CN113262551A - Filtering condition monitoring method of aluminum oxide flat disc filter and related equipment - Google Patents
Filtering condition monitoring method of aluminum oxide flat disc filter and related equipment Download PDFInfo
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- CN113262551A CN113262551A CN202110379772.0A CN202110379772A CN113262551A CN 113262551 A CN113262551 A CN 113262551A CN 202110379772 A CN202110379772 A CN 202110379772A CN 113262551 A CN113262551 A CN 113262551A
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- 238000001914 filtration Methods 0.000 title claims abstract description 87
- 238000000034 method Methods 0.000 title claims abstract description 58
- 238000012544 monitoring process Methods 0.000 title claims abstract description 35
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 title claims abstract description 35
- 239000004744 fabric Substances 0.000 claims abstract description 235
- 230000007547 defect Effects 0.000 claims abstract description 127
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 79
- 230000002950 deficient Effects 0.000 claims description 22
- 238000006243 chemical reaction Methods 0.000 claims description 20
- 238000004590 computer program Methods 0.000 claims description 12
- 230000011218 segmentation Effects 0.000 claims description 6
- 238000007689 inspection Methods 0.000 abstract description 13
- 238000004519 manufacturing process Methods 0.000 description 15
- 238000010586 diagram Methods 0.000 description 12
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 10
- 238000001514 detection method Methods 0.000 description 10
- 230000008569 process Effects 0.000 description 9
- 238000012545 processing Methods 0.000 description 8
- 239000000047 product Substances 0.000 description 8
- 239000002002 slurry Substances 0.000 description 8
- 238000007664 blowing Methods 0.000 description 7
- 230000006870 function Effects 0.000 description 6
- 239000007788 liquid Substances 0.000 description 6
- 238000012986 modification Methods 0.000 description 6
- 230000004048 modification Effects 0.000 description 6
- 230000009471 action Effects 0.000 description 4
- 239000003513 alkali Substances 0.000 description 4
- 238000004891 communication Methods 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 238000012423 maintenance Methods 0.000 description 4
- 239000012452 mother liquor Substances 0.000 description 4
- 230000000007 visual effect Effects 0.000 description 4
- 230000008859 change Effects 0.000 description 3
- 230000008439 repair process Effects 0.000 description 3
- 238000000926 separation method Methods 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- 230000005540 biological transmission Effects 0.000 description 2
- 238000003708 edge detection Methods 0.000 description 2
- 238000005265 energy consumption Methods 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 238000009776 industrial production Methods 0.000 description 2
- 230000000737 periodic effect Effects 0.000 description 2
- 238000001179 sorption measurement Methods 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000003889 chemical engineering Methods 0.000 description 1
- 238000004134 energy conservation Methods 0.000 description 1
- 239000012065 filter cake Substances 0.000 description 1
- 238000009499 grossing Methods 0.000 description 1
- 238000005286 illumination Methods 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 238000012806 monitoring device Methods 0.000 description 1
- 230000000877 morphologic effect Effects 0.000 description 1
- 238000003909 pattern recognition Methods 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D35/00—Filtering devices having features not specifically covered by groups B01D24/00 - B01D33/00, or for applications not specifically covered by groups B01D24/00 - B01D33/00; Auxiliary devices for filtration; Filter housing constructions
- B01D35/14—Safety devices specially adapted for filtration; Devices for indicating clogging
- B01D35/143—Filter condition indicators
- B01D35/1435—Filter condition indicators with alarm means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D33/00—Filters with filtering elements which move during the filtering operation
- B01D33/15—Filters with filtering elements which move during the filtering operation with rotary plane filtering surfaces
- B01D33/17—Filters with filtering elements which move during the filtering operation with rotary plane filtering surfaces with rotary filtering tables
- B01D33/19—Filters with filtering elements which move during the filtering operation with rotary plane filtering surfaces with rotary filtering tables the table surface being divided in successively tilted sectors or cells, e.g. for discharging the filter cake
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D33/00—Filters with filtering elements which move during the filtering operation
- B01D33/80—Accessories
- B01D33/804—Accessories integrally combined with devices for controlling the filtration
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- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Investigating Materials By The Use Of Optical Means Adapted For Particular Applications (AREA)
Abstract
The application discloses a method for monitoring the filtering condition of an alumina flat disc filter and related equipment, wherein the method comprises the following steps: collecting images above a weak filtering area of an aluminum oxide flat disc filter in operation; detecting a connected domain of the image, and judging whether a filter cloth defect area exists or not; if the filter cloth defect area exists, calculating the geometric parameters of the filter cloth defect area; and judging whether the geometric parameters of the filter cloth defect area are larger than a set threshold value or not, and if so, alarming the filter cloth defect of the alumina flat disc filter in operation. The online monitoring of the filtering condition of the aluminum oxide flat disc filter can be realized, the mode of personnel inspection can be replaced, a large amount of labor cost is saved, and the risk that the filter cloth is seriously damaged and hung up and equipment is shut down due to untimely inspection by personnel is avoided.
Description
Technical Field
The application relates to the technical field of industrial automation, in particular to a method for monitoring the filtering condition of an alumina flat disc filter and related equipment.
