volume data detection device is disposed on a three-dimensional cloud platform aligned with the high-temperature molten metal fluid outside the blast furnace, and the molten metal fluid volume data detection device is connected to the computer via a network.
The invention has the following beneficial effects:
the spatial temperature and speed distribution information of the high-temperature molten metal fluid can be synchronously detected on line, and the volume data of the high-temperature molten metal fluid is obtained; the device is convenient to install, safe to operate, suitable for smelting sites with severe environment, and widely applicable to information acquisition of the temperature, the flow rate and the like of high-temperature molten metal fluid in different industries with various heterogeneous spatial distribution characteristics.
The present invention will be described in further detail below with reference to the accompanying drawings.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate embodiments of the invention and, together with the description, serve to explain the invention and not to limit the invention. In the drawings:
FIG. 1 is a block diagram of an integrated module of a molten metal fluid volume data detection apparatus according to an embodiment of the present invention.
FIG. 2 is a block diagram of a molten metal fluid volume data detection system according to an embodiment of the present invention.
Fig. 3 is a block diagram of an infrared/visible light integrated optical module disclosed in the embodiment of the present invention.
Fig. 4 is a block diagram of an FPGA hardware module of the infrared thermal image preprocessing unit according to an embodiment of the present invention.
Fig. 5 is a block diagram of a DSP hardware module of a molten metal fluid temperature voxel detection unit according to an embodiment of the present invention.
Fig. 6 is a block diagram of an FPGA hardware structure of the visible light video preprocessing unit disclosed in the embodiment of the present invention.
Fig. 7 is a block diagram of a hardware structure of a DSP of the voxel detection unit of a molten metal fluid flow rate according to an embodiment of the present invention.
FIG. 8 is a block diagram of a guarding module of the molten metal fluid volume data detection device disclosed in the embodiments of the present invention.
FIG. 9 is a schematic view of a molten iron fluid data detection device for a blast furnace taphole according to an embodiment of the present invention.
Detailed Description
The embodiments of the invention will be described in detail below with reference to the drawings, but the invention can be implemented in many different ways as defined and covered by the claims.
Example one
The embodiment discloses a molten metal fluid volume data detection method, which comprises the following steps:
and step S1, acquiring the infrared thermal image and the visible light video of the molten metal fluid synchronously.
Alternatively, this step may be based on an infrared/visible light integrated optical module to acquire simultaneous infrared thermal images and visible light video of the molten metal fluid. Specifically, a main mirror light path, a spectroscope, a reflector and a transmission light path array are arranged in the infrared/visible light integrated optical module, infrared light and visible light share the main mirror light path, an optical signal passes through the main mirror light path and then is divided into two by the spectroscope, and the divided optical signals respectively pass through the transmission light path array and then are incident to the charge coupled device and the uncooled focal plane detection array to respectively form an infrared thermal image and a visible light video.
Step S2, carrying out area positioning on the molten metal fluid in the infrared thermal image, and calculating the molten metal fluid in the positioning area to obtain the temperature of the molten metal fluid; and meanwhile, decomposing a frame image from the visible light video, acquiring a flow velocity field of the molten metal fluid in a camera coordinate system according to the extracted image characteristics of the molten metal fluid, converting the flow velocity field in the camera coordinate system into a flow velocity field in a world coordinate system, and calculating the flow velocity of the molten metal fluid.
In this step, the flow velocity of the molten metal fluid is calculated by fusing the pyramid optical flow method and the cross-correlation method. Furthermore, the infrared emissivity of the molten metal fluid can be corrected according to the physical parameters of the molten metal fluid. Meanwhile, a temperature measurement correction model is established according to the influence of dust, so that the accuracy of accurately detecting temperature voxels on line is improved.
And step S3, correlating the obtained synchronous temperature and flow rate of the molten metal fluid into the molten metal fluid data.
