CN111947463A - Sintering machine charge level image analysis system and method - Google Patents

Sintering machine charge level image analysis system and method Download PDF

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Publication number
CN111947463A
CN111947463A CN202010801986.8A CN202010801986A CN111947463A CN 111947463 A CN111947463 A CN 111947463A CN 202010801986 A CN202010801986 A CN 202010801986A CN 111947463 A CN111947463 A CN 111947463A
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charge level
grid
level image
burner
grids
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CN202010801986.8A
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Chinese (zh)
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CN111947463B (en
Inventor
陈思墨
叶恒棣
廖婷婷
周浩宇
刘前
王业峰
李谦
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Zhongye Changtian International Engineering Co Ltd
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Zhongye Changtian International Engineering Co Ltd
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
    • F27B21/00—Open or uncovered sintering apparatus; Other heat-treatment apparatus of like construction
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
    • F27D21/00—Arrangements of monitoring devices; Arrangements of safety devices
    • F27D21/02—Observation or illuminating devices
    • G—PHYSICS
    • G08—SIGNALLING
    • G08B—SIGNALLING OR CALLING SYSTEMS; ORDER TELEGRAPHS; ALARM SYSTEMS
    • G08B21/00—Alarms responsive to a single specified undesired or abnormal condition and not otherwise provided for
    • G08B21/18—Status alarms
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
    • F27D21/00—Arrangements of monitoring devices; Arrangements of safety devices
    • F27D21/02—Observation or illuminating devices
    • F27D2021/026—Observation or illuminating devices using a video installation
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27M—INDEXING SCHEME RELATING TO ASPECTS OF THE CHARGES OR FURNACES, KILNS, OVENS OR RETORTS
    • F27M2003/00—Type of treatment of the charge
    • F27M2003/04—Sintering

Abstract

The application relates to the technical field of steel sintering, and provides a sintering machine charge level image analysis system and method. The method comprises the steps of dividing a charge level image into a plurality of grids in a direction perpendicular to the running direction of a sintering machine trolley by obtaining the charge level image; inputting the rasterized charge level image into an overgrowth judgment model, judging whether charge levels corresponding to a plurality of burner grids of the rasterized charge level image are overgrown, and if the charge levels are overgrown, generating a charge level overgrowth grade corresponding to the burner grids; if not, marking the corresponding burner grid as a non-overgrowth grid; inputting the rasterized charge level image into an over-melting judgment model, judging whether the charge level corresponding to the non-over-melting grid is over-melted or not, and if so, generating a charge level over-melting grade corresponding to the burner grid; if the melting is not carried out, the corresponding burner grid is marked as a normal grid so as to solve the problem that the charge level identification method in the prior art cannot provide accurate charge level state for the feedback control of the burner.

Description

Sintering machine charge level image analysis system and method
Technical Field
The application relates to the technical field of steel sintering, in particular to a sintering machine charge level image analysis system and method.
Background
Sintering is a main raw material processing technology for iron and steel smelting in China, and more than 75% of blast furnace raw materials come from sintered ores. At present, an ignition furnace is arranged at the head of a sintering machine, an ignition burner is installed in the ignition furnace, a sintering pallet is installed on the sintering machine in an end-to-end manner, wheels of the sintering pallet are installed on a sintering machine rail, and the sintering pallet runs along the sintering machine rail. The bottom air box is arranged below the sintering machine rail, the upper part of the air box corresponds to the bottom of the trolley, and the lower part of the air box is connected with a large sintering flue. The sintering of the device mainly utilizes the coal powder to burn and generate a large amount of heat, so that the energy consumption is higher and the emission pollution is heavier.
In the modern sintering process, an ignition furnace is used for providing high-temperature ribbon-shaped flame to the surface of a mixture to ignite and burn solid fuel in the mixture, the mixture on the surface layer is sintered under the combustion heat release action of high-temperature smoke of the ignition furnace and the solid fuel, and meanwhile, sufficient oxygen is provided by air draft of an exhaust fan to transfer heat accumulated on the surface layer to the mixture on the next layer, so that the solid fuel on the next layer is continuously combusted, and the sintering process is rapidly carried out downwards to complete the sintering process.
The ignition furnace conventionally comprises a furnace body and burners, the ignition furnace is divided into two rows of burners and three rows of burners according to the number of the burners, the ignition furnace with the two rows of burners is provided with a first row of ignition burners and a second row of ignition burners which are staggered on the furnace top, and a complete high-temperature flame zone can be formed on a sintering charge level during ignition, so that charge level ignition work is completed. The ignition furnace with the three rows of burners further comprises a third row of ignition burners parallel to the second row of ignition burners.
In the production application of the ignition furnace at the present stage, due to the influence of various factors such as moisture, material distribution, gas pressure fluctuation and the like, the charge level of the sintering machine ignited by the ignition furnace is easy to have the following two abnormal working conditions:
1. yellowing of local area of charge level (excessive charge level): the abnormal working condition is caused because the local area of the charge level is influenced by various factors, the ignition intensity is too low, and the solid carbon particles on the surface layer of the charge level are not completely ignited during ignition, so that the sintered ores produced in the area are defective ores, and the yield of the sintered ores is seriously reduced;
2. local area whitening of the charge level (charge level overfusion): the abnormal working condition is caused by that the ignition intensity is too high due to the influence of various factors in the local area of the charge level, so that not only solid carbon particles in the charge level are ignited, but also part of iron in the iron ore powder is melted and hardened together after being cooled, the air permeability is sharply reduced, the sinter yield is seriously reduced, and the energy waste is caused.