Background
In the production of aluminum oxide, an aluminum oxide flat disc filter is a key device in the finished product filtering link in the production process of aluminum oxide, is used for the dry-wet separation of aluminum hydroxide slurry, and can provide low-moisture and high-quality aluminum hydroxide filter cakes for odd-stage suspension roasting furnaces in subsequent processes. The condition of the filter cloth of the flat disc filter of the alumina can directly influence the filtering effect of finished products, if the filter cloth is damaged or has other defects, the efficiency of circulating filtration can be reduced, the consequences of high alkali attachment, large moisture and the like of the aluminum hydroxide are caused, the energy consumption cost can be increased, the production capacity of the alumina is reduced, and the production cost is improved.
In industrial production, the alumina flat-disc filter is usually installed in a higher factory building, the alumina flat-disc filter is operated in an open mode, alkali steam with certain concentration exists around the alumina flat-disc filter, and the environmental condition is poor. At present, the filtering condition of the alumina flat-disc filter is generally monitored by a personnel inspection mode, and 24-hour on duty is carried out or field inspection is carried out according to set frequency. Not only occupies a large amount of manpower, in case the routing inspection is not timely, the serious damage of the filter cloth can also lead to the risks of hanging the filter cloth, shutting down the equipment and the like.
Disclosure of Invention
The embodiment of the application provides a filtering condition monitoring method of an aluminum oxide flat disc filter and related equipment, which can realize online monitoring of the filtering condition of the aluminum oxide flat disc filter, can replace a mode of personnel inspection, save a large amount of labor cost, and avoid risks of hanging or equipment shutdown and the like due to serious damage of filter cloth caused by untimely personnel inspection.
In a first aspect, a method for monitoring the filtration condition of an alumina flat-disc filter comprises the following steps:
collecting images above a weak filtering area of an aluminum oxide flat disc filter in operation;
detecting a connected domain of the image, and judging whether a filter cloth defect area exists or not;
if the filter cloth defect area exists, calculating the geometric parameters of the filter cloth defect area;
and judging whether the geometric parameters of the filter cloth defect area are larger than a set threshold value or not, and if so, alarming the filter cloth defect of the alumina flat disc filter in operation.
In a possible embodiment, before the step of performing connected component detection on the image and determining whether a filter cloth defect area exists, the method further includes:
carrying out gray level conversion on the image to obtain a gray level image;
and carrying out smooth filtering and threshold segmentation on the gray level image to obtain a binary image.
In a possible embodiment, in the step of collecting images above the weak filtration zone of the operating alumina flat-disc filter, the number of the collected images is N, wherein N is a positive integer greater than 1;
before the step of detecting the connected domain of the image and judging whether the filter cloth defect area exists, the method further comprises the following steps:
and carrying out image splicing on the N images to obtain a spliced whole image.
In a possible embodiment, the step of performing gray-scale conversion on the image to obtain a gray-scale image includes:
according to the RGB color image conversion mode of 3 channels, carrying out gray scale conversion on the image according to the following formula to obtain a gray scale image:
GRAY＝0.2989×R+0.5870×G+0.1140×B，
wherein, GRAY is the pixel GRAY value of the GRAY image, R is the pixel red component value of the original image, G is the pixel green component value of the original image, and B is the pixel blue component value of the original image.
In one possible embodiment, the filter cloth defect comprises a filter cloth hole, and the filter cloth defect area comprises a filter cloth hole area;
the step of detecting the connected domain of the image and judging whether the filter cloth defect area exists comprises the following steps:
detecting a connected domain of the image to obtain a connected domain;
detecting the edge of the connected domain by using a CANNY operator, and performing circle fitting on the edge of the connected domain by using least square circle fitting to obtain a circle fitting error corresponding to the connected domain;
judging whether the circle fitting error is larger than a set fitting error or not;
if the circle fitting error is smaller than or equal to the set fitting error, judging that the connected domain is the filter cloth hole area;
the geometric parameter of the filter cloth hole area comprises a fitting circle diameter.
In a possible embodiment, the method further comprises:
judging whether the number of the defective areas of the filter cloth in a set area range is larger than a first set number or not, and if so, sending out a corresponding alarm; and/or the presence of a gas in the gas,
judging whether the number of the defective areas of the filter cloth in the whole flat-disc aluminum oxide filter is larger than a second set number or not, and if the number of the defective areas of the filter cloth in the whole flat-disc aluminum oxide filter is larger than the second set number, sending a corresponding alarm; and/or the presence of a gas in the gas,
and judging whether the distance between any two of the filter cloth defect areas is smaller than a set safe distance, if so, sending out a corresponding alarm if the distance between any two of the filter cloth defect areas is smaller than the set safe distance and the total area of any two of the filter cloth defect areas is larger than the set safe area.
In a possible embodiment, the step of determining whether the geometric parameter of the filter cloth defect area is greater than a set threshold, and if the geometric parameter of the filter cloth defect area is greater than the set threshold, alarming the filter cloth defect of the alumina flat disc filter in operation includes:
judging whether the geometric parameters of the defective area of the filter cloth are larger than the set threshold value or not;
if the geometric parameter of the filter cloth defect area is larger than the set limit value, multiplying the geometric parameter by a conversion coefficient so as to convert the geometric parameter on the image into an actual physical size;
and alarming the defect of the filter cloth of the operating alumina flat disc filter, wherein the alarm has alarm information, and the alarm information comprises the actual physical size corresponding to the defect area of the filter cloth and the number of the defect areas of the filter cloth.