Based on the method of the embodiment, optionally, two sets of independent FPGA + DSP resources are used for respectively performing temperature processing and molten metal flow rate processing on the molten metal fluid, wherein the FPGA resources are arranged in front of the DSP resources for corresponding preprocessing. Preferably, a protection module is provided outside the circuit resources for data processing, the protection module comprising: the protection device comprises a protection cylinder with air cooling protection, an air inlet, an air outlet and a protection lens; the air outlet is arranged at the front end of the protection module, and the protection lens is blown and swept by cold air or nitrogen introduced from the air inlet when the heat is taken away by the air outlet.
Furthermore, in this embodiment, an automatic cleaning mechanism may be further disposed on the protection module, and the automatic cleaning mechanism is configured to: cleaning the protective lens in a dormant state without collecting infrared thermal images and visible light videos, and automatically covering a cover to prevent dust pollution after cleaning is finished; and automatically opening the lid after initiating the infrared thermographic image and visible video acquisition.
Example two
The embodiment discloses a matching device and a system for executing the method of the embodiment.
The molten metal fluid volume data detection apparatus of the present embodiment includes at least the following first to fourth functional components. The functions of the components are as follows:
a first functional component for acquiring infrared thermal images and visible light videos of molten metal fluid in synchrony. Optionally, the first functional component includes: an infrared/visible light integrated optical module. Specifically, the infrared/visible light integrated optical module includes: the device comprises a main mirror light path, a spectroscope, a reflecting mirror and a transmission light path array; the infrared light and the visible light share a main mirror light path, the light signal is divided into two parts by the spectroscope after passing through the main mirror light path, and the divided light signals respectively pass through the transmission light path array and enter the charge-coupled device and the uncooled focal plane detection array to respectively form an infrared thermal image and a visible light video.
And the second functional component is used for carrying out regional positioning on the molten metal fluid in the infrared thermal image, and calculating the molten metal fluid in the positioned region to obtain the temperature of the molten metal fluid.
And the third functional component is used for decomposing a frame image from the visible light video, acquiring a flow velocity field of the molten metal fluid in a camera coordinate system according to the extracted image characteristics of the molten metal fluid, converting the flow velocity field in the camera coordinate system into a flow velocity field in a world coordinate system and calculating the flow velocity of the molten metal fluid.
A fourth functional component for correlating the resulting synchronized temperature and flow rate of the molten metal fluid into molten metal fluid volume data.
Preferably, in the embodiment, two independent FPGA + DSP resources are used to perform the temperature processing and the molten metal flow rate processing of the molten metal fluid, respectively, wherein the FPGA resources are pre-positioned in the DSP resources to perform the corresponding preprocessing.
The molten metal fluid volume data detecting system disclosed in this embodiment includes at least one molten metal fluid volume data detecting device as described above. Optionally, the molten metal fluid volume data detection device is disposed on a three-dimensional cloud platform aligned with the high-temperature molten metal fluid outside the blast furnace, and the molten metal fluid volume data detection device is connected to the computer via a network.
To facilitate better understanding of the present invention for those skilled in the art, the following concepts are further described in conjunction with logical architectural arrangements in specific application scenarios:
the molten metal fluid volume data detection device provided by the embodiment mainly comprises an infrared/visible light integrated optical module, a temperature voxel detection integrated module, a flow rate voxel detection integrated module, a protection module and the like, wherein the temperature voxel detection integrated module and the flow rate voxel detection integrated module are core modules of the device, as shown in fig. 1. When detecting the volume data of the high-temperature molten metal fluid, the volume data detecting device, the gigabit ethernet, the computer, the three-dimensional pan-tilt, and the like together form a molten metal fluid volume data detecting system, as shown in fig. 2, wherein the structural names corresponding to the respective reference numerals are: 40-molten metal fluid volume data detection device, 50-three-dimensional platform, 100-gigabit Ethernet, 200-computer. When the device is applied to online detection of molten metal fluid data, the device is fixed on a three-dimensional holder, and the device is aligned to the high-temperature molten metal fluid by adjusting the installation position and the angle of the device, so that an infrared thermal image and a visible light video of the molten metal fluid are acquired. A huge amount of online detection data is transmitted to a computer at high speed by utilizing a gigabit Ethernet.