At present, aiming at the two abnormal ignition working conditions which cause the quality deterioration of the sinter, two solutions are proposed in the prior art, and one method is described in the application number as follows: CN2711178736.8, name: another method of patent of "adaptive control type gas injection device based on charge level video recognition and method thereof" is described in the application nos.: CN2711178927.4, name: a sintering machine charge level diagnosis and self-adaptive control device based on video identification and a method thereof.
In both methods, the charge level is identified, and the burners to be controlled are determined according to the charge level area, but in both methods, when the charge level is rasterized, the charge level is equally divided, and each grid corresponds to a row of burners at the upstream. However, in the actual production process, referring to fig. 1, the structure of the arrangement of burners of the double-row ignition furnace with the first row of even number of burners is schematically shown; referring to fig. 2, it is a schematic structural diagram of a double-row ignition furnace burner arrangement in which the first row is odd number of burners; referring to fig. 3, a structural schematic diagram of arrangement of three rows of ignition furnace burners is shown, because of the particularity of burner distribution of the ignition furnace, a material surface edge region does not directly correspond to burner coverage, and in the material surface division process, whether a grid division mode by using a dotted line or a grid division mode by using a solid line in the figure is adopted, it cannot be perfectly realized that one grid corresponds to a row of burners at the upstream, and a plurality of burners can influence the ignition condition in a grid region.
Disclosure of Invention
The application provides a sintering machine charge level image analysis system and method, which aim to solve the problem that a charge level identification method in the prior art cannot provide an accurate charge level state for feedback control of a burner.
The first aspect of the application provides a sintering machine charge level image analysis system, which comprises a charge level identification device, a charge level detection device and a data processing device, wherein the charge level identification device is arranged at the downstream of an ignition furnace and is positioned at the upper part of a sintering machine trolley in the running direction of the sintering machine trolley; the sintering machine charge level image analysis system also comprises an industrial control computer connected with the charge level identification device;
the industrial control computer is configured to perform the steps of:
receiving a charge level image sent by a charge level identification device, dividing the charge level image into a plurality of grids in a direction perpendicular to the running direction of a sintering machine trolley, and obtaining a rasterized charge level image, wherein the grids at least comprise edge area grids at two side edges of the charge level and a plurality of burner grids positioned between the two edge area grids, and the burner grids correspond to a plurality of burners of an ignition furnace;
inputting the rasterized charge level image into an overgrowth judgment model, judging whether charge levels corresponding to a plurality of burner grids of the rasterized charge level image are overgrown, and if the charge levels are overgrown, generating a charge level overgrowth grade corresponding to the burner grids; if not, marking the corresponding burner grid as a non-overgrowth grid;
inputting the rasterized charge level image into an over-melting judgment model, judging whether the charge level corresponding to the non-over-melting grid is over-melted or not, and if so, generating a charge level over-melting grade corresponding to the burner grid; and if not, marking the corresponding burner grid as a normal grid.
Optionally, the charge level identifying device includes a light shield installed on the bracket and a light-shielding ventilation pipe on the light shield;
an industrial camera, an air cooling cover and an auxiliary light source are arranged in the light shield; the side part of the light shield is provided with a light-shielding ventilating pipe, and the industrial camera is arranged in the air cooling shield; the front end of the air cooling cover is also provided with a high-definition anti-abrasion high-temperature-resistant lens.
Optionally, a plurality of burner grids between the two edge area grids are uniformly distributed, and one burner grid corresponds to three burners of the ignition furnace.
Optionally, the plurality of burner grids located between the two edge area grids include a middle burner grid and a plurality of burner grids on two sides;
the middle burner grid is positioned in the middle of the charge level image and corresponds to one or four burners of the ignition furnace;
the burner grids on the two sides are uniformly distributed, and one burner grid on the two sides corresponds to three burners of the ignition furnace.
Optionally, the overgrowth determination model determines whether the grid charge level is overgrown and the overgrowth level according to the following steps:
calculating the area of the charge level image and the total area of the discrete variegated regions in the charge level image;
calculating the ratio of the total area of the variegated area to the area of the charge level image to obtain a variegated ratio Z;
judging whether the grid charge level is overgrown or not and the overgrowth grade according to the numerical value of the variegated color ratio Z; if it is
Figure BDA0002627730040000031
The grid is a non-overgrowth grid; if it is
Figure BDA0002627730040000032
The grid is first-level overgrowth; if it is
Figure BDA0002627730040000033
The grid is a secondary overgrowth; if it is
Figure BDA0002627730040000034
The grid is a third-level overgrowth; zmaxThe ratio of the area of a single variegated area with concentrated distribution and larger area to the area of a charge level image is obtained when the charge level is over-generated due to a cloth fault.
Optionally, the over-melting determination model determines whether the grid charge level is over-melted and the over-melting grade according to the following steps:
adding the RGB three-channel gray scale curves of the grid charge level image, averaging, and calculating to obtain an average gray scale curve of the image;
calculating pixel point occupation ratios corresponding to all gray scale values in an average gray scale curve of the image, and marking the gray scale values with the pixel point occupation ratios lower than 2-4% as abnormal gray scale values;
removing abnormal gray scale values in the image average gray scale curve, and obtaining the maximum gray scale value W of the image average gray scale curve;
judging whether the grid charge level is over-melted or not and judging the over-melting grade according to the numerical value of the maximum gray level value W; if W is less than or equal to a, the grid is a non-overfused grid, and if a is more than W and less than or equal to a +50, the grid is first-level overfused; if a +50 is larger than W and is not larger than a +95, the grid is subjected to secondary over-melting; if the a +95 is more than or equal to the W and is less than or equal to the a +140, the grid is subjected to three-stage over-melting; wherein a is the maximum gray scale value of the average gray scale curve of the normal charge level image.