In a possible embodiment, after the step of performing connected component detection on the image and determining whether a filter cloth defect area exists, the method further includes:
at a set time point, according to the image, carrying out filter cloth grading on the operating alumina flat disc filter, and generating a filter cloth state grade corresponding to the filter cloth grading;
generating a filter cloth grade table of the alumina flat disc filter in a set time period according to the filter cloth grade and the filter cloth state grade;
and when the filter cloth state grade reaches the replacement grade for the first time, sending out a filter cloth replacement alarm.
In a second aspect, an industrial personal computer comprises: the monitoring device comprises a memory, a processor and a computer program stored in the memory and capable of running on the processor, wherein the processor is used for realizing the steps of the filtering condition monitoring method of the alumina flat-disc filter when the computer program stored in the memory is executed.
In a third aspect, a filtration condition monitoring system for an alumina flat disc filter, comprises: the aluminum oxide flat disc filter, the bracket, the industrial control cabinet and the industrial control machine;
the support is erected above a weak filtration area of the aluminum oxide flat disc filter, an image acquisition device is arranged on the support and connected with the industrial personal computer, and the industrial personal computer is connected with the image acquisition device.
The filtering condition monitoring method of the alumina flat disc filter comprises the steps of collecting an image above a weak filtering area of the alumina flat disc filter in operation, detecting a communication domain of the image, judging whether a filter cloth defect area exists in the image, judging the geometric dimension of the filter cloth defect area if the filter cloth defect area exists, judging whether the geometric dimension of the filter cloth defect area is larger than a set threshold value, and if the geometric dimension of the filter cloth defect area is larger than the set threshold value, indicating that the defect size of the filter cloth has reached the degree of influencing normal production, and needing to alarm the filter cloth defect so as to repair the defect of the filter cloth or replace the filter cloth in time. The online monitoring of the filtering condition of the aluminum oxide flat disc filter can be realized, the defects of the filter cloth can be found in time and repaired or replaced in time, the normal operation of the aluminum oxide flat disc filter can be ensured, products with excellent quality can be produced, the mode of patrol and inspection of personnel can be replaced, a large amount of labor cost is saved, the risk that the filter cloth is seriously damaged and hung up or equipment is shut down due to untimely patrol and inspection of personnel is avoided, and the unmanned chemical engineering and industrial automation can be further realized.
Drawings
FIG. 1 is a schematic flow chart of a method for monitoring the filtration status of an alumina flat-disc filter according to an embodiment of the present application;
FIG. 2 is a schematic top view of an alumina flat-disc filter provided in an embodiment of the present application;
FIG. 3 is a schematic structural block diagram of an industrial personal computer provided in an embodiment of the present application;
FIG. 4 is a schematic block diagram of a filtration condition monitoring system of an alumina flat-disc filter according to an embodiment of the present application.
Detailed Description
In order to better understand the technical solutions provided by the embodiments of the present specification, the technical solutions of the embodiments of the present specification are described in detail below with reference to the drawings and specific embodiments, and it should be understood that the specific features in the embodiments and examples of the present specification are detailed descriptions of the technical solutions of the embodiments of the present specification, and are not limitations on the technical solutions of the embodiments of the present specification, and the technical features in the embodiments and examples of the present specification may be combined with each other without conflict.
In this document, relational terms such as first and second, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising an … …" does not exclude the presence of other identical elements in a process, method, article, or apparatus that comprises the element. The term "two or more" includes the case of two or more.
In industrial production, the alumina flat-disc filter is usually installed in a higher factory building, the alumina flat-disc filter is operated in an open mode, alkali steam with certain concentration exists around the alumina flat-disc filter, and the environmental condition is poor. At present, the filtering condition of the alumina flat-disc filter is generally monitored by a personnel inspection mode, and 24-hour on duty is carried out or field inspection is carried out according to set frequency. Not only occupies a large amount of manpower, in case the emergence is patrolled and examined untimely, the serious damage of filter cloth still can lead to the risk that the filter cloth is hung up, equipment shuts down moreover.
In view of the above, the present application provides a method and related apparatus for monitoring a filtration condition of an alumina flat-disc filter, and in a first aspect, fig. 1 is a schematic flow chart of a method for monitoring a filtration condition of an alumina flat-disc filter provided in an embodiment of the present application. As shown in fig. 1, an embodiment of the present application provides a method for monitoring a filtration condition of an alumina flat-disc filter, including:
s100: images were collected above the weak filtration zone of an alumina flat disc filter in operation. FIG. 2 is a schematic top view of an alumina flat-disc filter according to an embodiment of the present disclosure. As shown in figure 2, the space above the alumina filtering flat disc 1 of the alumina flat disc filter can be divided into a mother liquid zone 11, a strong filtering zone 12, a weak filtering zone 13 and a back blowing zone 14, the alumina filtering flat disc 1 can rotate anticlockwise and sequentially passes through the mother liquid zone 11, the strong filtering zone 12, the weak filtering zone 13 and the back blowing zone 14, and a scraper 2 is arranged at the boundary of the mother liquid zone 11 and the back blowing zone 14. The working process of the alumina flat-disc filter is generally as follows: the aluminum hydroxide slurry mother liquor is poured into the aluminum oxide filtering flat disc 1 from the mother liquor area 11, water is used for filtering the aluminum hydroxide slurry, along with the anticlockwise rotation of the aluminum oxide filtering flat disc 1, the filtering is basically completed after passing through the strong filtering area 12 and the weak filtering area 13, and the powder obtained after the filtering can be scraped off through the scraper 2 in the back blowing area 14, so that the filtering process is completed. In the mother liquor area 11 and the strong filtering area 12, the aluminum hydroxide slurry is thick slurry, the condition of the filter cloth is difficult to observe, a large amount of water is removed in the weak filtering area 13, compared with the mother liquor area 11 and the strong filtering area 12, the weak filtering area 13 is more suitable for detecting the damage condition of the filter cloth, the positions of alkaline high-temperature washing and hot water spraying can be avoided, the definition of the collected image is higher, and the interference on the image is less. Therefore, the image acquisition device needs to be erected above the weak filtering area of the alumina flat disc filter, and acquires images above the weak filtering area of the alumina flat disc filter in operation for detecting defects of the filter cloth.
