阅读说明：本技术 一种基于红外热波及图像处理的窑筒体缺陷在线检测方法 (Kiln cylinder defect online detection method based on infrared thermal wave and image processing ) 是由 王伟 王成健 陈之岳 宋金城 陶国柱 朱德鑫 于 2021-01-04 设计创作，主要内容包括：本发明涉及一种基于红外热波及图像处理的窑筒体缺陷在线检测方法,步骤包括：S1通过光电伺服控制系统对高精度分辨率红外热像仪进行控制和操作；S2高精度分辨率红外热像仪对窑筒体扫描采集,获取红外热波图像序列；S3微处理器将得到的红外热波多帧图像序列应用优化算法进行数据拟合、压缩与重建预处理；S4图像数据传输模块将预处理后的红外热波图像通过光纤传送至计算机；S5通过快速检查规范和判别程序、系统数据库对热波图像中的缺陷类型、尺寸参数检测和定量识别；S6对缺陷进行重建和三维显示,还原为视觉可见的图像,通过工业计算机显示出来,从而发现缺陷的类型和位置。(The invention relates to an on-line detection method for kiln cylinder defects based on infrared thermal wave and image processing, which comprises the following steps: s1, controlling and operating the high-precision resolution thermal infrared imager through the photoelectric servo control system; s2, scanning and collecting the kiln cylinder by a high-precision resolution thermal infrared imager to obtain an infrared thermal wave image sequence; the S3 microprocessor applies an optimization algorithm to the obtained infrared heat wave multi-frame image sequence to perform data fitting, compression and reconstruction preprocessing; the S4 image data transmission module transmits the preprocessed infrared thermal wave image to a computer through an optical fiber; s5, detecting and quantitatively identifying the defect type and size parameter in the thermal wave image through a quick inspection standard and discrimination program and a system database; s6, reconstructing and three-dimensionally displaying the defect, and restoring the defect into a visual image which is displayed by an industrial computer so as to find the type and the position of the defect.)

1. An online kiln cylinder defect detection method based on infrared thermal wave and image processing is characterized in that: the system mainly comprises a hardware system, an image acquisition and processing software system, a quick inspection standard and discrimination program, a system database, a management system and the like.

2. An online kiln cylinder defect detection method based on infrared thermal wave and image processing is characterized in that: the method comprises the following steps: s1, controlling and operating the high-precision resolution thermal infrared imager by the photoelectric servo control system; s2, scanning and collecting the kiln cylinder by a high-precision resolution thermal infrared imager to obtain a multi-frame infrared thermal wave image on the surface of the kiln cylinder; and step S3, the microprocessor applies an optimization algorithm to the obtained infrared heat wave multi-frame image sequence data to carry out fitting, compression and reconstruction preprocessing. Step S4, the image data transmission module transmits the preprocessed infrared thermal wave image sequence to a computer through an optical fiber; step S5, fusion, segmentation and pattern recognition technology of thermal wave image sequence data are applied to realize the detection and quantitative recognition of defect types and size parameters; step S6 reconstructs and three-dimensionally displays the defect, and restores the defect to a visually recognizable image.

3. The kiln cylinder defect online detection method based on infrared thermal wave and image processing as claimed in claim 2, characterized in that: the image acquisition processing module adopts the protective cover to shelter from to reduce the huge noise problem that factors such as environmental radiation brought the testing result, effectively improve detection ability.

4. The kiln cylinder defect online detection method based on infrared thermal wave and image processing as claimed in claim 2, characterized in that: the high-resolution thermal infrared imager is the core component of thermal infrared wave detection in step S2, and its performance directly affects the accurate detection of defects, and is preferably an uncooled thermal infrared focal plane array thermal imager.

5. The kiln cylinder defect online detection method based on infrared thermal wave and image processing as claimed in claim 2, characterized in that: in step S3, the optimization algorithm is applied to perform fitting, compression, and reconstruction preprocessing on the image sequence data, so that inter-frame time domain noise can be significantly reduced, the influence of uneven temperature is reduced, the contrast of defects is improved, the storage space is greatly compressed, and the precision and speed of detection are improved; meanwhile, the method is the basis of subsequent processing and is the key point for realizing qualitative and quantitative defect identification.