Optionally, the sintering machine charge level image analysis system further comprises an abnormality alarm device connected with the industrial control computer;
the industrial control computer is configured to perform the steps of:
inputting the rasterized charge level image into an overgrowth judgment model, judging whether the grid of the side area is overgrown or not, and if the grid is overgrown, generating abnormal alarm information; if not, inputting the rasterized charge level image into an over-melting judgment model, judging whether the grid of the edge area is over-melted or not, and if so, generating abnormal alarm information;
and sending the abnormal alarm information to the abnormal alarm device, and controlling the abnormal alarm device to send an ignition abnormal alarm of the ignition furnace.
The first aspect of the application provides a sintering machine charge level image analysis system, which comprises a charge level identification device, a charge level detection device and a data processing device, wherein the charge level identification device is arranged at the downstream of an ignition furnace and is positioned at the upper part of a sintering machine trolley in the running direction of the sintering machine trolley; the sintering machine charge level image analysis system also comprises an industrial control computer connected with the charge level identification device;
the industrial control computer is configured to perform the steps of:
receiving a charge level image sent by a charge level identification device, dividing the charge level image into a plurality of grids in a direction perpendicular to the running direction of a sintering machine trolley, and obtaining a rasterized charge level image, wherein the grids at least comprise edge area grids at two side edges of the charge level and a plurality of burner grids positioned between the two edge area grids, and the burner grids correspond to a plurality of burners of an ignition furnace;
inputting the rasterized charge level image into an over-melting judgment model, judging whether charge levels corresponding to a plurality of burner grids of the rasterized charge level image are over-melted or not, and if so, generating a charge level over-melting grade corresponding to the burner grids; if not, marking the corresponding burner grid as a non-overfusion grid;
inputting the rasterized charge level image into an overgrowth judgment model, judging whether the charge level corresponding to the non-overgrowth grid is overgrown or not, and if the charge level is overgrown, generating a charge level overgrowth grade corresponding to the burner grid; and if the grid is not overgrown, marking the corresponding burner grid as a normal grid.
The second aspect of the present application provides a sintering machine charge level image analysis method, including:
the method comprises the steps of obtaining a charge level image of a sintering pallet, dividing the charge level image into a plurality of grids in the running direction perpendicular to the sintering pallet, obtaining a rasterized charge level image, wherein the grids at least comprise edge area grids at two side edges of the charge level and a plurality of burner grids positioned between the two edge area grids, and the burner grids correspond to a plurality of burners of an ignition furnace;
inputting the rasterized charge level image into an overgrowth judgment model, judging whether charge levels corresponding to a plurality of burner grids of the rasterized charge level image are overgrown, and if the charge levels are overgrown, generating a charge level overgrowth grade corresponding to the burner grids; if not, marking the corresponding burner grid as a non-overgrowth grid;
inputting the rasterized charge level image into an over-melting judgment model, judging whether the charge level corresponding to the non-over-melting grid is over-melted or not, and if so, generating a charge level over-melting grade corresponding to the burner grid; and if not, marking the corresponding burner grid as a normal grid.
The application provides a sintering machine charge level image analysis system and a method, wherein the sintering machine charge level image analysis system comprises a charge level identification device which is arranged at the downstream of an ignition furnace and is positioned at the upper part of a sintering machine trolley in the running direction of the sintering machine trolley; the sintering machine charge level image analysis system also comprises an industrial control computer connected with the charge level recognition device.
The method comprises the steps of obtaining a charge level image, and dividing the charge level image into a plurality of grids in the direction perpendicular to the running direction of a sintering machine trolley to obtain a rasterized charge level image; inputting the rasterized charge level image into an overgrowth judgment model, judging whether charge levels corresponding to a plurality of burner grids of the rasterized charge level image are overgrown, and if the charge levels are overgrown, generating a charge level overgrowth grade corresponding to the burner grids; if not, marking the corresponding burner grid as a non-overgrowth grid; inputting the rasterized charge level image into an over-melting judgment model, judging whether the charge level corresponding to the non-over-melting grid is over-melted or not, and if so, generating a charge level over-melting grade corresponding to the burner grid; if the burner is not overfused, the corresponding burner grid is marked as a normal grid, and the system and the method for analyzing the charge level image of the sintering machine provided by the embodiment of the application solve the problem that the charge level identification method in the prior art cannot provide accurate charge level state for feedback control of the burner.
Drawings
In order to more clearly explain the technical solution of the present application, the drawings needed to be used in the embodiments will be briefly described below, and it is obvious to those skilled in the art that other drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is a schematic view of a grid distribution of dual-row ignition furnace burners in which the first row is an even number of burners in the prior art;
FIG. 2 is a schematic view of a grid distribution of dual-row ignition furnace burners in which the first row is an odd number of burners in the prior art;
FIG. 3 is a schematic view of a grid arrangement of three rows of ignition furnace burners in the prior art;
fig. 4 is a schematic overall structural diagram of a sintering machine charge level image analysis system according to an embodiment of the present application;
FIG. 5 is a schematic diagram of a top view of the sintering machine charge level image analysis system of FIG. 4;
FIG. 6 is a schematic view of the overall structure of the charge level recognition device of FIG. 4;
fig. 7 is a schematic view of a work flow of a sintering machine charge level image analysis system according to an embodiment of the present application;
FIG. 8 is a schematic view of a grid distribution of a first row of even numbered burners in a dual row ignition furnace burner as provided in an embodiment of the present application;
FIG. 9 is a schematic view of a grid distribution of dual-row ignition furnace burners with odd burners in the first row according to an embodiment of the present application;
FIG. 10 is a schematic view of a grid arrangement of three rows of ignition furnace burners according to an embodiment of the present application;
fig. 11 is a schematic work flow diagram of another sintering machine charge level image analysis system according to an embodiment of the present application.
