CN102393395B - Method and system for detecting copper grade in copper processing process - Google Patents
Method and system for detecting copper grade in copper processing process Download PDFInfo
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- CN102393395B CN102393395B CN 201110248514 CN201110248514A CN102393395B CN 102393395 B CN102393395 B CN 102393395B CN 201110248514 CN201110248514 CN 201110248514 CN 201110248514 A CN201110248514 A CN 201110248514A CN 102393395 B CN102393395 B CN 102393395B
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- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 title claims abstract description 181
- 239000010949 copper Substances 0.000 title claims abstract description 181
- 229910052802 copper Inorganic materials 0.000 title claims abstract description 181
- 238000000034 method Methods 0.000 title claims abstract description 28
- 230000008569 process Effects 0.000 title claims abstract description 20
- 238000012545 processing Methods 0.000 title claims abstract description 13
- 238000001514 detection method Methods 0.000 claims abstract description 29
- 239000012530 fluid Substances 0.000 claims description 79
- 238000000605 extraction Methods 0.000 claims description 15
- 238000001931 thermography Methods 0.000 claims description 12
- 239000000284 extract Substances 0.000 claims description 7
- 238000003909 pattern recognition Methods 0.000 claims description 3
- 239000007788 liquid Substances 0.000 abstract description 15
- 230000008859 change Effects 0.000 abstract description 2
- 238000005259 measurement Methods 0.000 description 4
- 238000012360 testing method Methods 0.000 description 4
- 239000000203 mixture Substances 0.000 description 3
- 238000006479 redox reaction Methods 0.000 description 3
- 238000005070 sampling Methods 0.000 description 3
- 238000012935 Averaging Methods 0.000 description 2
- 229910001369 Brass Inorganic materials 0.000 description 2
- 239000010951 brass Substances 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 230000006870 function Effects 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 238000012773 Laboratory assay Methods 0.000 description 1
- 238000003723 Smelting Methods 0.000 description 1
- 241001062472 Stokellia anisodon Species 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 238000003556 assay Methods 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 230000004456 color vision Effects 0.000 description 1
- 238000004040 coloring Methods 0.000 description 1
- 238000012937 correction Methods 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000009977 dual effect Effects 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 238000005286 illumination Methods 0.000 description 1
- 238000003384 imaging method Methods 0.000 description 1
- 239000004973 liquid crystal related substance Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 230000033116 oxidation-reduction process Effects 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
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Abstract
The invention discloses a method for detecting the copper grade in a copper processing process. The method comprises the following steps of: (1) acquiring a visible light image and an invisible light infrared image of a copper liquid sample to be detected in real time; (2) extracting the infrared ray strength of the copper liquid sample to be detected; (3) extracting a color vector angle of the copper liquid sample to be detected; and (4) estimating the copper grade of the copper liquid sample to be detected. In the invention, the temperature change of a molten copper sample is corrected by introducing infrared information of a high-temperature copper liquid, and real-time accurate detection of the copper grade is realized by fusing with the color characteristic information of the copper liquid, so that the detection method has the advantages of no contact, no damage, continuity, instantaneity and high accuracy. The invention further discloses a system for detecting the copper grade in the copper processing process. The detection system comprises an image acquiring unit, an infrared detecting unit and an image processing unit, and is used for extracting the color information and infrared information of the copper liquid sample to be extracted and estimating the copper grade quality index of the copper liquid, so that corresponding detection cost is reduced on the premise of ensuring the measuring accuracy.
Description
Technical field
The invention belongs to the metallurgical technology technical field of measurement and test, be specifically related to a kind of detection method and pick-up unit thereof about copper process copper grade.
Background technology
The copper process needs can to measure rapidly and accurately copper liquid about the quality index of sample copper grade, and copper grade detects in time online, judges efficiently that whether oxidation-reduction process finish extremely important.
In the copper process, copper grade is to realize the automatically crucial mass parameter of control.Yet, since the factors such as high temperature and corrosivity, the online technical barrier that becomes in the complete control system application that detects of this parameter.Under the existing technique, copper grade detects the sampling observation of general employing off-line and delivers to the detection mode of laboratory assay, and mostly is the chemical analysis mode, although accuracy of detection is higher, detection time is longer, can not satisfy the needs of on line real time control.