6. The kiln cylinder defect online detection method based on infrared thermal wave and image processing as claimed in claim 2, characterized in that: in step S5, the fusion, segmentation and pattern recognition techniques of the thermal wave image sequence data are applied to separate harmful and useless information affecting the visibility and recognition capability of the thermal wave image, and mutually verified equipment defect information is extracted, thereby realizing more accurate and effective nondestructive detection and evaluation.

7. The kiln cylinder defect online detection method based on infrared thermal wave and image processing as claimed in claim 2, characterized in that: in step S6, the defect is reconstructed and three-dimensionally displayed, and is restored to a visually recognizable image, which is displayed by an industrial computer, and the difference between the defect and the normal area is identified, so as to find the type and position of the defect.

Technical Field

The invention relates to an online nondestructive detection and image processing analysis method for internal defects and damages of running equipment components by using an infrared thermal wave detection technology, in particular to an online detection method for kiln cylinder defects based on infrared thermal wave and image processing.

Background

The essence of infrared thermal wave imaging is the mechanism of interaction between transient thermal waves and the internal structure and interface of a measured object and the characterization problem after the interaction, and complete carrying and high-fidelity reading of defect information are realized on the basis of the research, so that a theoretical basis is laid for quantitative identification of defects.

The rotary kiln is one of the core devices on a novel dry-method cement production equipment line and is a key device in the cement clinker calcining process. In the cement industry, the calcination of cement clinker is the most important process link of the whole production line, and the rotary kiln is the core of the calcination process link. The rotary kiln cylinder is obliquely arranged on a plurality of pairs of supporting idler sets and rotates to bear the weight of all rotary parts such as materials, kiln linings, outer gear rings and the like. The ore is crushed, ground and preheated by upstream equipment and then enters a rotary kiln, and the rotary kiln barrel bears the technical processes of calcination, decomposition, conveying and the like of materials; the rotary kiln is provided with a heat source by a kiln head coal injection burner, the temperature in the kiln can reach 1000-1450 ℃, materials are subjected to heat exchange and physical and chemical reaction in the kiln to be sintered into cement clinker blocks, and the cement clinker blocks are discharged from the lower end of a kiln cylinder body and enter a grate cooler after being sintered into the cement clinker blocks.

The rotary kiln cylinder body is dozens of meters in length and several meters in diameter, is formed by splicing and welding cylinder sections with different thicknesses on site, and is inevitably subjected to various types of damage and defects in the transportation, welding and use processes, and the existence and the expansion of the damage and the defects can greatly influence the running reliability and the service life of equipment; the technical performance and the operation condition of the kiln cylinder body are directly related to the quality and the yield of clinker, the coal powder consumption and the cost control, so that effective detection means must be adopted to judge and identify the damage and the defect, and the equipment is ensured to be in a safe and reliable state at any time during operation.

Disclosure of Invention

The invention aims to provide an on-line detection method for kiln cylinder defects based on infrared thermal waves and image processing. The invention mainly solves the following problems of how to detect the defects of the running equipment on line; and secondly, how to better realize the processing analysis and display of the micro defect image.

In order to achieve the purpose, the hardware system mainly comprises a protective cover, a computer, a high-precision resolution thermal infrared imager, a photoelectric servo control system, a microprocessor, a power supply and the like, and a software system mainly comprises an image acquisition and processing software system, a quick inspection standard and discrimination program, a system database, a management system thereof and the like. The technical scheme adopted by the invention is as follows: the protective cover is used for providing shielding protection for the image acquisition processing module; the photoelectric servo control system controls and operates the high-precision resolution thermal infrared imager; the high-precision resolution thermal infrared imager is arranged in the protective cover to scan the kiln cylinder body, and multi-frame images of infrared thermal waves on the surface of the kiln cylinder body are acquired and obtained; the microprocessor applies optimization algorithm fitting, compression and reconstruction algorithm pretreatment to the infrared thermal wave image sequence data; the data transmission module transmits the preprocessed infrared thermal wave image to the computer through an optical fiber; the rapid inspection standard and discrimination program and the system database detect and quantitatively identify the defect type and the size parameter in the thermal wave image. And the hardware system computer restores the defect image into a visual defect image and displays the visual defect image.

