CN111402195A - Infrared intelligent inspection method for electrolytic cell - Google Patents
Infrared intelligent inspection method for electrolytic cellDownload PDFInfo
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- CN111402195A CN111402195ACN202010010546.0ACN202010010546ACN111402195ACN 111402195 ACN111402195 ACN 111402195ACN 202010010546 ACN202010010546 ACN 202010010546ACN 111402195 ACN111402195 ACN 111402195A
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- G—PHYSICS
- G06—COMPUTING OR CALCULATING; COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T7/00—Image analysis
- G06T7/0002—Inspection of images, e.g. flaw detection
- G06T7/0004—Industrial image inspection
- G—PHYSICS
- G01—MEASURING; TESTING
- G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
- G01D21/00—Measuring or testing not otherwise provided for
- G01D21/02—Measuring two or more variables by means not covered by a single other subclass
- G—PHYSICS
- G06—COMPUTING OR CALCULATING; COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T7/00—Image analysis
- G06T7/70—Determining position or orientation of objects or cameras
- G06T7/73—Determining position or orientation of objects or cameras using feature-based methods
- G—PHYSICS
- G06—COMPUTING OR CALCULATING; COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T2207/00—Indexing scheme for image analysis or image enhancement
- G06T2207/10—Image acquisition modality
- G06T2207/10048—Infrared image
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Abstract
Description
Technical Field
The invention belongs to the technical field of infrared intelligent detection, and particularly relates to an infrared intelligent inspection method for an electrolytic cell.
Background
At present, in the domestic nonferrous metal smelting industry, because the distance between adjacent polar plates of an electrolytic bath is very small, impurities are adsorbed on the surface of a negative plate to form 'nodules' in the electrolytic refining process, and the short circuit between the polar plates is caused. Such short circuit failure of the plates can result in a reduction in the efficiency of copper electrolysis production and a waste of electrical energy. At present, the enterprise generally adopts artifical fault detection mode to waste time and energy, has obvious shortcoming: the method has no target for detecting the fault polar plate, the accuracy and efficiency of manual identification are low, and the productivity of the electrolysis industry is greatly influenced.
At present, some methods for automatically detecting the over-temperature pole plate are available at home and abroad. There are 3 points that are not enough: firstly, many of the engineering plants are still in the basic theory research stage and are not applied to practical engineering; secondly, the detection method has low automation and intelligence degree; thirdly, the accuracy rate of detecting the short circuit pole plate is not high, and the production requirement is difficult to meet.
Disclosure of Invention
The invention aims to solve the problem of low detection efficiency of the over-temperature polar plate of the electrolytic cell in the prior art.
Therefore, the invention provides an infrared intelligent inspection method for an electrolytic cell, which comprises the following steps:
s1: acquiring regional position coordinates of all polar plates in the electrolytic bath and corresponding infrared image information and transmitting the regional position coordinates and the corresponding infrared image information to a background;
s2: the background adopts an image processing and identifying algorithm to obtain the temperature information and the position information of the short-circuit polar plate in the electrolytic bath, and the image processing and identifying algorithm comprises the following steps: after preprocessing the infrared image information by gray level conversion, image correction, image cutting, image binarization, image filtering, expansion corrosion and feature point calibration, analyzing the characteristic quantity of an electrolytic cell, comparing the characteristic quantity of an image, dividing an image region, positioning the electrolytic cell, positioning a polar plate, analyzing the characteristic quantity of a overheated polar plate, positioning the overheated polar plate and converting the positioning information to obtain the temperature information and the position information of the short-circuit polar plate;
s3: and the background sends the temperature information and the position information of the short-circuit polar plate to the handheld terminal and prompts and alarms.
Preferably, the step S01 specifically includes: the electrolysis bath is scanned globally by an infrared scanner at the lower end of the intelligent robot, and the area position coordinates and the infrared image information of each polar plate identified after scanning are sent to the handheld control terminal.
Preferably, the intelligent robot is an automatic tracking trolley, and the automatic tracking travelling crane track is positioned above the electrolytic cell.
Preferably, infrared scanner includes wide angle camera, the orbit is the single straight line, the horizontal border of electrolysis trough is located the shooting range of wide angle camera, the longitudinal border of electrolysis trough is located under the single straight line.
Preferably, the power supply mode of the intelligent robot is a rail power supply mode.