At present in a lot of copper processing enterprises, the operator that useless composition brass is smelted the redox reaction process usually estimates the external appearance characteristics such as color of copper liquid and estimates whether copper grade is roughly up to standard, and then estimate degree that redox reaction carries out how, although satisfied to a certain extent the real-time that detects, whether accurate operating experience and the fatigue state that depends on the workman that it estimates; Therefore general accuracy of detection is not high, the reliability of testing result is low.
Therefore, domestic copper processing enterprise all can't realize the online in real time accurately measurement of copper grade parameter at present, and mostly accurate copper grade parameter is that the off-line assay of chamber obtains by experiment, but reaches several hours time lag; And the copper grade that the on-the-spot experience that relies on the operator estimates, the most precision of data is not high, and reliability is low.
Zhang Hongwei, Song Zhihuan is A Copper Compositions Soft Sensor Using Color Vision and LSSVR (Journal of Shanghai Jiaotong University at title, a kind of method of estimation of online copper grade of color-based feature is disclosed in article Vol.45 No.8Aug.2011), the method is by on-site sampling and solidify the coloured image of reclaimed copper sample, then use the RGB color space, color harmony color vector angle quantizes respectively the reclaimed copper color characteristic, utilize at last the least square support vector regression that the copper component parameter is set up regression model, and then realize the copper component parameter estimation.
Yet for a copper sample to be measured, even purity is constant, from about 1000 ℃, dropping to the process of normal temperature, color can become from the shiny red of melting solid-state color, color can change a lot in the temperature-fall period of copper sample, and this situation just has great error so that simple dependent color is judged the copper grade of high temperature copper sample; Therefore this method of estimation measurement data result's precision and reliability are not credible.
Summary of the invention
For the existing above-mentioned technological deficiency of prior art, the invention provides a kind of detection method and pick-up unit thereof about copper process copper grade, realized accurately measuring in real time of copper grade parameter.
A kind of detection method about copper process copper grade comprises the steps:
(1) visible images of Real-time Collection copper fluid samples to be measured and non-visible light infrared image;
(2) described non-visible light infrared image is carried out feature extraction, obtain the infra-red intensity of copper fluid samples to be measured;
(3) in described visible images, choose ROI (Region of Interesting, area-of-interest), ROI is carried out feature extraction, obtain the average RGB of pixel (RGB) value of ROI, and calculate the color vector angle of copper fluid samples to be measured by following equation expression formula;
C
R＝0.877[0.701Red-0.587(256-Green)-0.114Blue]
C
B＝-0.493[-0.299Red-0.587(256-Green)-0.886Blue] (1)
θ＝arctan(C
R/C
B)
In the formula 1: Red is the red channel pixel average of ROI, and Green is the green channel pixel average of ROI, and Blue is the blue channel pixel average of ROI, and θ is the color vector angle of copper fluid samples to be measured;
(4) obtain sample database, according to described color vector angle and infra-red intensity, calculate the copper grade of copper fluid samples to be measured by following equation expression formula;
In the formula 2: K (u
i, u) being the Non-linear Kernel function, y is the copper grade of copper fluid samples to be measured, and n is the number of sample database internal reference copper fluid samples, and i is the sequence number of sample database internal reference copper fluid samples, u
iBe the bivector that is consisted of with reference to color vector angle and the infra-red intensity of copper fluid samples by the i in the sample database, α
iBe i with reference to the coefficient of copper fluid samples, b is bias and for the practical experience value, the bivector that u consists of for color vector angle and infra-red intensity by copper fluid samples to be measured.
Described infra-red intensity is the average infrared value of the pixel of non-visible light infrared image.
A kind of detection system about copper process copper grade comprises:
Image acquisition units is for the visible images of Real-time Collection copper fluid samples to be measured;
Infrared detection unit is for the non-visible light infrared image of Real-time Collection copper fluid samples to be measured;
Graphics processing unit is used for described visible images and non-visible light infrared image are carried out feature extraction, and calculates the copper grade of copper fluid samples to be measured.