The infrared/visible light integrated optical module consists of a primary mirror light path, a spectroscope, a reflecting mirror and a transmission light path array. The infrared light and the visible light share a main mirror light path, an optical signal passes through the main mirror light path, then is divided into two parts by the spectroscope, and the divided optical signals respectively enter the transmission light path array and enter a Charge Coupled Device (CCD) and the uncooled focal plane detection array. As shown in fig. 3. When the volume data of the molten metal fluid is detected, the infrared/visible light module can receive infrared radiation and visible light of the molten metal fluid, and the visible light is received by a Charge Coupled Device (CCD) through the spectroscope to form a visible light image of the molten metal fluid for detecting a speed voxel of the molten metal fluid, so that the uncooled focal plane detection array receives infrared light of the molten metal to form an infrared thermal image of the molten metal for detecting a temperature voxel of the molten metal.
The temperature voxel detection integrated module comprises an infrared thermal image acquisition unit, an infrared thermal image preprocessing unit, a molten metal fluid temperature voxel detection unit and the like.
The infrared thermal image acquisition unit mainly comprises an uncooled focal plane infrared detection element array, an A/D conversion chip, a power supply and the like. The uncooled focal plane infrared detection element array senses infrared radiation of molten metal fluid, converts the infrared radiation into analog signals, converts the analog signals into digital signals convenient to process by using an A/D conversion chip, and sends the digital signals to a signal processing circuit formed by an FPGA, a DSP and the like.
The main function of the infrared thermal image preprocessing unit is to locate the molten metal fluid through an image processing algorithm so as to obtain the corresponding temperature data of the molten metal fluid. Since the infrared thermographic image contains both the molten metal stream and other non-interesting substances. Therefore, the infrared thermal image must be localized to obtain temperature data corresponding to the molten metal-containing fluid only. Because the temperature difference between the molten metal fluid and other non-interesting substances causes obvious boundaries between the molten metal fluid and other non-interesting substances on the infrared thermal image, the canny operator is adopted to carry out edge detection on the infrared thermal image so as to obtain the boundaries of the molten metal fluid and further position the position of the molten metal fluid. The boundary information of the molten metal stream and the original infrared thermographic image are then used to obtain an infrared thermographic image region containing only the molten metal stream.
As shown in fig. 4, the hardware module of the infrared thermal image preprocessing unit includes a communication control module, a flash memory module, a logic and timing management module, and an execution module. The communication control module is responsible for distributing the infrared thermal image information to be processed to the flash storage module; the flash storage module is used for storing and calling required algorithms or parameters; the execution module is responsible for processing the infrared thermal image; the logic and time sequence management module is responsible for providing data driving signals for the infrared thermal image acquisition unit and is responsible for logic and time sequence management among algorithms and among a plurality of execution modules. The molten metal fluid region obtained by preprocessing is used for a molten metal fluid temperature voxel detection unit.
The molten metal fluid temperature voxel detection unit is a core unit for detecting temperature voxels by the device, and the temperature of the molten metal fluid is finally obtained by utilizing a molten metal fluid region obtained by preprocessing and passing through the temperature voxel detection unit. When the thermal infrared imager is used for measuring the temperature in a molten metal smelting site, the emissivity of the thermal infrared imager needs to be corrected so as to ensure the accuracy of the temperature data of the original thermal infrared image. The smelting environment of molten metal is often severe, and the influence of slag splashing and randomly distributed dust exists. When environmental interference such as dust exists, a temperature correction model aiming at the dust influence is utilized to correct the temperature result of the molten metal, so that the accurate temperature of the molten metal is obtained.
Optionally, as shown in fig. 5, the hardware module of the molten metal fluid temperature voxel detection unit includes a buffer, a command module, a DSP, an external SRAM, and the like. The buffer zone may buffer an infrared thermal image of a region of molten metal flow; the command module transmits signals to the task management module when receiving idle signals sent by all DSP chips, and the task division module divides processing tasks and sends an operation instruction to the DSP; the DSP is responsible for initializing parameter storage, emissivity calculation, correction coefficient calculation and the like of the infrared thermal image temperature data; parameters such as emissivity and correction coefficient can be loaded into an external SRAM to calculate the molten metal temperature voxel.
