CN101281063A - High temperature furnace inner video image temperature measuring system - Google Patents
High temperature furnace inner video image temperature measuring system Download PDFInfo
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- CN101281063A CN101281063A CNA2008100531486A CN200810053148A CN101281063A CN 101281063 A CN101281063 A CN 101281063A CN A2008100531486 A CNA2008100531486 A CN A2008100531486A CN 200810053148 A CN200810053148 A CN 200810053148A CN 101281063 A CN101281063 A CN 101281063A
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Abstract
The invention relates to a high temperature furnace in-furnace temperature measuring system, in particular to relating to a high temperature furnace in-furnace video image temperature measuring system which directly collects single frame image data from high temperature TV. The system comprises an industrial control host which is separately connected with the high temperature TV and CRT. The industrial control host also comprises three parts: a database, a human-computer interface and computational analysis. The high temperature TV adopts a probe-type high temperature TV. A video capture card is arranged on the industrial control host. The industrial control host makes use of control program to complete collecting high temperature furnace in-furnace video images, and processes to extract, analyze, process, compute and display for image data. High temperature furnace in-furnace video image temperature measuring result can guide operating personnel to keep high temperature furnace optimal thermal situation, so as to improve thermal efficiency, reduce pollutant formation, and improve labor and material processing quality. At the same time the high temperature furnace in-furnace video image temperature measuring result has very important effect for furnace flameout protection, avoiding furnace wall coking, refractory material shedding and processing fault diagnosis for the high temperature furnace.
Description
Technical field
The present invention relates to temperature monitoring system in the high temperature furnace, relate in particular to a kind of based on utilizing radiation image to handle that the thermal technology detects principle in the stove, the temp measuring system that direct collection is extracted, analyzes, handles, calculates, shown from the single-frame images data of high temperature tv.
Background technology
Monitoring system all is to come according to the physicochemical property of material and the relation of temperature to the measurement of temperature in traditional high temperature furnace.Concerning the temperature survey of high temperature inner operating, generally be divided into contact type measurement and non-contact measurement.Contact type measurement can cause interference to measured medium, generally can only realize point measurement; Non-contact type temperature measurement is not owing to directly contact with measured medium, and thermal inertia is little, measures the upper limit and is not subjected to advantage such as materials limitations and receives much attention.
Non-contact measuring technology also is the thermometric technological development direction of high temperature kiln.The practical application of external existing high temperature kiln temperature non-contact measurement apparatus at present, but its equipment manufacturing cost is relatively costly, and some product also can only be realized spot measurement.Domestic research and the test that this respect is also arranged, but all be in the starting and the non-stage of ripeness, to must solve how the image information in the high temperature furnace is converted into this technical barrier of corresponding temperature for high temperature furnace provides the image monitoring of high-quality and temperature survey accurately.
Summary of the invention
The objective of the invention is to reduce the operating cost of producing in order to improve the automatization level that kiln is produced, improve the quality of products and the rate of reducing the number of rejects and seconds, the spy develops that a kind of thermometric is accurate, the reliable high temperature furnace inner video image temperature measuring system of data.Compare with temperature monitoring system in the traditional high temperature furnace, native system has been realized measurement truly, the accuracy of measurement from following some:
1. source video sequence aspect:
Native system is directly to gather to be used for thermometric from the auspicious image of the list of CCD camera, rather than extracts the auspicious image of the list image of overcompression (promptly through) of video flowing.Thereby guaranteed the high-quality in image source.
2. temperature computation aspect:
At black white image, native system uses the principle accounting temperature of similar infrared measurement of temperature, and at coloured image, native system uses a kind of brand-new computing method accounting temperature that combines monocolor method and colourimetry thermometric advantage, thereby has guaranteed the high-quality of temperature-measurement principle.
3. thermometric result calculated and demonstration aspect:
Native system has been realized the combination of cross thermometric and regional thermometric.
