Online Monitoring of Torpedo Car Shells Based on Equal Angle Scanning
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applied sciences Article Online Monitoring of Torpedo Car Shells Based on Equal Angle Scanning Yumei Tang * and Kefu Liu School of Information Science and Technology, Fudan University, No. 220 Handan Road, Shanghai 200433, China; kfliu@fudan.edu.cn * Correspondence: 19110720076@fudan.edu.cn Abstract: Infrared sensors are being applied more and more widely in industrial production appli- cations. Based on the theory of thermal radiation, this paper discusses the system design principle, temperature calibration method, and thermal image analysis method in detail. The system passed the measurement unit certification, showing that the field of view is 180◦ , the number of scanning points is 2048, the linear velocity is 10–100 Hz, the spatial resolution is 2.5 mrad, and the precision is ±1 ◦ C. An online monitoring test of torpedo car was carried out in the steelmaking plant of Bao Steel. The results show that the system has strong anti-interference ability, stability, and reliability, and meets the application requirements of online monitoring. Keywords: infrared sensors; calibration model; online monitoring; torpedo car 1. Introduction The torpedo car is a very important large-scale molten iron transportation equipment in the steel industry. It is a torpedo-type molten iron tank used in a large blast furnace. Citation: Tang, Y.; Liu, K. Online It is also called a mixed iron car. It has good insulation conditions, small heat loss, and Monitoring of Torpedo Car Shells insulation time. Furthermore, it is energy saving and enduring. Because of the large Based on Equal Angle Scanning. Appl. volume of the car, it can also store molten iron to coordinate the temporary imbalance Sci. 2021, 11, 8053. https://doi.org/ of ironmaking and steelmaking. At the same time, it can replace the steel-making mixer 10.3390/app11178053 and ordinary molten iron car to complete desulfurization, dephosphorization, and other operations during the transportation of molten iron [1,2]. Academic Editor: Carosena Meola The lining may crack, bulge, and spall due to chemical erosion, mechanical erosion, Received: 17 July 2021 and rapid cooling and heating. Due to its high cost of maintenance, repair, and replacement, Accepted: 25 August 2021 continuous monitoring and temperature detection are required to assess the lining of the Published: 30 August 2021 torpedo car. When the refractory material is locally damaged severely but not found, it will cause a serious accident [3,4]. Publisher’s Note: MDPI stays neutral Infrared thermography (IRT) is a science dedicated to the acquisition and processing with regard to jurisdictional claims in of thermal information from non-contact measurement devices [5]. It is an effective, fast, published maps and institutional affil- and noncontact measurement technology that is especially suitable for measuring the iations. temperature of moving objects [6–8]. To our knowledge, the traditional measurement method is commonly used in the steel industry; that is, the relevant staff carry portable infrared instruments to detect the quantity of torpedo cars on the transportation railway [9]. Not only is this method labor intensive, but also the measurement results are not stable, Copyright: © 2021 by the authors. especially in hot or rainy and snowy weather. In order to improve the efficiency of Licensee MDPI, Basel, Switzerland. monitoring and measurement stability, and effectively reduce the labor intensity of related This article is an open access article operators, online infrared sensors are wanted for scanning and imaging [10,11]. distributed under the terms and In this work, based on equal angle scanning, a 3–5 µm infrared scanner is designed. A conditions of the Creative Commons temperature calibration model is proposed and the panoramic thermal image of the torpedo Attribution (CC BY) license (https:// car is obtained. Furthermore, an online monitoring analysis system for the temperature creativecommons.org/licenses/by/ field of the torpedo car is developed. The inner lining thickness is simulated by thermal 4.0/). Appl. Sci. 2021, 11, 8053. https://doi.org/10.3390/app11178053 https://www.mdpi.com/journal/applsci