In a specific application example of the embodiment, the flow rate voxel detection integrated module may be composed of a visible light video acquisition unit, a visible light image preprocessing unit, a fluid flow rate voxel detection unit, and the like.
The visible light video acquisition unit mainly comprises a CCD, a high-speed video acquisition card, a video compression module and the like. The CCD is used for collecting high-frame-rate video stream information of high-temperature molten fluid outflow and transmitting the high-frame-rate video stream information to the high-speed collection card, received high-frame-rate video source analog signals are converted into digital signals through an A/D conversion module on the high-speed collection card, then the digital signals are sent to a memory of the high-speed collection card, after a period of storage, a large number of video signals are compressed through a video compression chip of the high-speed collection card, the compressed video signals are sent to a visible light video preprocessing unit at the rear end, meanwhile, a new storage space is opened up in the memory for storing the currently collected video stream by the high-speed video collection card, and the storage space of the video stream is released after the previous video stream is completely transmitted.
The visible light video preprocessing unit comprises a video stream decomposition module, a frame image denoising module, a molten fluid positioning module and the like. Firstly, a video stream decomposition module decomposes a compressed video stream signal transmitted by a video acquisition unit into frame images, and divides all the frame images into N frame image groups with the same number of frames N according to a time sequence by taking N frame images in a time T as a division period. In consideration of the fact that the field environment is severe and the interference of external noise such as dust exists, the collected video stream signal contains noise, and therefore the noise in the frame image group is removed by using a filter in the frame image denoising module. The preprocessed visible light frame image group is transmitted to a molten metal fluid flow rate online detection unit to be used for calculating a fluid flow rate voxel.
The hardware structure of the visible light video preprocessing unit is shown in fig. 6, and includes a communication control module, a flash memory module, a logic and timing management module, and an execution module. The communication control module is responsible for distributing high frame frequency video streams to be processed to the flash storage module; the flash storage module is used for storing and calling a video stream decomposition algorithm, an image denoising algorithm and a molten fluid positioning algorithm; the execution modules are multiple and are responsible for parallel processing of the high-frame-frequency images; the logic and time sequence management module is responsible for providing data driving signals for the high-speed video acquisition unit and is responsible for logic and time sequence management among algorithms and among a plurality of execution modules. The molten metal fluid region obtained by preprocessing is used for a molten metal fluid flow rate voxel detection unit.
The voxel detection unit of the flow rate of the molten metal fluid is a core unit for detecting the flow rate voxel of the device. Firstly, by utilizing each frame image group generated by the visible light video preprocessing unit, the image characteristics of the molten metal fluid in the n frame images are extracted through image processing algorithms such as edge detection and morphological processing, and interested image characteristics are selected, so that the image processing time can be reduced. And secondly, respectively acquiring a coarse flow velocity field of the molten metal fluid by using a pyramid optical flow method and a cross-correlation method, and acquiring a fine flow velocity field based on a fusion algorithm. And then calibrating the high-speed camera under a world coordinate system, converting the precise flow velocity field under the camera coordinate system into the world coordinate system, and finally obtaining the precise flow velocity field of the molten metal fluid.
The hardware modules of the voxel detection unit for flow rate of molten metal fluid are shown in fig. 7, and include a buffer, a command module, a multi-channel DSP, an external SRAM, and the like. The buffer area can buffer the high frame frequency image of the molten metal fluid area; when the command module receives idle signals sent by all DSP chips, the idle signals are transmitted to the task management module, the task division module divides processing tasks and sends an operation instruction to the DSP, so that the multi-channel DSP can process high frame frequency images of the molten metal fluid in parallel; the multi-channel DSP calculates a coarse flow velocity field of the high-frame-frequency visible light image by using an embedded pyramid optical flow algorithm, a cross-correlation algorithm and a coarse flow field fusion algorithm; the coarse flow field data may be loaded into a corresponding external SRAM for calculation of molten metal flow voxels.