Preferably, the step S02 specifically includes: and a temperature early warning value is preset in the background, the infrared image information is converted into corresponding temperature information, when the temperature information exceeds the temperature early warning value, the polar plate in the region is judged to be a short-circuit polar plate, and the temperature information and the position information of the short-circuit polar plate are recorded.
Preferably, the dilation etching includes two parts, namely dilation processing and erosion processing, the dilation processing includes expanding a local highlight area in the infrared image information, the erosion processing includes reducing the local highlight area in the infrared image information, and the dilation processing and the erosion processing are performed the same number of times.
Preferably, the characteristic quantity of the electrolytic cell comprises a plurality of rectangular small regions formed by dividing the passing region of the electrolytic cell, and each rectangular small region corresponds to one polar plate.
Preferably, the step S2 specifically includes: the method comprises the steps of presetting time intervals between two adjacent shooting, receiving infrared image information sent from different time periods by a background for storage, and analyzing and predicting temperature change trend according to the linear change rule of historical infrared image information so as to early warn the position of a short-circuit polar plate in advance.
Preferably, the step S3 specifically includes: the alarm information comprises temperature information and position information of all short-circuit pole plates in the electrolytic bath and prompts shutdown.
The invention has the beneficial effects that: the invention provides an infrared intelligent inspection method for an electrolytic cell, which is characterized by comprising the following steps: firstly, acquiring regional position coordinates and corresponding infrared image information of all polar plates in an electrolytic bath and transmitting the regional position coordinates and the corresponding infrared image information to a background; then the background adopts an image processing and identifying algorithm to obtain the temperature information and the position information of the short-circuit polar plate in the electrolytic bath; and finally, the background sends the temperature information and the position information of the short-circuit polar plate to the handheld terminal and prompts and alarms. The intelligent robot infrared inspection technology is adopted, the thermal imager is carried by the rail robot to inspect the electrolytic cell in real time, infrared images are shot, the acquired infrared images of the polar plates of the electrolytic cell are processed by an intelligent algorithm, software is used for automatically identifying over-temperature short-circuit polar plates, in addition, the temperature change of the same electrolytic cell can be compared by a longitudinal time axis, the polar plates to be short-circuited are predicted, and the position of the short-circuit polar plates is early warned in advance. Has great significance for improving the production efficiency of the nonferrous metal electrolysis industry.
The present invention will be described in further detail below with reference to the accompanying drawings.
Drawings
FIG. 1 is a schematic flow chart of the infrared intelligent inspection method for the electrolytic cell of the invention;
FIG. 2 is a functional schematic diagram of the infrared intelligent inspection method for the electrolytic cell.
Description of reference numerals: the intelligent robot comprises a handheld terminal 1, apolar plate 2, an intelligent robot 3, a travelling crane rail 4 and abackground 5.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
In the description of the present invention, it is to be understood that the terms "center", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", and the like indicate orientations or positional relationships based on those shown in the drawings, and are only for convenience of description and simplicity of description, and do not indicate or imply that the referenced devices or elements must have a particular orientation, be constructed and operated in a particular orientation, and thus, are not to be construed as limiting the present invention.
The terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature; in the description of the present invention, "a plurality" means two or more unless otherwise specified.
The embodiment of the invention provides an infrared intelligent inspection method for an electrolytic cell, which comprises the following steps:
s1: acquiring regional position coordinates of allpolar plates 2 in the electrolytic bath and corresponding infrared image information and transmitting the regional position coordinates and the corresponding infrared image information to abackground 5;
s2: thebackground 5 adopts an image processing and identifying algorithm to obtain the temperature information and the position information of the short-circuit polar plate in the electrolytic bath, and the image processing and identifying algorithm comprises the following steps: after preprocessing the infrared image information by gray level conversion, image correction, image cutting, image binarization, image filtering, expansion corrosion and feature point calibration, analyzing the characteristic quantity of an electrolytic cell, comparing the characteristic quantity of an image, dividing an image area, positioning the electrolytic cell, positioning apolar plate 2, analyzing the characteristic quantity of a overheatedpolar plate 2, positioning the overheatedpolar plate 2 and converting the positioning information to obtain the temperature information and the position information of a short-circuit polar plate;
s3: and thebackground 5 sends the temperature information and the position information of the short-circuit polar plate to the handheld terminal 1 and prompts and gives an alarm.