S200: and detecting a connected domain of the image, and judging whether a filter cloth defect area exists. The collected images are correspondingly analyzed and processed, and connected domain detection is carried out, wherein the connected domain detection is a common basic method in image processing and pattern recognition. The method has wide application in object segmentation, edge detection and area detection. Detecting a connected domain in the image, judging whether the connected domain exists, and judging whether the connected domain is a defective filter cloth area if the connected domain exists.
S300: if the filter cloth defect area exists, calculating the geometric parameters of the filter cloth defect area. The geometric parameter may be a circle-like diameter or a perimeter of a closed figure, and the present application is not particularly limited with respect to the geometric parameter.
S400: and judging whether the geometric parameters of the defective area of the filter cloth are larger than a set threshold value or not, and if so, alarming the defect of the filter cloth of the operating alumina flat disc filter. If the geometric parameters of the defective area of the filter cloth are larger than the set limit value, the defect on the filter cloth is shown, and the size of the defect of the filter cloth is larger than the set limit value, so that the production is greatly influenced, an alarm is required to be given, and the maintenance is convenient. The set threshold value may be set according to production specifications, and the application is not particularly limited. The alarm can carry alarm information, and can comprise position information of the defect of the filter cloth, size information, the number of the defect areas of the filter cloth and the like. It is easy to understand that the filter cloth defect area exists in the image and is not a realistic physical size, and therefore the set limit value corresponding thereto is also for the scale size in the image.
Generally, in an alumina flat-disc filter, a cavity is arranged below an alumina filter flat disc 1, and a suction pump is arranged in the cavity and used for generating downward negative pressure, so that the downward flow of moisture can be accelerated, and the dry-wet separation of aluminum hydroxide slurry is further accelerated. However, due to the existence of negative pressure, the filter cloth is easy to sink under the action of negative pressure to form a defect, and the defect can cause the aluminum hydroxide slurry to directly pour into the cavity below the aluminum oxide pan, so that the negative pressure in the cavity is influenced by pressure relief, and the operation of dry-wet separation of the aluminum hydroxide slurry is greatly influenced.
The filtering condition monitoring method of the alumina flat disc filter comprises the steps of collecting an image above a weak filtering area of the alumina flat disc filter in operation, detecting a communication domain of the image, judging whether a filter cloth defect area exists in the image, judging the geometric dimension of the filter cloth defect area if the filter cloth defect area exists, judging whether the geometric dimension of the filter cloth defect area is larger than a set threshold value, and if the geometric dimension of the filter cloth defect area is larger than the set threshold value, indicating that the defect size of the filter cloth has reached the degree of influencing normal production, and needing to alarm the filter cloth defect so as to repair the defect of the filter cloth or replace the filter cloth in time. The online monitoring of the filtering condition of the aluminum oxide flat disc filter can be realized, the defects of the filter cloth can be found in time and repaired or replaced in time, the normal operation of the aluminum oxide flat disc filter is ensured, products with excellent quality can be produced, the mode of patrol and inspection by personnel can be replaced, a large amount of labor cost is saved, the risk that the filter cloth is seriously damaged and hung up or equipment is shut down due to untimely patrol and inspection by personnel is avoided, the industrial automation level can be improved, and an unmanned factory is further realized.
In a possible implementation manner, before step S200, the method further includes:
and carrying out gray level conversion on the image to obtain a gray level image.
And carrying out smooth filtering and threshold segmentation on the gray level image to obtain a binary image. The smoothing filter may include gaussian filter, and the present application is not particularly limited. The Gaussian filtering can eliminate isolated noise and edges in the image, and then the self-adaptive threshold segmentation algorithm is used for converting the filtered gray level image into a binary image.
It is easily understood that the filter cloth on the alumina flat-disc filter is white or grey white conventionally, multiple layers of filter cloth are laid on the flat disc layer by layer, and negative pressure is arranged below the filter cloth to adsorb the filter cloth for a long time, so that the collected image has more special identification characteristics, such as sunken holes and the like. Therefore, the filter cloth defect may be a filter cloth hole, which may appear in the image with a different gray level from the surrounding, i.e. the gray level of the filter cloth hole area is lower and the adsorption due to the negative pressure is circular or approximately circular. The holes of the filter cloth are represented by a circle close to black on the binary image, so that whether defects exist on the filter cloth can be detected by correspondingly analyzing the collected color image according to the characteristics.