Described graphics processing unit comprises:
Color is extracted software, is used for reading ROI at described visible images, and extracts the pixel average RGB value of ROI, and then calculate the color vector angle of copper fluid samples to be measured;
Infrared extraction software is used for described non-visible light infrared image is carried out feature extraction, obtains the infra-red intensity of copper fluid samples to be measured;
Sample database is for the characteristic information of stored reference copper fluid samples;
The copper grade Survey Software is used for according to all calculating the copper grade of copper fluid samples to be measured by pattern-recognition with reference to the characteristic information of copper fluid samples and color vector angle and the infra-red intensity of copper fluid samples to be measured;
Human interface software, be used for showing described visible images and non-visible light infrared image and about the information of infra-red intensity, color vector angle and copper grade, and the operational order that receives the user extracts software, infrared extraction software, copper grade Survey Software and sample database to described color and carries out setting parameter.
Described characteristic information with reference to the copper fluid samples is served as reasons with reference to the bivector of the color vector angle of copper fluid samples and infra-red intensity formation.
Described image acquisition units is industrial camera; Described infrared detection unit is infrared thermography; Described graphics processing unit is industrial control computer.
Described industrial camera is connected with infrared thermography and is adopted gigabit ethernet interface and industrial control computer to realize being connected.
The present invention makes exactly correction by introducing the abundant infrared signature information of high-temperature copper liquid to the temperature variation of molten copper sample, and with the color characteristic information fusion of copper liquid after realize accurately the detecting in real time of high-temperature copper liquid copper grade, have advantages of do not contact, not damaged, continuously, in real time, precision is high; By being contained in industrial camera, the infrared thermography in the standard light source lamp house and related software being housed and the industrial control computer of database can be assessed out the copper grade quality index by real-time online, under the prerequisite that guarantees measuring accuracy, greatly reduced corresponding testing cost.
Description of drawings
Fig. 1 is the steps flow chart schematic diagram of detection method of the present invention.
Fig. 2 is the structural representation of detection system of the present invention.
Embodiment
In order more specifically to describe the present invention, below in conjunction with the drawings and the specific embodiments technical scheme of the present invention is elaborated.
As shown in Figure 1, a kind of detection method about copper process copper grade comprises the steps:
(1) visible images of Real-time Collection copper fluid samples to be measured and non-visible light infrared image.
Obtain the colouring information of copper fluid samples visible light part to be measured and the outer red information of non-visible light part.
(2) extract the infra-red intensity of copper fluid samples to be measured.
The non-visible light infrared image that collects is carried out feature extraction, extract the infrared value of each pixel in the non-visible light infrared image, then be averaging, calculate the average infrared value of pixel of non-visible light infrared image, and as the infra-red intensity of copper fluid samples to be measured.
(3) extract the color vector angle of copper fluid samples to be measured.
In the visible images that collects (size is 640 * 480), choose ROI (size is 200 * 150), ROI is carried out feature extraction, extract the rgb value of each pixel in the ROI, then be averaging, calculate the pixel average RGB value of ROI, and calculate the color vector angle of copper fluid samples to be measured by following equation expression formula;
C
R＝0.877[0.701Red-0.587(256-Green)-0.114Blue]
C
B＝-0.493[-0.299Red-0.587(256-Green)-0.886Blue] (1)
θ＝arctan(C
R/C
B)
In the formula 1: Red is the red channel pixel average of ROI, and Green is the green channel pixel average of ROI, and Blue is the blue channel pixel average of ROI, and θ is the color vector angle of copper fluid samples to be measured.
(4) copper grade of estimation copper fluid samples to be measured.
Obtain sample database, as shown in table 1, this databases has 13 with reference to the characteristic information of copper fluid samples.
Table 1: with reference to the characteristic information of copper fluid samples
According to color vector angle and the infra-red intensity of copper fluid samples to be measured, calculate the copper grade of copper fluid samples to be measured by following equation expression formula, testing result is as shown in table 2;
In the formula 2: K (u
i, u) being the Non-linear Kernel function, y is the copper grade of copper fluid samples to be measured, n is that 13, i is the sequence number of sample database internal reference copper fluid samples, u
iBe the bivector that is consisted of with reference to color vector angle and the infra-red intensity of copper fluid samples by the i in the sample database, α
iBe i with reference to the coefficient of copper fluid samples, to be 0.5211, u be the bivector that color vector angle and infra-red intensity by copper fluid samples to be measured consist of to b.