Appl. Sci. 2021, 11, 8053 2 of 9 map, and the temperature map is drawn according to the body shell size. Finally, the safety alarm and accurate positioning are realized. 2. Theory and Method 2.1. Infrared Radiation Theory According to Planck’s law of black body radiation [12], as long as the temperature of any object in nature is higher than absolute zero (−273.15 ◦ C), it will emit energy in the form of electromagnetic radiation in a very wide range of wavelengths, generating electromagnetic waves (radiation energy). Different materials, different temperatures, different surface brightness, different colors, etc., emit different infrared radiation intensity. Planck’s radiation law gives the specific spectral distribution of blackbody radiation. At a certain temperature, the energy radiated by a blackbody per unit area in unit time, unit solid angle, and unit wavelength interval is: 2hc2 1 B(λ, T) = 5 · hc (1) λ exp( λKT ) − 1 −2 −1 −1 8 − 1 (W − m −Sr −µm ) B(λ, T)—Blackbody’s spectral radiance c—Speed of light 2.998 ∗ 10 m·s T—Absolute temperature of blackbody (K, T = t + 273) −34 h—Planck constant 6.626 ∗ 10 J· s) K—Boltzmann constant 1.380 ∗ 10−23 J·K−1 At a certain temperature, the spectral radiance of a black body has an extreme value, and the position of this extreme value is related to the temperature. This is the Wien displacement law (Wien) [13]: λm × T = 2898(µm · K) (2) λm —Wavelength at maximum blackbody spectral radiance T—Absolute temperature of blackbody (K, T = t + 273) The normal temperature range of the shell of the torpedo car is 100–500 ◦ C, so we choose a medium-wave infrared detector (3–5 µm), probing to achieve the maximum signal-to-noise ratio. According to Planck’s Formula (1), we put forward the voltage response model of the infrared detector (3): A U= B −C (3) exp( t+273.2 )−1 Here, t is the target radiation temperature, U is the voltage signal output by the detector, and A, B, C are the correlation coefficients. 2.2. System Design As is shown in Figure 1, we design a high-speed line scan infrared temperature mea- surement system, which uses synchronous motor scanning and real-time image processing to realize the reconstruction and visualization of the two-dimensional temperature field of the moving target. It is composed of a refrigerated infrared temperature measurement module and a DC brushless motor synchronous scanning module, high-speed signal ac- quisition and processing module, computer real-time image splicing, and other technical components. The infrared sensor mainly receives the radiant energy emitted by the mea- sured object, focuses it on the detector through the receiving lens, completes the conversion of the optical signal to the electrical signal, and then obtains the voltage value by low noise amplifier, filtering, and analog-to-digital conversion.
components. The infrared sensor mainly receives the radiant energy emitted by the meas- Appl. Sci. 2021, 11, 8053 ured object, focuses it on the detector through the receiving lens, completes the conversion 3 of 9 SERVER of the optical signal to the electrical signal, and then obtains the voltage value TARGETby low noise amplifier, filtering, and analog-to-digital conversion. RTU SERVER TARGET Lens TEC-MCT (f=100mm) RTU (d=0.25mm) Mirror Blackbody SAR TEC-MCT ADC Lens Mirror (f=100mm) (d=0.25mm) Mirror RTU SAR Blackbody Motor Motor TCP/IPADC FPGA &PHY Driver Mirror Encoder RTU Motor Motor TCP/IP FPGA &PHY Driver Encoder Figure 1. System block. Figure 1.In Figure 1.Figure System 2, the SAR ADC sampling module obtains the voltage signal of the i block. System block. detector [−5 V, +5 V] and converts it into absolute voltage in the range of [0–5]. In Figure In Figure 2, the 2, the SARSAR ADC ADC sampling sampling module module obtains obtains thethe voltage voltage signal signal of the of the infrared infrared detector [ − 5 V, +5 V] and V it+into converts detector [−5 V, +5 V] and converts 5 absolute voltage in the range of [0–5]. it into absolute voltage in the range of [0–5]. V = in −V = adc _ data − V , Vin ∈ [ −5, + 5] V Vo+ 5+ 5 2 ref ref VVo o== in in − V−refVref = adc _ data −−Vref = adc_data Vref, Vin ∈∈ , Vin [ −[− + 5] 5, 5, +5] (4) (4) 22 where Vo is the digital output voltage, Vin is the AD sampling output voltage, and where where Vo V is the isothe digital digital output output voltage, VinVisinthe is the ADAD sampling output voltage, andand VrefVis ref is the reference voltage ofvoltage, ADC. sampling output