Therefore, as shown in fig. 1 and fig. 2, firstly, the region position coordinates of all thepolar plates 2 in the electrolytic cell and the corresponding infrared image information are obtained by the infrared scanning technology and are transmitted to thebackground 5, the real-time temperature image of thepolar plates 2 is obtained by the infrared scanning technology, then the characteristic extraction and identification are carried out by the image processing and identification technology at thebackground 5, specifically, the method comprises the steps of converting the infrared image information into gray scale, carrying out image correction, carrying out image cutting, carrying out image binaryzation, carrying out image filtering, carrying out expansion corrosion and calibrating the characteristic points for preprocessing, then, distinguishing and positioning eachpolar plate 2 in the electrolytic cell, namely thepolar plate 2 by analyzing the characteristic quantity of the electrolytic cell, then comparing the characteristic quantity of the image, carrying out image region division, carrying out positioning on thepolar plate 2, positioning on the actualpolar plate 2 and thepolar plate 2 in the image for corresponding region, then analyzing the characteristic quantity of the overheated polar, and obtaining the temperature information and the position information of the short-circuit polar plate. The method comprises the following steps of gray level conversion, image correction, image cutting, image binarization, image filtering, expansion corrosion and characteristic point calibration, belongs to the prior art, and high-precision image characteristic information is obtained through the cooperation of correct steps.
Therefore, the real-time monitoring is repeatedly scanned, when the temperature of one or morepolar plates 2 is detected to exceed the safety threshold, the alarm is started, and the specific alarm temperature value and the specific position are displayed on the handheld terminal 1, so that the staff can conveniently overhaul.
Preferably, step S01 specifically includes: the electrolytic bath is scanned globally by an infrared scanner at the lower end of the intelligent robot 3, and the area position coordinates and the infrared image information of eachpolar plate 2 identified after scanning are sent to the handheld control terminal. The intelligent robot 3 comprises an arm or a robot walking above the electrolytic bath, an infrared scanner is arranged below the arm, and the infrared scanner can regularly and comprehensively scan the electrolytic bath by moving the arm.
In the preferred scheme, the intelligent robot 3 is an automatic tracking trolley, and the automatic tracking travelling crane track 4 is positioned above the electrolytic cell. A travelling rail 4 is arranged above the electrolytic cell, the trolley is suspended below the travelling rail 4, the trolley is driven to move, the trolley can travel along the travelling rail 4, and the infrared scanner at the lower end of the trolley can gradually complete the scanning of the whole electrolytic cell.
According to the preferable scheme, the infrared scanner comprises a wide-angle camera, the travelling crane track 4 is a single straight line, the transverse boundary of the electrolytic cell is located in the shooting range of the wide-angle camera, and the longitudinal boundary of the electrolytic cell is located under the single straight line. Therefore, when the transverse width of the coverage area of the electrolytic cell is moderate, the travelling rail 4 can be installed, and meanwhile, the infrared scanner comprises the wide-angle camera, so that the whole electrolytic cell can be comprehensively covered and scanned after straight-line walking, the walking path can be saved, the scanning efficiency is improved, the control is simple, and the user only needs to make a round trip along the rail to walk straight lines.
Preferably, the power supply mode of the intelligent robot 3 is a rail power supply mode. An electrical interface is arranged on the track, and the power supply principle is the same as the subway power supply mode. The tail end of the track can be provided with a power supply interface, the intelligent robot 3 is provided with a storage battery, and after the electric quantity of the storage battery is used up, the intelligent robot 3 is driven to the tail end of the track to be charged.
Preferably, step S02 specifically includes: thebackground 5 is preset with a temperature early warning value, the infrared image information is converted into corresponding temperature information, when the temperature information exceeds the temperature early warning value, thepolar plate 2 in the area is judged to be a short-circuit polar plate, and the temperature information and the position information of the short-circuit polar plate are recorded.
Preferably, the dilation corrosion includes two parts, namely dilation processing and corrosion processing, the dilation processing includes expanding a local highlight area in the infrared image information, the corrosion processing includes reducing the local highlight area in the infrared image information, and the dilation processing and the corrosion processing are performed at the same time. The erosion and swelling are for portions where the pixel value is large, i.e., highlight white portions instead of black portions; the expansion is that the high-brightness part in the image is expanded, the field is expanded, and the effect image has a high-brightness area larger than that of the original image; the corrosion is that the highlight part in the image is corroded, the field is reduced, and the effect image has a highlight area smaller than that of the original image; its effect is to eliminate boundary points, causing the image boundaries to shrink inward.