Table 2: the detection data of copper fluid samples to be measured
As seen from Table 2, the measured value that the copper grade estimated value that the online test method of present embodiment draws and the chemical examination of laboratory off-line obtain is very nearly the same, has higher precision and reliability therefore verified the measurement result of present embodiment, and is credible.
As shown in Figure 2, a kind of detection system about copper process copper grade comprises: an industrial camera, an infrared thermography and an industrial control computer.
The visible images of industrial camera Real-time Collection copper fluid samples to be measured, and send image to industrial control computer; The non-visible light infrared image of infrared thermography Real-time Collection copper fluid samples to be measured also sends image to industrial control computer.
Industrial camera and infrared thermography are installed near the standard light source lamp house of smelting furnace, because the variation of ambient light photograph can cause the fluctuation of copper sample imaging color, so need the Application standard luminous source lamp box that product to be checked and ambient light photograph are kept apart, the intensity of illumination when guaranteeing each the detection is constant.
Industrial camera uses Germany to reflect 800,000 pixel color industrial camera 31AG03 of U.S. essence, this industrial camera adopts 1/3 ' ccd image sensor of 800,000 pixels, full frame scan mode line by line, valid pixel 1024 (H) * 768 (V), sampling precision can reach 8bit, 15 frame/seconds of frame rate, output interface is network TCP/IP, the camera lens bayonet socket is the C/CS mouth, and volume is small and exquisite, is easy to install.
Infrared thermography adopts the online thermal imaging system of the FlIR SC305 of company model.
Industrial control computer receives visible images and the non-visible light infrared image that industrial camera and infrared thermography provide respectively, and these two kinds of images are carried out feature extraction, estimates the copper grade of copper fluid samples to be measured.
Industrial control computer adopts and grinds magnificent industrial control computer, and this machine adopts the Intel dual core processor, dominant frequency 3.0G, and the 1100M network interface card, the 1G internal memory, the 160G hard disk, 19 cun liquid crystal display satisfy the requirement of industry spot rugged surroundings;
Industrial control computer is equipped with color and extracts software, infrared extraction software, copper grade Survey Software, sample database and human interface software; And by gigabit Ethernet connection industrial camera and infrared thermography.
Color is extracted software and read ROI from visible images, and extracts the pixel average RGB value of ROI, and then calculates the color vector angle of copper fluid samples to be measured;
Infrared extraction software carries out feature extraction to the non-visible light infrared image, obtains the infra-red intensity of copper fluid samples to be measured;
Sample database stores the characteristic information with reference to the copper fluid samples;
The copper grade Survey Software with reference to the characteristic information of copper fluid samples and color vector angle and the infra-red intensity of copper fluid samples to be measured, calculates the copper grade of copper fluid samples to be measured according to all by pattern-recognition.
Human interface software shows visible images and non-visible light infrared image and about the information of infra-red intensity, color vector angle and copper grade, and the operational order that receives the user extracts software, infrared extraction software, copper grade Survey Software and sample database to color and carries out setting parameter.
Present embodiment gathers respectively visible images and the non-visible light infrared image of copper liquid by video camera and infrared instrument, and image transmitting carried out feature extraction to industrial computer, estimate the copper grade of copper liquid according to characteristic information and sample data, and then control useless composition brass and smelt the redox reaction process.
Claims (5)
1. the detection method about copper process copper grade comprises the steps:
(1) visible images of Real-time Collection copper fluid samples to be measured and non-visible light infrared image;
(2) described non-visible light infrared image is carried out feature extraction, obtain the infra-red intensity of copper fluid samples to be measured, described infra-red intensity is the average infrared value of the pixel of non-visible light infrared image;
(3) in described visible images, choose ROI, ROI is carried out feature extraction, obtain the pixel average RGB value of ROI, and calculate the color vector angle of copper fluid samples to be measured by following equation expression formula;
C
R=0.877[0.701Red-0.587(256-Green)-0.114Blue ]
C
B=-0.493[-0.299Red-0.587(256-Green)-0.886Blue]（1)
θ=arctan(C
R/C
B)
In the formula (1): Red is the red channel pixel average of ROI, and Green is the green channel pixel average of ROI, and Blue is the blue channel pixel average of ROI, and θ is the color vector angle of copper fluid samples to be measured;
(4) obtain sample database, according to described color vector angle and infra-red intensity, calculate the copper grade of copper fluid samples to be measured by following equation expression formula;
In the formula (2): K (u
i, u) being the Non-linear Kernel function, y is the copper grade of copper fluid samples to be measured, and n is the number of sample database internal reference copper fluid samples, and i is the sequence number of sample database internal reference copper fluid samples, u
iBe the bivector that is consisted of with reference to color vector angle and the infra-red intensity of copper fluid samples by the i in the sample database, α
iBe i with reference to the coefficient of copper fluid samples, b is bias, the bivector of u for being made of color vector angle and the infra-red intensity of copper fluid samples to be measured.