Furthermore, because the smelting environment of the molten metal is severe, interference such as high-temperature radiation, slag splashing, randomly distributed dust and the like exists, and in order to enable the molten metal body data detection device to stably operate on a smelting site for a long time, the device must be protected. The protection module of the high-temperature molten metal fluid data detection device mainly comprises a protection cylinder, a protection lens, an automatic cleaning mechanism, an air inlet and the like, as shown in fig. 8, wherein the structural names corresponding to the reference numerals are respectively: 1-automatic cleaning mechanism, 2-protective cylinder, 3-air inlet, 4-flange, 5-inlet, 6-integrated cable, 7-protective glass, 8-optical system, temperature and flow rate voxel detection module. In order to avoid the influence of high-temperature radiation on the detection precision of the detection device, a protection cylinder with air cooling protection is designed, cold air or nitrogen is introduced through an air inlet, so that the flowing cold air or nitrogen can exchange heat with the internal detection module continuously, and the heat is taken away through an air outlet at the front end of the detection device, so that the purpose of air cooling and cooling the detection device is achieved, and the device can be used on an industrial field stably for a long time. Meanwhile, the protective lens is designed for preventing dust, slag and the like from splashing on the inner lens in consideration of the fact that dust is large in the smelting environment of the high-temperature molten metal fluid and the high-temperature molten metal fluid is easy to splash, and the protective lens plays a role in protecting the inner lens of the temperature and flow velocity voxel detection module. When the device works, if dust covers the protective lens, the back-end imaging can be caused to generate a black shadow. In order to avoid the surface of the protective lens from being polluted by dust when the device works, an automatic cleaning mechanism is designed, and the protective lens is swept by cold air or nitrogen introduced from an air inlet while the heat is taken away through a front end exhaust port, so that the infrared thermal image and the visible light video acquisition unit can acquire clear high-temperature molten fluid images. In addition, the automatic cleaning mechanism cleans the protective lens of the device in the non-working time of the device, and after cleaning is finished, the automatic cleaning mechanism automatically covers the protective lens to prevent dust pollution. When the detection device starts to work, the automatic cleaning mechanism automatically opens the cover, so that the device can acquire images or videos of the high-temperature molten fluid.
Further, referring to fig. 9, the structural names corresponding to the labels are: 10-blast furnace, 20-tap hole, 30-molten iron fluid, 40-molten metal fluid data detection device, 50-three-dimensional platform, 6-comprehensive cable. In this embodiment, a 2650m3 large-sized blast furnace in a certain iron works is used as an experimental platform, and the molten metal fluid data detection device of the invention is applied to the molten iron flow detection of the No. 1 tap hole of the blast furnace.
In order to meet the requirement of detecting the temperature and the flow rate of the high-speed high-temperature molten iron flow, the resolution of the uncooled focal plane detection element array is 1024 × 768, the infrared temperature measurement frame frequency is 30Hz, the CCD resolution is 1280 × 720, the visible light temperature measurement frame frequency is 240Hz, and the front-end field angle is 30 degrees. The detection device is arranged beside an operating platform of a No. 1 tap hole and is 8m away from the tap hole, a detection system shown in the attached figure 9 is constructed, and the implementation steps of the molten iron data detection are as follows:
1. a volume data detection device is arranged near a blast furnace operation table, so that a front end lens of the device is over against the molten iron flow of a blast furnace taphole. And detecting the temperature of molten iron higher than the lower part of the tap hole by using a rapid thermocouple, and acquiring the infrared emissivity based on an emissivity correction method. And calibrating the visible camera according to the field installation parameters of the detection device, and determining the relationship between a world coordinate system and the image pixel coordinates.
2. And acquiring an infrared thermal image and a visible light video of the molten iron flow by using the infrared/visible light integrated optical module, the infrared thermal image acquisition unit and the visible light video acquisition unit, and transmitting the infrared thermal image and the visible light video to FPGA (field programmable gate array) and DSP (digital signal processor) hardware for parallel preprocessing.