Illustration of the drawings:
the method comprises the following steps of 1-sintering machine trolley, 2-burner, 3-charge level recognition device, 301-industrial camera, 302-auxiliary light source, 303-air cooling cover, 304-shading ventilation pipe, 305-bracket, 306-shading cover, 5-industrial control computer, 6-side area grid, 7-burner grid, 71-middle burner grid, 8-ignition furnace and 9-abnormity warning device.
Detailed Description
Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings. When the following description refers to the accompanying drawings, like numbers in different drawings represent the same or similar elements unless otherwise indicated. The embodiments described in the following examples do not represent all embodiments consistent with the present application. But merely as exemplifications of systems and methods consistent with certain aspects of the application, as recited in the claims.
Referring to fig. 4, a schematic view of an overall structure of a sintering machine charge level image analysis system provided in the embodiment of the present application is shown. The sintering machine charge level image analysis system that this application embodiment provided, sintering machine charge level image analysis system includes on 1 traffic direction of sintering machine platform truck, sets up 8 low reaches in ignition furnace and is located the charge level recognition device 3 on 1 upper portion of sintering machine platform truck, nozzle 2 sets up inside 8 in ignition furnace. The sintering pallet 1 passes through the lower part of the furnace of the ignition furnace 8.
Referring to fig. 5, which is a schematic top view of the sintering machine charge level image analysis system of fig. 4, and fig. 6 is a schematic overall structure of the charge level recognition device of fig. 4, the charge level recognition device 3 includes a light shield 306 mounted on a support 305 and a light-shielding ventilation pipe 304 on the light shield 306, and an industrial camera 301, an air cooling hood 303 and an auxiliary light source 302 are mounted inside the light shield 306. The side part of the light shield 306 is provided with a light shielding vent pipe 304, the light shielding vent pipe 304 not only can prevent external light from entering the light shield 306, but also can ventilate the charge level of the sintering pallet 1, and a fan can be arranged inside the light shielding vent pipe 304 to actively supply air. The industrial camera 301 is installed in an air cooling cover 303, and compressed air is introduced to cool the industrial camera 301 to maintain its normal operating temperature. The front end of the air cooling cover 303 is also provided with a high-definition anti-abrasion high-temperature-resistant lens, so that the high temperature of the trolley and sintering materials and the damage of dust particles to the industrial camera 301 during starting and stopping are prevented. The auxiliary light source 302 can change the illumination intensity and the color temperature thereof according to the requirement, thereby improving the success rate of visual identification.
The charge level image analysis system also comprises an industrial control computer 5 connected with the charge level recognition device 3. The industrial control computer 5 can receive the charge level image transmitted by the charge level recognition device 3.
As shown in fig. 7, in order to implement the charge level image-based monitoring, the sintering machine charge level image analysis system may be configured to perform the following S701 to S716.
The charge level identifying device 3 is configured to execute the following S701 and S702.
And S701, acquiring a charge level image.
S702, sending the material surface image.
The charge level image of the sintering pallet 1 is captured by the industrial camera 301 of the charge level recognition device 3, and the captured charge level image is transmitted to the industrial control computer 5.
The industrial control computer 5 is configured to execute the following S703 to S708.
And S703, receiving the charge level image.
S704, the burden surface image is divided into a plurality of grids in a direction perpendicular to the traveling direction of the sintering pallet 1, and a rasterized burden surface image is obtained.
The plurality of grids at least comprise edge area grids 6 at two side edges of the charge level and a plurality of burner grids 7 positioned between the two edge area grids 6, and the burner grids 7 correspond to the plurality of burners 2 of the ignition furnace 8.
In the practical application process, different grid division modes are adopted according to different arrangement positions of the burners 2 of the ignition furnace 8, specifically, if the number of the rows of the burners 2 is two and the number of the burners in the first row is an even number, see fig. 8, a grid distribution schematic diagram of the burners of the double-row ignition furnace is provided for the embodiment of the application, wherein the first row is an even number of burners. And uniformly dividing and distributing a plurality of burner grids 7 between the two edge area grids 6, wherein one burner grid 7 corresponds to three burners 2.
Specifically, if the number of rows of burners 2 is two, and the number of burners in the first row is odd, refer to fig. 9, which is a schematic grid distribution diagram of double-row ignition furnace burners in which the first row is odd burners provided in the embodiment of the present application; the plurality of burner grids 7 positioned between the two edge area grids 6 comprise a middle burner grid 71 and a plurality of burner grids 72 at two sides; the middle burner grid 71 is positioned in the middle of the charge level image, and the middle burner grid 71 corresponds to one burner 2; the burner grids 72 on the two sides are uniformly distributed, and one burner grid 72 on the two sides corresponds to three burners 2.
Specifically, if the number of rows of burners 2 is three, refer to fig. 10, which is a schematic diagram of grid distribution of three rows of burners of the ignition furnace provided in the embodiment of the present application; the plurality of burner grids 7 between the two edge area grids 6 comprise a middle burner grid 71 and a plurality of burner grids 72 at two sides; the middle burner grids 71 are positioned in the middle of the charge level image, and the middle burner grids 71 correspond to the four burners 2; the burner grids 72 on the two sides are uniformly distributed, and one burner grid 72 on the two sides corresponds to three burners 2.