The technical scheme that native system is taked is: a kind of high temperature furnace inner video image temperature measuring system, comprise the industrial control host that is connected with high temperature tv and CRT respectively, it is characterized in that: described industrial control host also comprises three parts: database, man-machine interface and computational analysis, wherein database comprises the real-time recorded data storehouse, historical record data storehouse, image recording database and record data storehouse, man-machine interface comprise file, basic setup, application setting, system's setting, pseudo-colours setting, check and log off; Computational analysis comprises that high temperature image processing module, temperature set up algoritic module, temperature display module and compute mode display module; Described high temperature tv adopts the sonde-type high temperature tv that includes protective device, gearing, control device and camera head; On the described industrial control host video frequency collection card is housed, industrial control host utilizes control program to finish the collection of high temperature furnace inner video image, and to extracting, analyze, handle, calculate, show as data.
The beneficial effect that native system reached is: the high temperature furnace inner video image temperature measuring result can instruct the operations staff to keep the best thermal technology state of high temperature kiln burner hearth; thereby raising hot working efficiency; reducing pollutant generates; improve the labor and materials crudy; to the burner hearth flame failure protection, avoid furnace wall coking, fire resistive material to come off and high temperature kiln carried out fault diagnosis that important effect is all arranged simultaneously.
Description of drawings
Fig. 1 is that system of the present invention constitutes block scheme and as Figure of abstract.
Fig. 2 is the sonde-type high temperature tv structural representation that the present invention adopts.
Fig. 3 be high temperature camera probe image space and with CCD camera probe imaging target surface concern synoptic diagram.
Fig. 4 is a CCD camera probe angle modification synoptic diagram.
Fig. 5 is a system functional block diagram of the present invention.
Fig. 6 is a system program module frame chart of the present invention.
Fig. 7 is a control program process flow diagram of the present invention.
Embodiment
The present invention is described in detail below in conjunction with accompanying drawing.
With reference to Fig. 1,2, the front end of native system mainly is the high temperature tv that is made of camera head, gearing, protective device, control device.Camera head in the high temperature tv is a high-temperature probe, and high-temperature probe is visited in the high temperature furnace by gearing and protective device.In the high temperature furnace image by pre-manufactured hole (or by viewport) by high temperature resistant camera lens to imaging combustion, on the mirror pipe is transferred to thereafter video camera target surface, change electric signal into and pass to the pulpit industrial control host through concentric cable again.Gearing mainly is made up of furnace wall protective device, tractor, travel switch, motor and speed reducer etc., the effect of kinematic train is to promote camera probe turnover burner hearth, probe can be worked in stove for a long time under the normal condition, control system is controlled kinematic train automatically probe is withdrawed from burner hearth when occurring reporting to the police, and closes fire door automatically.
Gear train adopts the chain assembly of anticorrosive, high temperature resistant and high dust, and motor adopts the single phase poaer supply source that is used as power, and the rugged surroundings of industrial furnace occasion are had extremely strong adaptability.Water-cooled sealing gland protective device is the important assurance of total system trouble free service.Abominable situation in view of the closed-circuit TV system working environment; native system is under the first class of protection of conventional water-cooled probe; developed the second class protection of furnace wall water cooling substrate again; and probe carried out gas seal protection; guarantee good supervision effect when reducing heat interchange to greatest extent, guaranteed video camera operate as normal under hot environment.
The camera probe that control device aims at control and protection high-temperature industrial television designs, the execution action of control gearing and protection alarm.The electric control gear control circuit adopts electronic technology to combine with electrotechnics; with the logic control circuit is core; accompany by sensor detection circuit, electronic execution control circuit, report to the police and indicate and function circuit, the control motor finally reaches the purpose of control and protection camera probe.Electric-control system has perfect full-automatic defencive function, all sends the sound and light alarm signal and the video camera probe is fallen back on outside the stove automatically under the abnormal conditions such as cold gas air pressure reduces, the video camera environment temperature raises, system's input power cut-off, motor overload.]
The principle of work of native system: native system is a kind of video camera and by the integrated application equipment of the temperature measurer of computer drives, the temperature of the zone in the image range of being seen on this temperature measurer energy measurement monitor screen (being selected by the operator).In order to obtain more detailed image scene, be necessary the close processing procedure of the Liar of video camera.That the object lens of this device are placed on cooling and allow to enter in the barrel of high temperature kiln.Object lens external application sapphire covers to satisfy under the rugged surroundings protection to camera lens.Object lens can form image with great visual angle, are sent to video camera by a series of transmission eyeglass then.There is the camera lens in different visual angles and different optical path available.Both can see on being installed in video camera on the suitable observation port of high temperature kiln that the combustion zone also can see established material.