voltage, thethe reference reference voltage voltage of ADC. of ADC. Figure 2. ADC Figure sample 2. ADC based sample on equal based angle on equal scanning. angle scanning. Figure 2. ADC sample based on equal angle scanning. Figure Figure3a 3a is isthe theproposed proposed infrared scanner scannerbased basedonon equal equal angle angle scanning. scanning. As isAs is shown shown in in FigureFigure Figure 3b, 3b, in in 3aorderis order to compensate to compensate the proposed for for the the infrared influence influence ofbased background of background scanner radiation, onradiation, equal wewe angle carry scanning carry out out real-time real-time temperature temperature correction correction through through background background sampling.The sampling. Thekey keytechnical tech- shown in Figure 3b, in order to compensate for the influence of background radiat nical index index is listed is listed in in Table Table 1. 1. carry out real-time temperature correction through background sampling. The ke nical index Table 1. is listed Key technical in of index Table 1. scanner. infrared Parameter Value wavelength range 3–5 µm FOV 180◦ focal length 100 mm pixel number/line 2048 sampling rate 500 kSPS scan speed 10–100 Hz precision ±1 ◦ C spatial resolution 2.5 mrad
Appl. Sci. 2021, 11, 8053 4 of 9 Appl. Sci. 2021, 11, x FOR PEER REVIEW 4 of 9 (b) START (cnt_409610 cnt_4096=14'd1600 Vref_temp
330 2.1 340 2.3 350 2.5 380 3.25 Appl. Sci. 2021, 11, 8053 400 3.8 5 of 9 450 5.45 According to Formula (3), we can obtain the temperature inversion Formula (5) of According tomeasurement the temperature Formula (3), we can obtain the temperature inversion Formula (5) of the system: temperature measurement system: B t= BA − 273.2 t = log(A − 273.2 (5) (5) log( U+ + 1) UC++C1) As As is is shown shown in in Figure Figure4, 4, we we use use the the Matlab Matlab R2016a R2016acurve curvefitting fittingtool toolto toperform performcurve curve fitting fitting on on Formula (3), and and obtain obtainthe thecorrelation correlationcoefficients: coefficients:AA= 631.2, = 631.2, B =B3444, = 3444, andand C= C = 0.002758. 0.002758. Figure4. Figure 4. Curve Curve fitting fitting of oftemperature temperaturevoltage voltageresponse responsemodel. model. The The ADC(AD7321, ADI) ADI) input rangeisis±5±V, inputrange 5 V, thethe full-scale full-scale range range is 10isV10with V with 8192 8192 codes, codes, andLSB and the the size LSB is size is mV. 1.22 1.22 mV. Here, Here,wewedefine defineK(t) K(t)as asdt/dU Temperature of resolution is ∆T dt/dU = K(t). Temperature ∆T == K(t) ∗∗ LSB.. Table 3 is the temperature resolution in different ranges. Table 3 is the temperature resolution in different ranges. Table3.3.Temperature Table Temperatureresolution resolutioninindifferent differenttemperature temperatureranges. ranges. t/°C t/◦ C U/V U/V dt/dU dt/dU Resolution/◦ C Resolution/°C 100 0.06 646.02 0.8 100 0.06 646.02 0.8 200 200 0.42 0.42 152.38 152.38 0.2 0.2 300 300 1.55 1.55 61.25 61.25 0.07 0.07 400 400 3.8 3.8 34.37 34.37 0.04 0.04 3. Experiments 3. Experiments As isisshown As shownininFigure Figure 5, the 5, the mainmain equipment equipment at monitoring at the the monitoring site includes site includes two two scan- scanners (in the red dashed line ellipse in Figure 5); four RFID antennas ners (in the red dashed line ellipse in Figure 5); four RFID antennas (in the yellow dashed (in the yellow dashed line circlelinein circle Figurein3); Figure 3); andtags and RFID RFID tags installed installed on the torpedo on the torpedo car (eachcartorpedo (each torpedo car is car is equipped equipped withRFID with four four RFID tags,tags tags, two two both tags both on theonfront the front and back and back sides). sides). The The sys- system tem collects, calculates, and transmits temperature data on the shell surface, collects, calculates, and transmits temperature data on the shell surface, and transmits and transmits itit to to the thecentral centralcontrol controlroom roomthrough throughan anoptical opticalfiber fibernetwork. network.The Thesoftware softwareadopts adoptsthe the B/S(Browser/Server) architecture. The main equipment in the central control room is the temperature data server and the large-screen display platform in the console. The large-screen display platform is used for real-time display, and the temperature data server can be used for offline data analysis.