S705, inputting the rasterized charge level image into an overgrowth judgment model, judging whether charge levels corresponding to a plurality of burner grids 7 of the rasterized charge level image are overgrown, and if the charge levels are overgrown, generating a charge level overgrowth grade corresponding to the burner grids 7; if not, the corresponding burner grid 7 is marked as a non-overgrowing grid.
The overgrowth judgment model judges whether the grid charge level is overgrown or not and the overgrowth grade according to the following steps:
and calculating the area of the charge level image and the total area of the discrete variegated regions in the charge level image. The excessive generation judging model judges whether the grid charge level is excessive and the excessive generation grade according to the following method:
firstly, identifying and distinguishing colors of a charge level picture, calculating the whole area of the charge level picture, calculating the area of a region occupied by the variegated colors in the charge level picture, and calculating the ratio of the total area of the region occupied by the variegated colors to the area of the charge level picture to obtain the variegated color ratio Z.
Figure BDA0002627730040000071
Wherein, the overgrowth degree of the charge level is determined by determining the numerical value of the variegated color ratio Z, SzIdentifying the area of the variegated zone in the zone for the charge level, S being the charge levelThe area of the region is identified.
The method for judging whether the grid charge level is overgrown or not and the overgrowth grade according to the numerical value of the variegated color ratio Z is as follows:
if it is
Figure BDA0002627730040000072
The grid is a non-overgrowth grid; if it is
Figure BDA0002627730040000073
The grid is first-level overgrowth; if it is
Figure BDA0002627730040000074
The grid is a secondary overgrowth; if it is
Figure BDA0002627730040000075
The grid is a third-level overgrowth;
wherein Z ismaxThe ratio of the area of a single variegated area with concentrated distribution and larger area to the area of a charge level image is obtained when the charge level is over-generated due to a cloth fault. The over-grown variegated regions are distributed in a scattered manner, and the area S of a single variegated regionzSmaller, smaller values of Z. The mottled color regions of the abnormal raw meal passing surface caused by the cloth failure are distributed and concentrated, and a single mottled color region with a larger area exists, and the area S of the single mottled color regionzThere is a maximum value SzmaxZ has a maximum value Zmax。
Wherein, if Z > ZmaxThis indicates that the sintering system is operating abnormally. The criteria for determining the degree of overgrowth are shown in table 1 below.
TABLE 1 criteria for determining degree of overgrowth
Figure BDA0002627730040000081
S706, inputting the rasterized charge level image into an over-melting judgment model, judging whether the charge level corresponding to the non-over-melting grid is over-melted, and if so, generating a charge level over-melting grade corresponding to the burner grid 7; if not, the corresponding burner grid 7 is marked as a normal grid.
The gray scale values of the RGB gray scale values of the normal charge level image and the overfused charge level image are obviously different, the gray scale image converted from the color image is adopted in the embodiment of the application, and whether the charge level is overfused or not is judged in a mode that the maximum gray scale value is used as an overfused judgment boundary.
The method for specifically judging whether the grid charge level is over-melted or not and the over-melting grade comprises the following steps:
and adding the RGB three-channel gray scale curves of the grid charge level image, averaging, and calculating to obtain an image average gray scale curve.
Calculating the pixel point proportion used by each gray-scale value in the average gray-scale curve of the image, and marking the gray-scale value with the pixel point proportion lower than 2-4% as an abnormal gray-scale value.
Removing abnormal gray scale values in the image average gray scale curve, and obtaining the maximum gray scale value W of the image average gray scale curve;
judging whether the grid charge level is over-melted or not and judging the over-melting grade according to the numerical value of the maximum gray level value W; if W is less than or equal to a, the grid is a non-overfused grid, and if a is more than W and less than or equal to a +50, the grid is first-level overfused; if a +50 is larger than W and is not larger than a +95, the grid is subjected to secondary over-melting; if the a +95 is more than or equal to the W and is less than or equal to the a +140, the grid is subjected to three-stage over-melting; wherein a is the maximum gray scale value of the average gray scale curve of the normal charge level image.
The condition that W is greater than a +140 indicates that the work of an ignition furnace system is abnormal, the ratio of the number of pixel points corresponding to the abnormal gray level value is less than 3, the value range of a is 40-60, the value of a is determined by detecting the maximum gray level value of a normal charge level image in advance according to the actual ignition process, and the judgment criterion of the degree of over-melting is shown in the following table 2.
TABLE 2 criterion for degree of over-melting
Degree of over-melting Number of criteria for judgment
Non-overfusion W≤a
Two-stage over-melting a<W≤a+50
Two-stage over-melting a+50<W≤a+95
Three-stage over-melting a+95<W≤a+140
Abnormality (S) W>a+140
It should be noted that in the embodiment of the present application, when the excessive melting determination is performed, the excessive grade and the excessive melting grade are divided into three grades, but not limited to three grades, and more or less grades may be divided according to actual production requirements.
The first aspect of the embodiment of the application provides a sintering machine charge level image analysis system, which comprises a charge level recognition device 3, a charge level recognition device and a detection device, wherein the charge level recognition device is arranged at the downstream of an ignition furnace 8 and is positioned at the upper part of a sintering machine trolley 1 in the running direction of the sintering machine trolley 1; the sintering machine charge level image analysis system also comprises an industrial control computer 5 connected with the charge level recognition device 3.