Vision signal is digitized in processor inside and some graphic elements that superpose (as the cursor of definition measured zone and temperature demonstration).Final image can be seen on color computer display (CRT).The picture quality that is obtained by this device is goodish, and sharpness is also high.The user both can see that the temperature of grog also can obtain a clear picture in kiln internal combustion zone.The different video control of image can be finished by the mouse that is connected to processor in the pulpit.This function allows the operator not need the interior video camera of contact furnace just can be optimized adjustment to picture quality easily according to the needs of oneself.On-screen menu then provides another friendly interface to the operator.This Unit Installation is unlike installing a cover common camera complexity, and just front end performs the high temperature protection of camera system, and Central Control Room inserts the data image processor with information.
It is interior Anywhere that native system can scan the video camera angular field of view.36 measurement zones that it can allow processor processing be defined on monitor screen by the user.Place that can Direct observation temperature measuring area positive sense is the topmost advantage of this technology just, because a subject matter of traditional temperature measurer is to be difficult to definite know which zone just measured, a large amount of dust can have influence on measurement in the stove sometimes.The operator can't determine measuring condition when using traditional temperature measurer.And native system provides very big dirigibility at the temperature survey aspect of performance, and 36 temperature survey districts can be superimposed upon on the video image, and these zones can be mobile arbitrarily in image range, and therefore the precise information of measurement point can be provided for the operator.The size of measurement zone also can be changed.Each regional temperature can be provided with and represent this regional mean value, minimum value, maximal value respectively.
The technical matters that native system solves:
(1) non-contact measurement not with high temperature furnace in measured medium directly contact.
(2) the CCD camera probe can satisfy thermometric environment from 0 ℃ to 2000 ℃ various high temperature kilns as direct temperature information harvester, and can not produce thermal inertia, thereby has avoided the inaccurate problem of thermometric brought owing to the thermal inertia of measuring sonde.
(3) wide-angle lens can collect burner hearth high temperature image as much as possible, for realizing that high temperature kiln temperature online image monitoring is laid a good foundation on a large scale.
(4) overcome the limitation of traditional thermometric mode point measurement, can monitor the temperature information in whole visual ranges.
(5), guaranteed the accuracy and the reliability of thermometric to the blackbody furnace demarcation of CCD camera head and the distortion correction of angle and brightness.
(6) can realize the real time monitoring of high temperature kiln operating mode, can be the quantitative temperature information that the kiln operation provides real-time online again.
(7) measurement result can in time be fed back the active foresight information of putting out a fire in emphasis operating mode offset information, working of a furnace abnormal alarm information and the stove in the stove as the foundation of high temperature kiln production technology adjustment.
The emphasis of native system research and development is how the high temperature kiln image information to be converted into corresponding temperature information in real time.Because measurement, processing and the calculating of this monitoring device serve as to measure the interface with the CCD photographic images, and there is the practical problems of colourity, brightness, angle distortion in the CCD photographic images, so whether the distortion correction to blackbody furnace demarcation, brightness and the angle of CCD camera head accurately will directly influence the accuracy of measurement result, also be the gordian technique place of this product research exploitation.
The technical indicator of native system:
Thermometric range ability: 0 ℃～2000 ℃;
Temperature-measuring range: the full frame scope can be provided with 36 independent thermometric windows;
Each the window's position, size are all adjustable;
Measuring accuracy: 1% (in the range ability);
Response time: less than 80ms;
Temperature information refresh time: less than 1s;
Regional location is judged precision: greater than 90%;
Display mode: (stack) synchronous each window temperature value of independent displaying on the real-time video image;
Control interface: standard industrial interface;
Data storage: 24 hours temperature variation records;
Working method: continuously, in real time, online.