Appl. Sci. 2021, 11, x FOR PEER REVIEW 6 of 9 B/S(Browser/Server) architecture. The main equipment in the central control room is the Appl. Sci. 2021, 11, 8053 temperature data server and the large-screen display platform in the console. The large- 6 of 9 screen display platform is used for real-time display, and the temperature data server can be used for offline data analysis. Appl. Sci. 2021, 11, x FOR PEER REVIEW 6 of 9 B/S(Browser/Server) architecture. The main equipment in the central control room is the temperature data server and the large-screen display platform in the console. The large- screen display platform is used for real-time display, and the temperature data server can be used for offline data analysis. Figure 5. Figure 5. Online Online monitoring monitoring application. application. 4. 4.5.Results Figure and and Discussion Online monitoring Results application. Discussion 4.1. Real Time Analysis of 4.1. Real 4. Results Time Analysis and Discussion of Heat Heat Map Map As 4.1. Real Time is is shown AsAnalysis shown in of Heat Figure Figure 6a, inMap 6a, the the length length of of the the torpedo torpedo car car is is 14.5 14.5 m, m, the the speed speed of of the the torpedo As is shown torpedo car carinwith Figuretwo with tanks 6a, the two isisabout length tanks of 88km/h the torpedo about km/h car(normally 6–10 is 14.5 m, the (normally km/h), speed 6–10 of the and km/h), and scanning scanning time time is is about torpedo 6.6 s. car with two As is shown tanks is about is Figure 8 km/h 6b, if 6–10 (normally the km/h), line speed is 20 ms, and scanning timethe is image resolution is about aboutno 6.6less 6.6 s. Asthan s. As is shown is shown is Figure 6b, if the line speed is 20 ms, the image resolution is no 330isline. FigureIf 6b, theifline the line speedisisset speed 20 ms, as 10thems, image resolution the image isresolution no is no less than less330 less than than line.330 line. If the lineIf the isline speed speed set as 10 ms,isthe setimage as 10resolution ms, theisimage no less resolution than 660 is no less than 660 660 line. line. line. Appl. Sci. 2021, 11, x FOR PEER REVIEW 7 of 9 (a) (a) (b) Figure 6. (a) Mechanical Figure 6. diagram of 320 t torpedo (a) Mechanical car, (b) diagram of thermal imaging. car, 320 t torpedo (b) thermal imaging. As is shown in Figure 7, we use the pseudo-color to describe the surface temperature field distribution on the two sides of the torpedo car. By comparing the temperature cor- responding to the color scale on the left, the temperature and relative height of each sur- face position can be visually distinguished from the figure. Through the temperature in- formation fed back from the graph, it is analyzed and inferred whether the torpedo tank body lining is damaged, whether there is sediment at the bottom, etc., as well as the spe- cific geometric dimensions and precise physical location on the surface of the torpedo car