The method comprises the steps of obtaining a charge level image, and dividing the charge level image into a plurality of grids in the direction perpendicular to the running direction of a sintering machine trolley 1 to obtain a rasterized charge level image; inputting the rasterized charge level image into an overgrowth judgment model, judging whether charge levels corresponding to a plurality of burner grids 7 of the rasterized charge level image are overgrown, and if the charge levels are overgrown, generating a charge level overgrowth grade corresponding to the burner grids 7; if not, marking the corresponding burner grid 7 as a non-overgrowth grid; inputting the rasterized charge level image into an over-melting judgment model, judging whether the charge level corresponding to the non-over-melting grid is over-melted or not, and if so, generating a charge level over-melting grade corresponding to the burner grid 7; if the melting is not carried out, the corresponding burner grid 7 is marked as a normal grid, and the sintering machine charge level image analysis system provided by the embodiment of the application solves the problem that the charge level identification method in the prior art cannot provide accurate charge level state for feedback control of the burner.
As shown in fig. 4, in some embodiments of the present application, the sintering machine charge level image analysis system further includes an abnormality alarm device 9 connected to the industrial control computer 5; as shown in fig. 7, the industrial control computer 5 is further configured to execute the following S707 to S711.
And S707, inputting the rasterized charge level image into the overgrowth judgment model, judging whether the edge area grid 6 is overgrown, and if the edge area grid 6 is overgrown, generating abnormal alarm information.
And S708, sending abnormal alarm information.
S709, if not, inputting the rasterized charge level image into an over-melting judgment model, judging whether the edge area grid 6 is over-melted or not, and if so, generating abnormal alarm information;
and S711, sending abnormal alarm information.
Wherein the abnormal alarm information of the industrial control computer 5 is sent to the abnormal alarm device 9. Because the side grid 6 is not correspondingly ignited by the burner 2, when the side grid 6 is over-melted or over-grown, the abnormal condition of the ignition furnace system is indicated.
The abnormality warning device 9 is configured to execute the following S715 and S716.
And S712, receiving the abnormal alarm information.
And S713, giving an ignition abnormal alarm of the ignition furnace.
Through unusual alarm device 9 receives unusual alarm information to send ignition stove ignition abnormal alarm, make the staff can in time discover that the ignition stove system takes place abnormal conditions, avoid the ignition stove system to be in abnormal operating condition for a long time.
The following is an embodiment of a sintering machine charge level image analysis system provided in the second aspect of the present application, which belongs to the same inventive concept as the sintering machine charge level image analysis system provided in the first aspect of the present application, and for details that are not disclosed in the embodiment of the sintering machine charge level image analysis system provided in the second aspect of the present application, please refer to the embodiment of the sintering machine charge level image analysis system provided in the first aspect of the present application.
A second aspect of the embodiment of the present application provides another sintering machine charge level image analysis system, which includes a charge level recognition device 3 disposed downstream of an ignition furnace 8 and at an upper portion of a sintering machine pallet 1 in a running direction of the sintering machine pallet 1; and a burner controller 4 for controlling the burner 2; the sintering machine charge level image analysis system also comprises an industrial control computer 5 connected with the charge level recognition device 3 and the burner controller 4.
Referring to fig. 11, a schematic view of a work flow of another sintering machine charge level image analysis system provided in the embodiment of the present application is shown. The sintering machine charge level image analysis system may be configured to perform the following S1101 to S1110:
the charge level identifying device 3 is configured to execute the following S1101 and S1102.
S1101, acquiring a charge level image.
And S1102, sending the material surface image.
The industrial control computer 5 is configured to execute the following S1103 to S1108.
S1103, receiving the charge level image.
S1104, the charge level image is divided into a plurality of grids in the direction perpendicular to the traveling direction of the sintering pallet 1, and a rasterized charge level image is obtained.
The plurality of grids at least comprise edge area grids 6 at two side edges of the charge level and a plurality of burner grids 7 positioned between the two edge area grids 6, and the burner grids 7 correspond to the plurality of burners 2.
S1105, inputting the rasterized charge level image into an over-melting judgment model, judging whether charge levels corresponding to a plurality of burner grids 7 of the rasterized charge level image are over-melted, and if so, generating a charge level over-melting grade corresponding to the burner grids 7; if not, the corresponding burner grid 7 is marked as a non-overflowed grid.
S1106, inputting the rasterized charge level image into an overgrowth judgment model, judging whether the charge level corresponding to the non-overgrowth grid is overgrown or not, and if the charge level is overgrown, generating a charge level overgrowth grade corresponding to the burner grid 7; if not, the corresponding burner grid 7 is marked as a normal grid.
Compared with the sintering machine charge level image analysis system provided by the first aspect, the sintering machine charge level image analysis system provided by the second aspect of the embodiment of the present application has a certain difference in the execution steps in which the industrial control computer 5 is configured, so as to illustrate that when the sintering machine charge level image analysis system provided by the embodiment of the present application judges whether an image is overgrown or overflowed, an existing sequence does not necessarily exist, the overflowed condition of the charge level image can be judged first, the overgrowth process of the charge level image can be judged first, the overflowed and overflowed processes of the charge level image can be separately and independently judged, and the overall condition of the charge level image can be obtained according to the results of the two independent judgments.
The following is an embodiment of a sintering machine charge level image analysis method provided by the third aspect of the present application, which is used for implementing the sintering machine charge level image analysis system provided by the first aspect of the present application. For details that are not disclosed in the embodiment of the sintering machine charge level image analysis method of the present application, please refer to the embodiment of the sintering machine charge level image analysis system provided in the first aspect of the present application.