2. the detection system about copper process copper grade is characterized in that, comprising:
Image acquisition units is for the visible images of Real-time Collection copper fluid samples to be measured;
Infrared detection unit is for the non-visible light infrared image of Real-time Collection copper fluid samples to be measured;
Graphics processing unit is used for described visible images and non-visible light infrared image are carried out feature extraction, and calculates the copper grade of copper fluid samples to be measured; Its concrete processing procedure is as follows:
At first, described non-visible light infrared image is carried out feature extraction, obtain the infra-red intensity of copper fluid samples to be measured, described infra-red intensity is the average infrared value of the pixel of non-visible light infrared image;
Then, in described visible images, choose ROI, ROI is carried out feature extraction, obtain the pixel average RGB value of ROI, and calculate the color vector angle of copper fluid samples to be measured by following equation expression formula;
C
R=0.877[0.701Red-0.587(256-Green)-0.114Blue ]
C
B=-0.493[-0.299Red-0.587(256-Green)-0.886Blue]（1）
θ=arctan(C
R/C
B)
In the formula (1): Red is the red channel pixel average of ROI, and Green is the green channel pixel average of ROI, and Blue is the blue channel pixel average of ROI, and θ is the color vector angle of copper fluid samples to be measured;
At last, obtain sample database, according to described color vector angle and infra-red intensity, calculate the copper grade of copper fluid samples to be measured by following equation expression formula;
In the formula (2): K (u
i, u) being the Non-linear Kernel function, y is the copper grade of copper fluid samples to be measured, and n is the number of sample database internal reference copper fluid samples, and i is the sequence number of sample database internal reference copper fluid samples, u
iBe the bivector that is consisted of with reference to color vector angle and the infra-red intensity of copper fluid samples by the i in the sample database, α i is that i is with reference to the coefficient of copper fluid samples, b is bias, the bivector that u consists of for color vector angle and infra-red intensity by copper fluid samples to be measured.
3. the detection system about copper process copper grade according to claim 2, it is characterized in that: described graphics processing unit comprises:
Color is extracted software, is used for reading ROI at described visible images, and extracts the pixel average RGB value of ROI, and then calculate the color vector angle of copper fluid samples to be measured;
Infrared extraction software is used for described non-visible light infrared image is carried out feature extraction, obtains the infra-red intensity of copper fluid samples to be measured;
Sample database is for the characteristic information of stored reference copper fluid samples;
The copper grade Survey Software is used for according to all calculating the copper grade of copper fluid samples to be measured by pattern-recognition with reference to the characteristic information of copper fluid samples and color vector angle and the infra-red intensity of copper fluid samples to be measured;
Human interface software, be used for showing described visible images and non-visible light infrared image and about the information of infra-red intensity, color vector angle and copper grade, and the operational order that receives the user extracts software, infrared extraction software, copper grade Survey Software and sample database to described color and carries out setting parameter.
4. the detection system about copper process copper grade according to claim 2, it is characterized in that: described image acquisition units is industrial camera; Described infrared detection unit is infrared thermography; Described graphics processing unit is industrial control computer.
5. the detection system about copper process copper grade according to claim 4 is characterized in that: described industrial camera is connected with infrared thermography and is adopted gigabit ethernet interface and industrial control computer to realize being connected.
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| CN103307896B (en) * | 2013-06-09 | 2014-11-05 | 浙江大学 | Control method and control system for scrap copper smelting furnace based on image analysis |
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