Appl. Sci. 2021, 11, 8053 7 of 9 (b) Figure 6. (a) Mechanical diagram of 320 t torpedo car, (b) thermal imaging. As isAsshown is shownin Figure 7, we in Figure 7, use the pseudo-color we use the pseudo-color to describe the surface to describe temperature the surface temperature fieldfield distribution on the two sides of the torpedo car. By comparing distribution on the two sides of the torpedo car. By comparing the temperature cor- the temperature corresponding responding to to the the color color scale scale on on the the left, the temperature left, the temperature and and relative relative height height ofofeach eachsur- surface position can be visually distinguished from the figure. Through face position can be visually distinguished from the figure. Through the temperature in- the temperature information formation fed back fed backfrom fromthethe graph, graph,it isitanalyzed is analyzed andand inferred whether inferred whetherthe the torpedo tanktank torpedo body lining body is damaged, lining is damaged,whether therethere whether is sediment at the at is sediment bottom, etc., asetc., the bottom, wellasaswell the specific as the spe- geometric dimensions and precise physical location on the surface of cific geometric dimensions and precise physical location on the surface of the torpedothe torpedo car when car the above when the above situation occurs. Based on the heat transfer model and boundary[14], situation occurs. Based on the heat transfer model and boundary conditions condi- we perform tions [14], linear mapping, we perform which linear can simulate mapping, which thecan radial temperature simulate distribution the radial temperature of the distri- car shell, butionproviding of the car ashell, basisproviding for the design a basisoffor refractory the design linings and the linings of refractory establishment and the of estab- accurate heatof lishment transfer accurate models. heat transfer models. (a) Thermal imaging on the two sides (b) axial temperature profile. Figure Figure 7. Thermal 7. Thermal imaging imaging and and axialaxial temperature temperature profile. profile. 4.2. 4.2. Statistical Statistical Analysis Analysis of Heat of Heat MapMap Appl. Sci. 2021, 11, x FOR PEER REVIEW As isAs is shown shown in Figure in Figure 8, image 8, image reconstruction reconstruction and unitand unit segmentation segmentation (20 ×8 10 of 9ele- (20 × 10 elements) ments) are based are performed performed on thebased axialon the axial temperature temperature data and thedata and the physical physical model of themodel shell. of the shell. Figure8. Figure 8. Image Image reconstruction reconstructionof oftorpedo torpedocar. car. Each Each unit unit is is preset preset to toaalimit limitvalue valueof 350◦°C. of350 C. Whenever Wheneveraatemperature temperaturevalue valuehigher higher than than this this preset presetvalue valueisisread, read,the thesystem systemoutputs outputsthe thehigh-temperature high-temperaturealarm alarmstatus, status,and and displays displays the the temperature temperature value value table table of of each each unit unit on onthe themonitor monitorscreen, screen,and andinforms informsthethe operator operator ofof aa“high “hightemperature” temperature”alarm alarmby byvoice. voice. 5. Conclusions Based on the theory of thermal radiation, this paper discusses the system design prin- ciple, temperature calibration method, and thermal image analysis method in detail. The system has passed the measurement unit certification, showing that the field of view is 180°, the number of scanning points is 2048, the linear velocity is 10–100 Hz, the spatial resolution is 2.5 mrad, and the precision is ±1 °C.