A third aspect of the embodiments of the present application provides a method for analyzing a sintering machine charge level image, where the method for analyzing a sintering machine charge level image includes:
the method comprises the steps of obtaining a charge level image of a sintering pallet, dividing the charge level image into a plurality of grids in the running direction perpendicular to the sintering pallet, obtaining a rasterized charge level image, wherein the grids at least comprise edge area grids 6 at two side edges of the charge level and a plurality of burner grids 7 positioned between the two edge area grids 6, and the burner grids 7 correspond to a plurality of burners.
Inputting the rasterized charge level image into an overgrowth judgment model, judging whether charge levels corresponding to a plurality of burner grids 7 of the rasterized charge level image are overgrown, and if the charge levels are overgrown, generating a charge level overgrowth grade corresponding to the burner grids 7; if not, the corresponding burner grid 7 is marked as a non-overgrowing grid.
Inputting the rasterized charge level image into an over-melting judgment model, judging whether the charge level corresponding to the non-over-melting grid is over-melted or not, if so, generating a charge level over-melting grade corresponding to the burner grid 7; if not, the corresponding burner grid 7 is marked as a normal grid.
And determining the control quantity of each burner according to the charge level overgrowth grade or the charge level overfusion grade of each burner grid 7 and the burner corresponding to the charge level of each burner grid 7.
And controlling the burners according to the control quantity of each burner.
The embodiment of the application provides a sintering machine charge level image analysis system and a method, wherein the sintering machine charge level image analysis system comprises a charge level identification device 3 which is arranged at the downstream of an ignition furnace 8 and is positioned at the upper part of a sintering machine trolley 1 in the running direction of the sintering machine trolley 1; the sintering machine charge level image analysis system also comprises an industrial control computer 5 connected with the charge level recognition device 3.
The method comprises the steps of obtaining a charge level image, and dividing the charge level image into a plurality of grids in the direction perpendicular to the running direction of a sintering machine trolley 1 to obtain a rasterized charge level image; inputting the rasterized charge level image into an overgrowth judgment model, judging whether charge levels corresponding to a plurality of burner grids 7 of the rasterized charge level image are overgrown, and if the charge levels are overgrown, generating a charge level overgrowth grade corresponding to the burner grids 7; if not, marking the corresponding burner grid 7 as a non-overgrowth grid; inputting the rasterized charge level image into an over-melting judgment model, judging whether the charge level corresponding to the non-over-melting grid is over-melted or not, and if so, generating a charge level over-melting grade corresponding to the burner grid 7; if the melting is not carried out, the corresponding burner grid 7 is marked as a normal grid, and the sintering machine charge level image analysis system and method provided by the embodiment of the application solve the problem that the charge level identification method in the prior art cannot provide accurate charge level state for feedback control of the burner.
The embodiments provided in the present application are only a few examples of the general concept of the present application, and do not limit the scope of the present application. Any other embodiments extended according to the scheme of the present application without inventive efforts will be within the scope of protection of the present application for a person skilled in the art.

Claims (9)

1. The sintering machine charge level image analysis system is characterized by comprising a charge level recognition device (3) which is arranged at the downstream of an ignition furnace (8) and is positioned at the upper part of a sintering machine trolley (1) in the running direction of the sintering machine trolley (1); the sintering machine charge level image analysis system also comprises an industrial control computer (5) connected with the charge level recognition device (3);
the industrial control computer (5) is configured to perform the following steps:
receiving a charge level image sent by a charge level recognition device (3), dividing the charge level image into a plurality of grids in a direction perpendicular to the running direction of a sintering machine trolley (1), and obtaining a rasterized charge level image, wherein the grids at least comprise edge area grids (6) at two side edges of the charge level and a plurality of burner grids (7) positioned between the two edge area grids (6), and the burner grids (7) correspond to a plurality of burners (2) of an ignition furnace (8);
inputting the rasterized charge level image into an overgrowth judgment model, judging whether charge levels corresponding to a plurality of burner grids (7) of the rasterized charge level image are overgrown, and if the charge levels are overgrown, generating a charge level overgrowth grade corresponding to the burner grids (7); if not, marking the corresponding burner grid (7) as a non-overgrowth grid;
inputting the rasterized charge level image into an over-melting judgment model, judging whether the charge level corresponding to the non-over-melting grid is over-melted or not, and if so, generating a charge level over-melting grade corresponding to the burner grid (7); if not, marking the corresponding burner grid (7) as a normal grid.
2. The sintering machine charge level image analysis system according to claim 1, characterized in that the charge level recognition device (3) comprises a light shield (306) mounted on a stand (305) and a light shield vent pipe (304) on the light shield (306); an industrial camera (301), an air cooling cover (303) and an auxiliary light source (302) are arranged in the light shield (306); the side part of the light shield (306) is provided with a light shielding ventilating pipe (304), and the industrial camera (301) is arranged in the air cooling shield (303); the front end of the air cooling cover (303) is also provided with a high-definition anti-abrasion and high-temperature-resistant lens.
3. The sintering machine charge level image analysis system according to claim 1, characterized in that a plurality of burner grids (7) between two edge area grids (6) are uniformly distributed, and one burner grid (7) corresponds to three burners (2) of an ignition furnace (8).