Native system has adopted the advanced detection method of comprehensive monocolor method and duochrome method heat radiation image temperature.The detection method of heat radiation image temperature generally has monocolor method and two kinds of methods of duochrome method.The characteristics of monocolor method are that the grey scale signal to the heat radiation image compares and calculates and draw temperature value, and the characteristics of duochrome method are the ratio calculation between the Red Green Blue signal that adopts in the heat radiation image and draw temperature value.Studies show that although the supposition thermal radiation property is an ash, owing to be subjected to the influence of edge reflection by the detected homogeneous radiant energy of imaging mode on the border, continuing to use radiation spectrum characteristic that the ash object followed, to carry out result calculated very undesired.And since color image processor spare in can distribute to three primary colors separately the quantity of information of storage unit only reach 1/3rd of monochrome image half-tone information location information amount, and because high-temperature temperature variation range broad, differ greatly between the tricolor signal, so the scope of application of duochrome method heat radiation image temperature checking method also is restricted.The subject matter of puzzlement cement kiln is: profile and raw-material heat emissivity coefficient that dust has blured image change, and the variation of heat emissivity coefficient is that the change owing to temperature or surface condition causes.
The accuracy key of native system also is the selection of measuring method.The heat radiation image temperature checking method that adopts combines the advantage of monocolor method and duochrome method heat radiation image temperature checking method, concrete grammar is: gather a width of cloth coloured image, a representative pixels is selected in the highest zone of brightness in the high temperature image, utilizes the radiometer behind calibrated between any two the primary colors digitalized datas in its three primary colors to calculate reference temperature; Coloured image is converted into gray level image,, utilizes reference temperature to calculate heat radiation image temperature by the relation that the ratio between the biquadratic of the temperature between the ratio between each pixel grey scale and each pixel is directly proportional.
The correction of CCD high temperature camera probe: because the optical mirror slip group can cause brightness of image decay and distortion in imaging process, and being meant radiation energy that all grids are launched, the energy information that different pixels is obtained in our imaging model can arrive the share sum within the pairing angular range of this pixel, image after the distortion will no longer meet this corresponding relation, so must revise brightness of image and the pairing angle of each pixel.Simultaneously, owing to will pass through a series of pilot process such as photoelectricity, digital-to-analog conversion in the ccd video camera imaging process, (B) value can not reflect the size of corresponding radiation energy fully for R, G to enter the three primary colours of pixel in the interior flame image of computing machine at last.So must revise to the pixel in the radiation image.
The relation of high temperature camera probe image space and CCD camera imaging target surface as shown in Figure 3.Image imaging is the circular position of 6mm at diameter, and CCD camera target surface is a rectangle that joins with this circle, and size is 3.6mm * 4.8mm.Circle is 0 with the center of rectangle, and the cornerwise field angle of CCD target surface is 120 °.
CCD high temperature camera probe brightness correction: the variation of the absolute value of the radiation energy that the decay of brightness of image just has influence on each pixel and obtained gets final product so only need to multiply by a correction factor on the monochrome information that the pixel that brightness changes is obtained.Correction factor is drawn by the correction data fitting that manufacturer provides, and fitting formula is as follows:
σ＝1.0-0.1004X+0.07875X
2-0.17578X
3+0.01761X
4
+0.02888X
5-0.00652X
6 (1)
Wherein, σ is a correction factor, and X is the distance (unit be mm) of pixel from the target surface center.
CCD high temperature camera probe angle modification: suppose that each pixel institute corresponding angle divides equally, set up the one-to-one relationship of pixel and grid.And the image that the CCD high temperature camera probe that actual producer provides is absorbed is because distortion, and one-to-one relationship originally will be upset, so calculate and need carry out angular divisions again according to the concrete condition of actual CCD high temperature camera probe; In the analysis of a kind of fast definite flame central position that we proposed in the back, the pairing angle of each pixel also plays critical effect.So we must carry out accurate angle modification to angle.Producer provides some data of angle modification, and still owing to the problem of installation accuracy in the installation process of camera lens and lens set, these data are incredible, so must think its method in addition.Its modification method as shown in Figure 4.