Appl. Sci. 2021, 11, 8053 8 of 9 5. Conclusions Based on the theory of thermal radiation, this paper discusses the system design principle, temperature calibration method, and thermal image analysis method in detail. The system has passed the measurement unit certification, showing that the field of view is 180◦ , the number of scanning points is 2048, the linear velocity is 10–100 Hz, the spatial resolution is 2.5 mrad, and the precision is ±1 ◦ C. The temperature of the torpedo car shell is 100–500 degrees Celsius. Low-cost area array thermal imaging cameras mainly use uncooled long-wave infrared technology (8–14 microns). There are phenomena such as large temperature measurement errors in high-temperature sections, inaccurate data, and poor environmental adaptability [15,16]. According to Wien’s law, to accurately measure the temperature, the mid-wave infrared imaging technology can obtain the best performance. The cooling medium-wave infrared scanning temperature measurement system can cool the detector thermoelectricity and compensate for the temperature, which can output data steadily day and night; the unique large field of view (0–180 degrees) is especially suitable for online detection of moving objects. In order to adapt to rain, snow, fog, and other weather, the installation distance should not be too far. In addition, it can simulate the lining thickness and locate the fault accurately, to assist in the analysis and infer the damage trend of the inner lining, and then help determine when the torpedo car is repaired, which not only greatly reduces the manpower and material costs, but also reduces the number of spare torpedo cars. Author Contributions: Conceptualization, methodology, software, validation, formal analysis, in- vestigation, resources, data curation, writing—original draft preparation, Y.T.; writing—review and editing, visualization, supervision, project administration, K.L. All authors have read and agreed to the published version of the manuscript. Funding: This research was funded by Hefei GoodTech, Co., Ltd. Institutional Review Board Statement: Not applicable. Informed Consent Statement: Not applicable. Conflicts of Interest: The authors declare no conflict of interest. References 1. Zhao, J.Y.; Zang, Y.; Qin, Q.; Wu, D.P. Thermo-Mechanical Analysis of Torpedo Car. Appl. Mech. Mater. 2011, 44–47, 1198–1202. [CrossRef] 2. Yemelyanov, V.; Tochilkina, T.; Vasilieva, E.; Nedelkin, A.; Shved, E. Computer Diagnostics of the Torpedo Ladle Cars. In International Conference on Inventive Material Science Applications; Bindhu, V., Wang, H.H., Ranganathan, G., Eds.; Amer Inst Physics: Melville, NY, USA, 2018. 3. Jin, S.L.; Harmuth, H.; Gruber, D.; Buhr, A.; Sinnema, S.; Rebouillat, L. Thermomechanical Modelling of a Torpedo Car by Considering Working Lining Spalling. Ironmak. Steelmak. 2020, 47, 145–149. [CrossRef] 4. Goldwaser, A.; Schutt, A. Optimal Torpedo Scheduling. J. Artif. Intell. Res. 2018, 63, 955–986. [CrossRef] 5. Usamentiaga, R.; Venegas, P.; Guerediaga, J.; Vega, L.; Molleda, J.; Bulnes, F.G. Infrared Thermography for Temperature Measurement and Non-Destructive Testing. Sensors 2014, 14, 12305–12348. [CrossRef] 6. Dai, S.; Nie, H.; Yi, W.; Yang, Y.; Li, J.; Li, D. Research on a New Method of Multi-Zone High Temperature Point Tracking of Rotary Kiln Surface Temperature Based on Equal Angle Scanning. Infrared Phys. Technol. 2019, 103, 103078. [CrossRef] 7. Gade, R.; Moeslund, T.B. Thermal Cameras and Applications: A Survey. Mach. Vis. Appl. 2014, 25, 245–262. [CrossRef] 8. Hodgkinson, J.; Tatam, R.P. Optical Gas Sensing: A Review. Meas. Sci. Technol. 2012, 24, 012004. [CrossRef] 9. Botelho, R.A.; Calente, A. Online Monitoring of Torpedo Car Shells. In Proceedings of the Spie the International Society for Optical Engineering, Aerospace/Defense Sensing, Simulation, and Controls, Orlando, FL, USA, 23 March 2001. 10. Jiang, Z.; Guo, Y.; Pan, D.; Gui, W.; Maldague, X. Polymorphic Measurement Method of Feo Content of Sinter Based on Heterogeneous Features of Infrared Thermal Images. IEEE Sens. J. 2021, 21, 12036–12047. 11. Holst, G.C.; Driggers, R.; Furxhi, O. Design Considerations for Advanced Mwir Target Acquisition Systems. Appl. Opt. 2020, 59, 4339–4348. [CrossRef] 12. Bose, S.N. Planck’s Law and Light Quantum Hypothesis. Z. Phys. 1924, 26, 178–181. 13. Saurel, P. On Wien’s Displacement Law. Phys. Rev. 1910, 30, 356–358. [CrossRef]
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