In the method for monitoring the filtering condition of the flat disc filter for aluminum oxide, the image for detecting the connected component needs to be a binary image, so that the acquired image is subjected to gray level conversion, a color image is converted into a gray level image, the gray level image is subjected to smooth filtering and threshold segmentation, a binary image can be obtained, and the binary image can be used for detecting the connected component.
In a possible implementation manner, before step S200, the method further includes:
and removing the defects which are smaller than or equal to the preset minimum hole diameter in the binary image.
The filtering condition monitoring method of the flat disc filter for the aluminum oxide, provided by the embodiment of the application, can eliminate the interference of small-area noise in a binary image, wherein the small-area noise is possibly caused by small gravel or other impurities and does not belong to the detection range of the embodiment of the application, so that the interference needs to be removed, and the detection accuracy of the defect of the filter cloth can be enhanced. The effective minimum hole size can be set according to the actual situation, the circular structural element is set according to the size, the binary image is processed by using the morphological operator of the structural element so as to eliminate small-region noise, and the larger circular hole region is not influenced by the operation.
In a possible embodiment, a single image may be processed and analyzed for filter cloth defects. The single image processing condition may be a situation that a single image covers the whole filter cloth, or only covers a part of the filter cloth, and the defect of the filter cloth is reflected by images at different filter cloth positions, which is not specifically limited in the present application.
In a possible embodiment, in step S100, the number of the acquired images is N, where N is a positive integer greater than 1;
before step S200, the method further includes:
and carrying out image splicing on the N images to obtain a spliced whole image.
For example, the angular velocity of the main transmission shaft for driving the flat disc of the alumina flat disc filter to rotate may be 2r/min, where the angular velocity may be an average velocity, and the image acquisition may be performed 20 times in succession at time intervals of 30s, so as to obtain 20 images, that is, N is 20. And splicing the 20 images to obtain a spliced whole image, and then performing gray level conversion and binarization processing on the spliced whole image to obtain a binary image. It should be noted that, in the process of graph stitching, each image also needs to be adaptively edited, for example, the background image outside the flat disc is removed, and the image is repeated, the obtained whole stitched image is only a fixed sector area, and more than half of the two adjacent acquired images are overlapped, which can avoid missing detection and is beneficial to image stitching, and finally N images with overlapped parts are stitched into a complete flat disc filtering plane image.
The method for monitoring the filtering condition of the flat disc filter of the aluminum oxide has the advantages that the mode of splicing a plurality of images firstly and then analyzing the images can be realized without erecting an overhigh image acquisition device, the space can be saved, missing shooting can be reduced, and the image acquisition device can be arranged closer to a shooting target, so that a clearer image can be obtained, and the detection precision of the defect of the filter cloth is improved.
In one possible embodiment, the step of performing gray-scale conversion on the image to obtain a gray-scale image includes:
according to the RGB color image conversion mode of 3 channels, carrying out gray scale conversion on the image according to the following formula to obtain a gray scale image:
GRAY＝0.2989×R+0.5870×G+0.1140×B，
wherein, GRAY is the pixel GRAY value of the GRAY image, R is the pixel red component value of the original image, G is the pixel green component value of the original image, and B is the pixel blue component value of the original image.
In one possible embodiment, the filter cloth defect may comprise a filter cloth hole and the filter cloth defect area may comprise a filter cloth hole area. Step S200 may include:
and detecting the connected domain of the image to obtain the connected domain.
And detecting the edge of the connected domain by using a CANNY operator (computational term of edge detection), and performing circle fitting on the edge of the connected domain by using least square circle fitting to obtain a circle fitting error corresponding to the connected domain. Due to the adsorption effect of the negative pressure, the defect of the filter cloth is usually circular or approximately circular, and can be a filter cloth hole.
And judging whether the circle fitting error is larger than the set fitting error or not. When the circle fitting error is larger, namely larger than the set fitting error, the detected communicated domain is not enough circular, and the filter cloth holes caused by the defects of the filter cloth are not more likely.
And if the circle fitting error is less than or equal to the set fitting error, judging that the connected domain is the filter cloth hole area. On the premise that the defect of the filter cloth is circular or quasi-circular, the connected region can be judged to be the filter cloth hole region only if the circle fitting error is smaller than or equal to the set fitting error.
The geometric parameters of the filter cloth hole area include the fitting circle diameter.
According to the method for monitoring the filtering condition of the flat disc filter for the aluminum oxide, the defect of the filter cloth is regarded as a round or similar round hole, so that the round fitting is carried out on the communication domain detected in the image, and whether the area is the area of the defective hole of the filter cloth is judged according to the round fitting error, so that whether the defect exists on the filter cloth is detected. The detection of the defects of the filter cloth is accurate.
In a possible implementation manner, the method for monitoring the filtration condition of the alumina flat-disc filter provided by the embodiment of the application further comprises the following steps:
and judging whether the number of the filter cloth defect areas in the set area range is greater than a first set number or not, and if so, sending out a corresponding alarm. The number of the filter cloth defect areas in the local area is monitored, so that the phenomenon that excessive filter cloth defects exist in a certain local area, the filter cloth defects are intensively communicated due to the excessive filter cloth defects, and one or more large filter cloth holes are finally formed. By setting a set number, effective early warning can be performed before large filter cloth holes appear.