3. And in an FPGA hardware platform for processing the infrared thermal image, positioning temperature data corresponding to a molten iron flow area by using a molten iron flow area positioning algorithm embedded in the FPGA. And meanwhile, in an FPGA hardware platform for processing the visible light video, a frame image decomposition algorithm and an image denoising algorithm embedded in the FPGA hardware platform are utilized to obtain a visible light frame image group.
4. And respectively inputting the molten iron flow area temperature data and the visible light frame image group output by the multi-channel FPGA hardware platform into a DSP hardware structure for molten iron temperature voxel detection and a multi-channel DSP hardware structure for molten iron flow speed voxel detection, and acquiring a temperature field and a flow speed field of high-temperature molten iron to form molten iron volume data.
In summary, the present embodiment has the following features:
(1) and the data of the high-temperature molten metal fluid is firstly provided to describe the information of the temperature, the flow speed and the like of the molten metal fluid with the characteristics of multi-class heterogeneous space distribution.
(2) The high-temperature molten metal fluid volume data detection device is designed for the first time to detect the volume data of the molten metal fluid, and various types of heterogeneous information of the molten metal fluid can be synchronously detected.
(3) An infrared/visible light integrated optical module is designed, the infrared radiation and the visible light of the molten metal fluid share a main mirror light path, and the uncooled focal plane detection element array receives the infrared radiation through a spectroscope and a transmission light path array, so that the ccd receives the visible light.
(4) And a molten metal fluid temperature voxel detection module is designed. And correcting the infrared emissivity of the molten metal fluid according to the physical parameters of the molten metal fluid. Meanwhile, a temperature measurement correction model is established according to the influence of dust, and temperature voxels can be accurately detected on line.
(5) And a molten metal flow velocity voxel detection module is designed. And acquiring a high-frame-rate visible light video image of the molten metal fluid, and acquiring a flow velocity voxel of the molten metal fluid by fusing a pyramid optical flow method and a cross-correlation method.
(6) And a protective cylinder with air cooling protection and an automatic cleaning mechanism is designed to overcome the influence of high-temperature radiation on an internal detection circuit and the pollution of dust on a detection device on a smelting site.
In summary, the apparatus, method and system for detecting molten metal fluid data disclosed in the above embodiments of the present invention at least have the following advantages:
the spatial temperature and speed distribution information of the high-temperature molten metal fluid can be synchronously detected on line, and the volume data of the high-temperature molten metal fluid is obtained; the device is convenient to install, safe to operate, suitable for smelting sites with severe environment, and widely applicable to information acquisition of the temperature, the flow rate and the like of high-temperature molten metal fluid in different industries with various heterogeneous spatial distribution characteristics.
The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (10)
1. A molten metal fluid volume data detection apparatus, comprising:
a first functional assembly for acquiring simultaneous infrared thermal images and visible light video of a molten metal fluid, wherein the first functional assembly comprises: an infrared/visible light integrated optical module for acquiring infrared thermal images and visible light videos synchronized with molten metal fluid, the infrared/visible light integrated optical module comprising: the device comprises a main mirror light path, a spectroscope, a reflecting mirror and a transmission light path array; the infrared light and the visible light share a main mirror light path, the light signal is divided into two parts by the spectroscope after passing through the main mirror light path, and the divided light signals respectively pass through the transmission light path array and are incident to the charge-coupled device and the uncooled focal plane detection array to respectively form an infrared thermal image and a visible light video;
the second functional component is used for carrying out regional positioning on the molten metal fluid in the infrared thermal image and calculating the molten metal fluid in the positioned region to obtain the temperature of the molten metal fluid;
the third functional component is used for decomposing a frame image from the visible light video, acquiring a flow velocity field of the molten metal fluid in a camera coordinate system according to the extracted image characteristics of the molten metal fluid, converting the flow velocity field in the camera coordinate system into a flow velocity field in a world coordinate system and calculating the flow velocity of the molten metal fluid;
a fourth functional component for correlating the resulting synchronized temperature and flow rate of the molten metal fluid into molten metal fluid volume data.