Drawings

The description includes the following figures, the contents shown are respectively:

FIG. 1 is a schematic block diagram of infrared thermal wave detection;

FIG. 2 is a flow diagram of an image processing analysis module;

Detailed Description

In order to make the technical means, the original characteristics, the achieved purposes and the effects of the invention easy to understand, the invention is further explained by combining the specific embodiments, and the invention is explained and not limited.

The invention provides a technical solution: an online kiln cylinder defect detection method based on infrared thermal wave and image processing can well perform online nondestructive detection and evaluation on the defects of operating equipment; more and more comprehensive characterization defect information can be obtained and utilized based on the image processing technology, the accuracy, the scientificity and the integrity of detection are guaranteed, a better maintenance solution can be formulated, and the detection efficiency and the detection quality are improved. Referring to fig. 1 to 2, the method specifically includes the following steps:

step S1: the high-precision resolution thermal infrared imager is controlled and operated by the photoelectric servo control system, so that the visual axis of the photoelectric tracking equipment is stabilized and the target is accurately tracked. The image acquisition and processing module is shielded by the protective cover, so that the problem of huge noise caused by factors such as environmental radiation and the like to the detection result is reduced, and the detection capability is effectively improved.

And S2, scanning and collecting the kiln cylinder by the high-resolution thermal infrared imager, performing corresponding decoding operation and image frame extraction processing, and acquiring an infrared thermal wave multi-frame image on the surface of the kiln cylinder.

And S3, fitting, compressing and reconstructing pretreatment by the microprocessor by applying an optimization algorithm to the infrared thermal wave multi-frame image sequence data acquired in the step S2.

And step S4, transmitting the infrared thermal wave image preprocessed in the step S3 to a central control computer through an optical fiber by a data transmission module.

Step S5, the defect type and size parameter detection and quantitative identification are realized by rapidly checking the standard and discrimination program, the system database and applying the fusion, segmentation and pattern recognition technology of the thermal wave image sequence data.

Step S6: and (4) reconstructing and three-dimensionally displaying the defect of the image obtained in the step (S4) on the basis of quantitative defect identification, restoring the defect into a visual image, and displaying the visual image through a computer to distinguish the difference between the defect and a normal area so as to find the type and the position of the defect.

In step S2, the thermal infrared imager with high resolution is a core component of thermal infrared wave detection, and its performance directly affects the accurate detection of defects. Preferably an uncooled infrared focal plane array thermal imager, which has a very high temperature resolution, up to 0.01 ℃, and is substantially capable of meeting the requirements of thermal wave detection.

The fitting, compression and reconstruction preprocessing of the image sequence data by applying an optimization algorithm in the step S3 is a key common core technology in infrared thermal wave nondestructive testing. The method can not only obviously reduce the inter-frame time domain noise, reduce the influence of uneven temperature and improve the contrast of defects, but also greatly compress the storage space and improve the detection precision and speed; meanwhile, the reconstructed infrared thermal wave image is the basis of subsequent processing, and is the key point for realizing qualitative and quantitative defect identification.

In step S4, by applying the fusion, segmentation and pattern recognition techniques of the thermal wave image sequence data, not only harmful and useless information affecting the visibility and recognition capability of the thermal wave image can be separated, but also mutually verified equipment defect information can be effectively extracted, and more accurate and effective nondestructive detection and evaluation can be realized.

Accordingly, the present invention has been described above in connection with the appended drawings. It is to be understood that the specific embodiments of the present invention are not limited to the above-described embodiments, and that the present invention is within the scope of the present invention as long as the method and the technical solution of the present invention are directly applied to other fields without substantial or substantial modification.