The ccd image monitor is placed on the O position, direction is that level is towards right (OA direction), placing a vertical scale apart from the position of its L rice, scale is marked with the scale (what we used is common coordinate paper) of five equilibrium here, uses the ccd image monitor to gather the piece image of this scale then.Determine the imaging pixel of each scale correspondence in the scale by this image, definite pixel is determined the distance X of these pixels apart from the target surface center O apart from the distance method at target surface center in the use brightness correction, imaging angle (is example with the B position in scheming) by determining each scale correspondence then, so just set up the distance of a series of pixel distance target surface center O and the data of the corresponding relation of the imaging angle of this pixel, by these data, simulate following formula:
α＝19.36117X-52.85264X
2+95.84988X
3-55.56153X
4+12.7944X
5-0.9868X
6 (2)
Wherein, α is the angle (unit is degree) of pixel correspondence, and X is the distance (unit be mm) of pixel from the target surface center.
Need to prove,, under the enough big situation of L, can be similar to and regard it as point because CCD high temperature camera probe camera lens is less.Though this can bring certain error, such error is within allowed band.
Radiation image is demarcated: a narrow and small pixel area is selected in the zone of brightness the highest (unsaturation) in the image in the high temperature kiln stove, utilize the ratio between the numerical value of any two primary colors in its average three primary colors to calculate reference temperature by colourimetry, this reference temperature has determined to rebuild the bulk temperature level (credibility of Temperature numerical in other words) in the temperature field of coming out.If the wavelength of ruddiness and green glow be respectively with, same pixel obtains R and the G that the numerical value of ruddiness and green glow is in the radiation energy image, the following calculating of temperature value of this pixel correspondence during the variation of radiance under ignoring different wave length:
But owing to will pass through a series of pilot process such as photoelectricity, digital-to-analog conversion in the ccd video camera imaging process, (B) value can not reflect the size of corresponding radiation energy fully for R, G to enter the three primary colours of pixel in the interior flame image of computing machine at last.So must demarcate to ccd video camera.Native system is demarcated by the standard blackbody furnace in experiment,
The temperature of blackbody furnace can accurately be set, and under the situation of knowing the blackbody furnace temperature, through type 3 just can instead be released the R/G value of this temperature correspondence.If absorb piece image under this temperature by ccd video camera so, we just obtain the R that each pixel measures in this width of cloth image
Meas/ G
Meas, the ratio that we establish them is k, their direct relations are R/G=kR just so
Meas/ G
MeasSo formula 3 becomes following form:
K is the coefficient that will demarcate.
The modular design structure based on this machine data storehouse is adopted in the design of native system software.The firing space behavior that uses computer image processing technology and relevant radiation energy theory to detect at ccd video camera, calculate fire box temperature and emphasis position monitoring, by further analyzing and processing, real-time, quantitative reflection firing space behavior instructs crew's regulation and control system.Total adopts the modular design principle, is made up of database, man-machine interface, computational analysis three parts.The software program flow process is seen Fig. 7.
Control program may further comprise the steps:
(1), start-up system at first, program is carried out the detection of environmentally advantageous property, then the user name and the password of input is confirmed;
(2), user name, password confirming effectively after, the program variable initialization, the capture card initialization starts real-time working thread program, promptly enters program master interface;
(3), enter program master interface, be defaulted as in real time and record, promptly start video in real time; If close video, the playback of can recording,, can operate system's master's user interface by user's response;
(4) if select shutdown system, then enter the system resource playback, system closing after initialization information writes;
(5), then turn back to the real-time video state of acquiescence if select not shutdown system;
(6), in system operation, take place if any the system time incident, then image preserve and in real time computational threads begin, this moment, image reproduction data calculated buffering, started computational threads simultaneously, preserved the video data;
(7), take place, the image acquisition thread begins if any gathering the playback incident, this moment images acquired to buffering, upgrade simultaneously that user interface image shows and the time shows.
Make native system have good expandability based on modular design, be convenient to upgrading and maintenance.In the native system, the principle of handling is followed in the foundation of database and maintenance nearby, by the program realization of place main frame.The various data resources of system's operation are kept in the database, are convenient to the analysis management of data, the structuring degree height of program.