And/or the presence of a gas in the gas,
and judging whether the number of the defective areas of the filter cloth in the whole alumina flat disc filter is greater than a second set number or not, and if so, sending a corresponding alarm. The number of the defective areas of the filter cloth in the whole aluminum oxide flat disc filter is monitored, so that the phenomenon that the defective areas of the filter cloth are too many in the whole aluminum oxide flat disc filter to influence normal production, influence product quality, cause negative pressure reduction, further influence product quality and increase production energy consumption can be prevented. By setting a set number, effective early warning can be carried out before more filter cloth holes appear.
And/or the presence of a gas in the gas,
and judging whether the distance between any two filter cloth defect areas is smaller than a set safety distance or not, and if the distance between any two filter cloth defect areas is smaller than the set safety distance and the total area of any two filter cloth defect areas is larger than the set safety area, sending out a corresponding alarm. If the distance between the two filter cloth defect areas is too close, the two filter cloth defect areas are communicated to form a large filter cloth defect. Or the distance between the plurality of filter cloth defect areas is too close, so that the plurality of filter cloth defect areas are communicated to form a large filter cloth defect area, and if the whole area of the formed large filter cloth defect area is larger than the set safety area, normal production is easily influenced, and corresponding alarm needs to be carried out. Through the early warning of the distance between any two filter cloth defect areas, filter cloth can be found in time and repaired and replaced, and the condition that two or more filter cloth defect areas are communicated to form a large filter cloth defect can be prevented. The set safety distance and the set safety area can be preset according to specific production conditions, and the application is not particularly limited.
In one possible implementation, step S400 may include:
and judging whether the geometric parameters of the defective area of the filter cloth are larger than a set threshold value or not.
And if the geometric parameters of the defective area of the filter cloth are larger than the set limit value, multiplying the geometric parameters by a conversion coefficient to convert the geometric parameters on the image into actual physical dimensions.
And alarming the defect of the filter cloth of the operating flat disc filter, wherein the alarm has alarm information, and the alarm information comprises the actual physical size corresponding to the defect area of the filter cloth and the number of the defect areas of the filter cloth.
Illustratively, in the process of installing the image acquisition device, a reference object with a known size needs to be selected or set as a standard object, the size of the standard object in the image is measured by photographing, the size in the image is divided by the actual physical size to obtain a conversion coefficient, and the conversion coefficient can convert the size of the object in the image into the actual physical size, so that the actual size data of the object in the image can be reflected more intuitively. For example, the actual physical size of the defect of the filter cloth can be obtained by multiplying the geometric parameters of the defect area of the filter cloth by the conversion coefficient, the actual physical size of the defect of the filter cloth is directly presented in alarm information, and a maintenance worker can visually obtain the size of the defect.
In a possible implementation manner, after the step S200, the method further includes:
and at a set time point, according to the image, carrying out filter cloth grading on the operating alumina flat disc filter, and generating a filter cloth state grade corresponding to the filter cloth grading. The set time point may be set according to specific needs, may be an integral time point, or may be other time points, and the present application is not limited specifically. For example, the set time point may be 8 points, 10 points, 12 points, and the like. The basis for scoring the filter cloth of the operating alumina flat disc filter can be the number of the defective areas of the filter cloth on the whole filter cloth or the number of the defective areas of the filter cloth exceeding the set size. The filter cloth defect area may be exemplary of filter cloth holes, and if the number of filter cloth holes on the whole filter cloth is below 10, the score may be 99 points; between 10-30 (including endpoints), the score may be 95, and so on. For another example, if the number of holes in the whole filter cloth with a diameter greater than 5cm is less than 5, the score may be 99 points, 5 to 15 points (including end points), the score may be 95 points, and so on, which is not listed in this application. For example, the grade of the filter cloth state corresponding to the grade may include a good grade, a pass grade, a defective grade, a replacement grade, and the like, and the present application is not particularly limited.
And generating a filter cloth grade table of the alumina flat disc filter in a set time interval according to the filter cloth grade and the filter cloth state grade. The filter cloth scoring table may include data such as scoring time points, scoring and scoring grades, the number of filter cloth defect regions, and the total area of the filter cloth defect regions, which is not specifically limited in this application. The filter cloth scoring table can be used for analyzing the state of the filter cloth, analyzing the reasons of the occurrence of the defects of the filter cloth, the rules of the occurrence of the defects of the filter cloth and the like, improving the means of repairing the filter cloth or the maintenance scheme of the filter and the like better, archiving and storing the filter cloth scoring table to facilitate the calling and checking of subsequent data, and the application is not particularly limited. The set period may be 24 hours, or one shift, and the application is not particularly limited.
And when the filter cloth state grade reaches the replacement grade for the first time, sending out a filter cloth replacement alarm. Illustratively, according to the list of the filter cloth state grades, when the filter cloth grades are in a good grade, a qualified grade and a defective grade, a maintenance worker can be arranged to repair the filter cloth correspondingly, and when the filter cloth grades reach a replacement grade for the first time, a filter cloth replacement alarm needs to be sent out to replace the filter cloth in time. The change of present filter cloth is periodic replacement usually, probably the filter cloth has not reached the change standard and has just changed, and the filter cloth does not obtain make full use of, is unfavorable for energy-conservation and reduces the cost, and the control to the filter cloth state can replace the operation mode of periodic replacement, can the utilization ratio of filter cloth, avoids the filter cloth to change the waste that arouses in advance.