4. The sintering machine charge level image analysis system according to claim 1, characterized in that the plurality of burner grids (7) between the two edge area grids (6) comprise a middle burner grid (71) and a plurality of two side burner grids (72);
the middle burner grids (71) are positioned in the middle of the charge level image, and the middle burner grids (71) correspond to one or four burners (2) of the ignition furnace (8);
the burner grids (72) on the two sides are uniformly distributed, and one burner grid (72) on the two sides corresponds to the three burners (2) of the ignition furnace (8).
5. The system according to claim 1, wherein the overgrowth determination model determines whether the grid charge level is overgrown and the overgrowth level according to the following steps:
calculating the area of the charge level image and the total area of the discrete variegated regions in the charge level image;
calculating the ratio of the total area of the variegated area to the area of the charge level image to obtain a variegated ratio Z;
according to the proportion of variegated colourThe numerical value of Z is used for judging whether the grid charge level is overgrown or not and the overgrowth grade; if it is
Figure FDA0002627730030000011
The grid is a non-overgrowth grid; if it is
Figure FDA0002627730030000012
The grid is first-level overgrowth; if it is
Figure FDA0002627730030000013
The grid is a secondary overgrowth; if it is
Figure FDA0002627730030000021
The grid is a third-level overgrowth; zmaxThe ratio of the area of a single variegated area with concentrated distribution and larger area to the area of a charge level image is obtained when the charge level is over-generated due to a cloth fault.
6. The system according to claim 1, wherein the over-melting determination model determines whether the grid charge level is over-melted and the over-melting grade according to the following steps:
adding the RGB three-channel gray scale curves of the grid charge level image, averaging, and calculating to obtain an average gray scale curve of the image;
calculating pixel point occupation ratios corresponding to all gray scale values in an average gray scale curve of the image, and marking the gray scale values with the pixel point occupation ratios lower than 2-4% as abnormal gray scale values;
removing abnormal gray scale values in the image average gray scale curve, and obtaining the maximum gray scale value W of the image average gray scale curve;
judging whether the grid charge level is over-melted or not and judging the over-melting grade according to the numerical value of the maximum gray level value W; if W is less than or equal to a, the grid is a non-overfused grid, and if a is less than or equal to alpha +50, the grid is first-stage overfused; if a +50 is less than or equal to a +95, the grid is subjected to secondary over-melting; if a +95 is less than or equal to a +140, the grid is three-stage over-melting; wherein a is the maximum gray scale value of the average gray scale curve of the normal charge level image.
7. The sintering machine charge level image analysis system according to claim 1, characterized in that it further comprises an abnormality alarm device (9) connected to the industrial control computer (5);
the industrial control computer (5) is configured to perform the following steps:
inputting the rasterized charge level image into a overgrowth judgment model, judging whether the side area grid (6) is overgrown, and if the side area grid is overgrown, generating abnormal alarm information; if not, inputting the rasterized charge level image into an over-melting judgment model, judging whether the edge area grid (6) is over-melted or not, and if so, generating abnormal alarm information;
and sending the abnormal alarm information to the abnormal alarm device (9), and controlling the abnormal alarm device (9) to send an ignition abnormal alarm of the ignition furnace.
8. The sintering machine charge level image analysis system is characterized by comprising a charge level recognition device (3) which is arranged at the downstream of an ignition furnace (8) and is positioned at the upper part of a sintering machine trolley (1) in the running direction of the sintering machine trolley (1); the sintering machine charge level image analysis system also comprises an industrial control computer (5) connected with the charge level recognition device (3);
the industrial control computer (5) is configured to perform the following steps:
receiving a charge level image sent by a charge level recognition device (3), dividing the charge level image into a plurality of grids in a direction perpendicular to the running direction of a sintering machine trolley (1), and obtaining a rasterized charge level image, wherein the grids at least comprise edge area grids (6) at two side edges of the charge level and a plurality of burner grids (7) positioned between the two edge area grids (6), and the burner grids (7) correspond to a plurality of burners (2) of an ignition furnace (8);
inputting the rasterized charge level image into an over-melting judgment model, judging whether charge levels corresponding to a plurality of burner grids (7) of the rasterized charge level image are over-melted, and if so, generating a charge level over-melting grade corresponding to the burner grids (7); if not, marking the corresponding burner grid (7) as a non-overfusion grid;
inputting the rasterized charge level image into an overgrowth judgment model, judging whether the charge level corresponding to the non-overgrowth grid is overgrown or not, and if the charge level is overgrown, generating a charge level overgrowth grade corresponding to the burner grid (7); if not, marking the corresponding burner grid (7) as a normal grid.
9. A sintering machine charge level image analysis method applied to the sintering machine charge level image analysis system according to any one of claims 1 to 8, comprising:
the method comprises the steps of obtaining a charge level image of a sintering pallet, dividing the charge level image into a plurality of grids in the running direction perpendicular to the sintering pallet, obtaining a rasterized charge level image, wherein the grids at least comprise edge area grids (6) at two side edges of the charge level and a plurality of burner grids (7) positioned between the two edge area grids (6), and the burner grids (7) correspond to a plurality of burners of an ignition furnace;
inputting the rasterized charge level image into an overgrowth judgment model, judging whether charge levels corresponding to a plurality of burner grids (7) of the rasterized charge level image are overgrown, and if the charge levels are overgrown, generating a charge level overgrowth grade corresponding to the burner grids (7); if not, marking the corresponding burner grid (7) as a non-overgrowth grid;
inputting the rasterized charge level image into an over-melting judgment model, judging whether the charge level corresponding to the non-over-melting grid is over-melted or not, and if so, generating a charge level over-melting grade corresponding to the burner grid (7); if not, the corresponding burner grid (7) is marked as a normal grid.
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