" real-time recorded data storehouse " carried out real time record to the temperature of system monitoring and refreshed, and the data of record are effective, bring in constant renewal in.These data show for temperature and the running status demonstration provides real time data.
What write down in " historical record data storehouse " is some Temperature numerical typical or stage particular moment, by this data of database, can reappear the historical trend figure of some period system's operation, corresponding corresponding firing space behavior.
" image recording database " mainly is the temperature change value of reproducing some period burner hearth with the continually varying form.Be convenient to the temperature variation that the unit operation personnel observe burner hearth.This is characteristic technology performance of native system, also is the key problem in technology that control is introduced temperature variation in further research.
" record data storehouse " record be the system operation that the operations staff of system is carried out, simultaneously also the register system certain operations of carrying out is automatically switched.Like this, be convenient to from now on analysis and crash analysis to system performance.
Carried out the structure of software divides according to the major function of system.Wherein " man-machine interface " comprises file, basic setup, application setting, system's setting, pseudo-colours setting, checks and logs off.Man-machine interface mainly realizes man-machine conversation, and operation behavior is made an explanation and makes system make response to operational order, sets up the system operation interface, opens up the functions such as passage of manual intervention system.Multithreading is adopted in the operation of module, has improved system and has carried out efficient.
" high temperature image processing module " need finish the real-time collection to the burner hearth image, carries out image data extraction, analysis, processing simultaneously, obtains the related data of burner hearth, offers " algoritic module ".
" temperature is set up algoritic module " realized by compiled Fortran dynamic link library, mainly is the accounting temperature field.Adopting the Fortran language, is because it has the irreplaceable advantage of other programming languages aspect the science calculating.
" temperature display module " showed the Temperature Distribution of firing space behavior intuitively to the unit operation personnel.The crew can select different burner hearth zones voluntarily.
" running status display module " mainly quantizes some responsive temperature province, instructs the control of unit operation personnel improvement to high temperature kiln in modes such as numerical value, images.
Consider that high temperature kiln operation monitoring system physical space is wide, electromagnetic interference (EMI) is strong, and the hardware layout of system is divided into two aspects, and the one, the installation of the CCD camera head of high temperature kiln, the 2nd, the placement of industrial computer in the central station of floating dock.Require between the two to connect with anti-interference strong cable.
Claims (2)
1, a kind of high temperature furnace inner video image temperature measuring system, comprise the industrial control host that is connected with high temperature tv and CRT respectively, it is characterized in that: described industrial control host also comprises three parts: database, man-machine interface and computational analysis, wherein database comprises the real-time recorded data storehouse, historical record data storehouse, image recording database and record data storehouse, man-machine interface comprise file, basic setup, application setting, system's setting, pseudo-colours setting, check and log off; Computational analysis comprises that high temperature image processing module, temperature set up algoritic module, temperature display module and compute mode display module; Described high temperature tv adopts the sonde-type high temperature tv that includes protective device (1), gearing (2), control device (3) and camera head (4); On the described industrial control host video frequency collection card is housed, industrial control host utilizes control program to finish the collection of high temperature furnace inner video image, and to extracting, analyze, handle, calculate, show as data.
2, high temperature furnace inner video image temperature measuring system as claimed in claim 1 is characterized in that: described control program may further comprise the steps:
(1), start-up system at first, program is carried out the detection of environmentally advantageous property, then the user name and the password of input is confirmed;
(2), user name, password confirming effectively after, the program variable initialization, the capture card initialization starts real-time working thread program, promptly enters program master interface;
(3), enter program master interface, be defaulted as in real time and record, promptly start video in real time; If close video, the playback of can recording,, can operate system's master's user interface by user's response;
(4) if select shutdown system, then enter the system resource playback, system closing after initialization information writes;
(5), then turn back to the real-time video state of acquiescence if select not shutdown system;
(6), in system operation, take place if any the system time incident, then image preserve and in real time computational threads begin, this moment, image reproduction data calculated buffering, started computational threads simultaneously, preserved the video data;
(7), take place, the image acquisition thread begins if any gathering the playback incident, this moment images acquired to buffering, upgrade simultaneously that user interface image shows and the time shows.
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