The filtering condition monitoring method of the aluminum oxide flat disc filter provided by the embodiment of the application can analyze and judge the filtering effect of a finished product by grading and grading the condition of the filter cloth of the aluminum oxide flat disc filter, timely improve the filtering effect of the finished product, improve the circulating filtering efficiency, reduce the alkali attached to aluminum hydroxide, reduce moisture, further improve the production capacity of aluminum oxide and reduce the production cost. It should be noted that the alarm mentioned in any embodiment of the present application may be an audible and visual alarm or an alarm with a display screen, and the present application is not limited specifically.
In a second aspect, fig. 3 is a schematic structural block diagram of an industrial personal computer provided in an embodiment of the present application. As shown in fig. 3, an embodiment of the present application provides an industrial personal computer 300, which includes a memory 310, a processor 320, and a computer program 311 stored in the memory 310 and executable on the processor 320, wherein the processor 320 executes the computer program 311 to implement the following steps:
images were collected above the weak filtration zone of an alumina flat disc filter in operation.
And detecting a connected domain of the image, and judging whether a filter cloth defect area exists.
If the filter cloth defect area exists, calculating the geometric parameters of the filter cloth defect area.
And judging whether the geometric parameters of the defective area of the filter cloth are larger than a set threshold value or not, and if so, alarming the defect of the filter cloth of the operating alumina flat disc filter.
In specific implementation, when the processor 320 executes the computer program 311, it can implement any of the methods for monitoring the filtration condition of the flat-disc alumina filter described in the above embodiments.
Since the electronic device described in this embodiment is for implementing the method for monitoring the filtration condition of the flat-disc alumina filter in this embodiment, based on the method described in this embodiment, those skilled in the art can understand the specific implementation manner of the electronic device of this embodiment and various modifications thereof, so that how to implement the method in this embodiment by the electronic device will not be described in detail herein, and as long as those skilled in the art implement the method in this embodiment, the adopted device will fall within the scope of protection of this application.
In a third aspect, fig. 4 is a schematic structural block diagram of a filtration condition monitoring system of an alumina flat disc filter provided in an embodiment of the present application. As shown in fig. 4, an embodiment of the present application provides a system for monitoring a filtration condition of an alumina flat-disc filter, including: the device comprises an alumina flat-disc filter, a bracket 3 arranged above the alumina flat-disc filter and an industrial personal computer 5 provided by the embodiment. The upper space of an alumina filtering flat disc 1 of the alumina flat disc filter can be divided into a mother liquid area 11, a strong filtering area 12, a weak filtering area 13 and a back blowing area 14, the alumina filtering flat disc 1 can rotate anticlockwise and sequentially passes through the mother liquid area 11, the strong filtering area 12, the weak filtering area 13 and the back blowing area 14, and a scraper 2 is arranged at the boundary of the mother liquid area 11 and the back blowing area 14. Support 3 erects in the weak filtration zone 13 top of aluminium oxide flat disc filter, is provided with image acquisition device 31 on the support 3, image acquisition device 31 with industrial computer 5 is connected, connects and can include cable junction, communication connection etc. and this application does not do specifically and restricts.
For example, the industrial control cabinet 4 disposed between the industrial control computer 5 and the bracket 3 may be used to accommodate part of power supply equipment, a controller, a transmission device, an audible and visual alarm device, and the audible and visual alarm device may include a horn, an alarm bell, an alarm lamp, and the like, and the application is not limited specifically. The bracket 3 can be further provided with an illuminating device 32, and the illuminating device 32 can provide illumination for the image acquisition device 31, so that the brightness of the photographing environment can be enhanced to obtain a clear image. The industrial personal computer cabinet 4 can supply power to the image acquisition device 31, the lighting device 32 and the like on the bracket, and the industrial personal computer 5 and the industrial personal computer cabinet 4 can be powered separately, so that the application is not specifically limited.
By way of example, the area of an alumina flat-disc filter may be 80m2(the diameter of the alumina filter flat disc 1 may be 2.6m), the bracket 3 is installed at a position 1.3m away from the circumference of the alumina filter flat disc 1, and the height of the bracket 3 may be 2 m. The industrial personal computer 5 can realize the related functions of image processing, alarm condition judgment and alarm. The alarm may be an audible and visual alarm, and may also have a display function to display alarm information, which is not specifically limited in this application.
The description has been presented with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the description. It will be understood that each flow and/or block of the flow diagrams and/or block diagrams, and combinations of flows and/or blocks in the flow diagrams and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions specified in the flowchart flow or flows and/or block diagram block or blocks.
These computer program instructions may also be stored in a computer-readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instruction means which implement the function specified in the flowchart flow or flows and/or block diagram block or blocks.
These computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the functions specified in the flowchart flow or flows and/or block diagram block or blocks.
While preferred embodiments of the present specification have been described, additional variations and modifications in those embodiments may occur to those skilled in the art once they learn of the basic inventive concepts. Therefore, it is intended that the appended claims be interpreted as including preferred embodiments and all changes and modifications that fall within the scope of the specification.
It will be apparent to those skilled in the art that various changes and modifications may be made in the present specification without departing from the spirit and scope of the specification. Thus, if such modifications and variations of the present specification fall within the scope of the claims of the present specification and their equivalents, the specification is intended to include such modifications and variations.