2. The molten metal fluid volume data detection device of claim 1, wherein two independent sets of FPGA + DSP resources are used to perform molten metal fluid temperature processing and molten metal flow rate processing, respectively, wherein the FPGA resources are pre-located in the DSP resources for corresponding preprocessing.
3. A molten metal fluid volume data detection apparatus as recited in claim 1, further comprising:
a protection module disposed outside of circuit resources for data processing, the protection module comprising: the protection device comprises a protection cylinder with air cooling protection, an air inlet, an air outlet and a protection lens; the air outlet is arranged at the front end of the protection module, and the protection lens is blown and swept by cold air or nitrogen introduced from the air inlet when the heat is taken away by the air outlet.
4. A molten metal fluid volume data detection apparatus according to claim 3, further comprising:
set up in automatic mechanism that cleans on the protection module for: cleaning the protective lens in a dormant state without collecting infrared thermal images and visible light videos, and automatically covering a cover to prevent dust pollution after cleaning is finished; and automatically opening the lid after initiating the infrared thermographic image and visible video acquisition.
5. A molten metal fluid volume data detection method, comprising:
acquiring an infrared thermal image and a visible light video which are synchronous with molten metal fluid, specifically acquiring the infrared thermal image and the visible light video which are synchronous with the molten metal fluid based on an infrared/visible light integrated optical module, wherein a main mirror light path, a spectroscope, a reflector and a transmission light path array are arranged in the infrared/visible light integrated optical module, infrared light and visible light share the main mirror light path, an optical signal is divided into two by the spectroscope after passing through the main mirror light path, and the divided optical signals respectively pass through the transmission light path array and are incident to a charge coupled device and a non-refrigeration focal plane detection array to respectively form the infrared thermal image and the visible light video;
carrying out regional positioning on the molten metal fluid in the infrared thermal image, and calculating the molten metal fluid in the positioned region to obtain the temperature of the molten metal fluid;
decomposing a frame image from the visible light video, acquiring a flow velocity field of the molten metal fluid in a camera coordinate system according to the extracted image characteristics of the molten metal fluid, converting the flow velocity field in the camera coordinate system into a flow velocity field in a world coordinate system, and calculating the flow velocity of the molten metal fluid;
correlating the resulting synchronized temperature and flow rate of the molten metal fluid into the molten metal fluid volume data.
6. The molten metal fluid volume data detection method according to claim 5, wherein two sets of independent FPGA + DSP resources are used for performing molten metal fluid temperature processing and molten metal flow rate processing, respectively, wherein the FPGA resources are pre-positioned in the DSP resources for performing corresponding preprocessing.
7. A molten metal fluid volume data detection method according to claim 5, wherein a guard module is provided outside of circuit resources for data processing, the guard module comprising: the protection device comprises a protection cylinder with air cooling protection, an air inlet, an air outlet and a protection lens; the air outlet is arranged at the front end of the protection module, and the protection lens is blown and swept by cold air or nitrogen introduced from the air inlet when the heat is taken away by the air outlet.
8. A molten metal fluid volume data detection method according to claim 7, further comprising:
set up automatic mechanism of cleaning on the protection module, automatic mechanism of cleaning is used for: cleaning the protective lens in a dormant state without collecting infrared thermal images and visible light videos, and automatically covering a cover to prevent dust pollution after cleaning is finished; and automatically opening the lid after initiating the infrared thermographic image and visible video acquisition.
9. A molten metal fluid volume data detection system, comprising:
at least one molten metal fluid data detecting apparatus according to any one of claims 1 to 4.
10. A molten metal fluid volume data detection system as claimed in claim 9 wherein said molten metal fluid volume data detection device is disposed on a three dimensional cloud platform external to the blast furnace aimed at the high temperature molten metal fluid, said molten metal fluid volume data detection device establishing a network connection with a computer.
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