Claims (10)
1. A method for monitoring the filtering condition of an alumina flat-disc filter is characterized by comprising the following steps:
collecting images above a weak filtering area of an aluminum oxide flat disc filter in operation;
detecting a connected domain of the image, and judging whether a filter cloth defect area exists or not;
if the filter cloth defect area exists, calculating the geometric parameters of the filter cloth defect area;
and judging whether the geometric parameters of the filter cloth defect area are larger than a set threshold value or not, and if so, alarming the filter cloth defect of the alumina flat disc filter in operation.
2. The method for monitoring the filtration status of an alumina flat-disc filter according to claim 1, wherein the step of detecting the connected components of the image and determining whether the filter cloth defect area exists is preceded by the steps of:
carrying out gray level conversion on the image to obtain a gray level image;
and carrying out smooth filtering and threshold segmentation on the gray level image to obtain a binary image.
3. The method of claim 1, wherein in the step of collecting images above the weak filtration zone of the operating flat-disc alumina filter, the number of the collected images is N, wherein N is a positive integer greater than 1;
before the step of detecting the connected domain of the image and judging whether the filter cloth defect area exists, the method further comprises the following steps:
and carrying out image splicing on the N images to obtain a spliced whole image.
4. The method of claim 2, wherein the step of performing a gray scale conversion on the image to obtain a gray scale image comprises:
according to the RGB color image conversion mode of 3 channels, carrying out gray scale conversion on the image according to the following formula to obtain a gray scale image:
GRAY＝0.2989×R+0.5870×G+0.1140×B，
wherein, GRAY is the pixel GRAY value of the GRAY image, R is the pixel red component value of the original image, G is the pixel green component value of the original image, and B is the pixel blue component value of the original image.
5. The method of claim 2, wherein the filter cloth defect comprises a filter cloth hole, and the filter cloth defect area comprises a filter cloth hole area;
the step of detecting the connected domain of the image and judging whether the filter cloth defect area exists comprises the following steps:
detecting a connected domain of the image to obtain a connected domain;
detecting the edge of the connected domain by using a CANNY operator, and performing circle fitting on the edge of the connected domain by using least square circle fitting to obtain a circle fitting error corresponding to the connected domain;
judging whether the circle fitting error is larger than a set fitting error or not;
if the circle fitting error is smaller than or equal to the set fitting error, judging that the connected domain is the filter cloth hole area;
the geometric parameter of the filter cloth hole area comprises a fitting circle diameter.
6. The method of claim 1, further comprising:
judging whether the number of the defective areas of the filter cloth in a set area range is larger than a first set number or not, and if so, sending out a corresponding alarm; and/or the presence of a gas in the gas,
judging whether the number of the defective areas of the filter cloth in the whole flat-disc aluminum oxide filter is larger than a second set number or not, and if the number of the defective areas of the filter cloth in the whole flat-disc aluminum oxide filter is larger than the second set number, sending a corresponding alarm; and/or the presence of a gas in the gas,
and judging whether the distance between any two of the filter cloth defect areas is smaller than a set safe distance, if so, sending out a corresponding alarm if the distance between any two of the filter cloth defect areas is smaller than the set safe distance and the total area of any two of the filter cloth defect areas is larger than the set safe area.
7. The method for monitoring the filtration status of an alumina flat disc filter according to any one of claims 1 to 6, wherein the step of judging whether the geometric parameter of the filter cloth defect area is larger than a set threshold value, and alarming the filter cloth defect of the alumina flat disc filter in operation if the geometric parameter of the filter cloth defect area is larger than the set threshold value comprises:
judging whether the geometric parameters of the defective area of the filter cloth are larger than the set threshold value or not;
if the geometric parameter of the filter cloth defect area is larger than the set limit value, multiplying the geometric parameter by a conversion coefficient so as to convert the geometric parameter on the image into an actual physical size;
and alarming the defect of the filter cloth of the operating alumina flat disc filter, wherein the alarm has alarm information, and the alarm information comprises the actual physical size corresponding to the defect area of the filter cloth and the number of the defect areas of the filter cloth.
8. The method for monitoring the filtration status of an alumina flat-disc filter according to claim 1, wherein the step of detecting the connected components of the image and determining whether the filter cloth defect area exists further comprises the following steps:
at a set time point, according to the image, carrying out filter cloth grading on the operating alumina flat disc filter, and generating a filter cloth state grade corresponding to the filter cloth grading;
generating a filter cloth grade table of the alumina flat disc filter in a set time period according to the filter cloth grade and the filter cloth state grade;
and when the filter cloth state grade reaches the replacement grade for the first time, sending out a filter cloth replacement alarm.
9. An industrial personal computer, comprising: a memory, a processor and a computer program stored in the memory and executable on the processor, the processor being configured to implement the steps of the method for monitoring the filtration condition of an alumina flat disc filter according to any one of claims 1 to 8 when the computer program stored in the memory is executed.
10. A filtration condition monitoring system of an alumina flat-disc filter is characterized by comprising: the aluminum oxide flat disc filter, the bracket, the industrial control cabinet and the industrial control computer of claim 9;
the support is erected above a weak filtration area of the aluminum oxide flat disc filter, an image acquisition device is arranged on the support and connected with the industrial personal computer, and the industrial personal computer is connected with the image acquisition device.
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