Preferably, the characteristic quantity of the electrolytic cell comprises a plurality of rectangular small areas formed by dividing the passing area of the electrolytic cell, and each rectangular small area corresponds to onepolar plate 2. The actual electrolytic tank is divided into a plurality of rectangular small areas, the scanned images are also divided into rectangular areas according to the proportion, and the positions of the images correspond to the positions of the actualpolar plates 2 one by one.
Preferably, the step S2 specifically includes: the time interval between two adjacent shots is preset, thebackground 5 receives infrared image information sent from different time intervals for storage, and the temperature change trend is analyzed and predicted according to the linear change rule of historical infrared image information so as to early warn the position of the short circuit polar plate in advance. Therefore, the faultpolar plate 2 can be quickly positioned through the information that thepolar plate 2 is short-circuited, and the short circuit is eliminated. And comparing and analyzing the historical infrared image information and the current infrared image information at the same position, so that thepole plate 2 to be short-circuited can be predicted, and the short-circuit time of thepole plate 2 can be predicted through an algorithm. Through predicting thepolar plate 2 to be short-circuited, the maintenance can be prevented before the short circuit, the intelligent temperature inspection and the intelligent short-circuit polar plate positioning of the nonferrous metal electrolytic cell are realized, the labor cost is greatly reduced, the production efficiency is improved, and the cost is reduced.
Preferably, step S3 specifically includes: the alarm information comprises temperature information and position information of all short-circuit pole plates in the electrolytic bath and prompts shutdown. The temperature information and the position information of all the short circuit substrates are uniformly displayed, all the overhaul is completed at one time, and the working efficiency is improved.
The invention has the beneficial effects that: the invention provides an infrared intelligent inspection method for an electrolytic cell, which is characterized by comprising the following steps: firstly, acquiring regional position coordinates and corresponding infrared image information of all polar plates in an electrolytic bath and transmitting the regional position coordinates and the corresponding infrared image information to a background; then the background adopts an image processing and identifying algorithm to obtain the temperature information and the position information of the short-circuit polar plate in the electrolytic bath; and finally, the background sends the temperature information and the position information of the short-circuit polar plate to the handheld terminal and prompts and alarms. The intelligent robot infrared inspection technology is adopted, the thermal imager is carried by the rail robot to inspect the electrolytic cell in real time, infrared images are shot, the acquired infrared images of the polar plates of the electrolytic cell are processed by an intelligent algorithm, software is used for automatically identifying over-temperature short-circuit polar plates, in addition, the temperature change of the same electrolytic cell can be compared by a longitudinal time axis, the polar plates to be short-circuited are predicted, and the position of the short-circuit polar plates is early warned in advance. Has great significance for improving the production efficiency of the nonferrous metal electrolysis industry.
The above examples are merely illustrative of the present invention and should not be construed as limiting the scope of the invention, which is intended to be covered by the claims and any design similar or equivalent to the scope of the invention.
Claims (10)
1. An infrared intelligent inspection method for an electrolytic cell is characterized by comprising the following steps:
s1: acquiring regional position coordinates of all polar plates in the electrolytic bath and corresponding infrared image information and transmitting the regional position coordinates and the corresponding infrared image information to a background;
s2: the background adopts an image processing and identifying algorithm to obtain the temperature information and the position information of the short-circuit polar plate in the electrolytic bath, and the image processing and identifying algorithm comprises the following steps: after preprocessing the infrared image information by gray level conversion, image correction, image cutting, image binarization, image filtering, expansion corrosion and feature point calibration, analyzing the characteristic quantity of an electrolytic cell, comparing the characteristic quantity of an image, dividing an image region, positioning the electrolytic cell, positioning a polar plate, analyzing the characteristic quantity of a overheated polar plate, positioning the overheated polar plate and converting the positioning information to obtain the temperature information and the position information of the short-circuit polar plate;
s3: and the background sends the temperature information and the position information of the short-circuit polar plate to the handheld terminal and prompts and alarms.
2. The infrared intelligent inspection method for the electrolytic cells according to claim 1, wherein the step S01 specifically comprises: the electrolysis bath is scanned globally by an infrared scanner at the lower end of the intelligent robot, and the area position coordinates and the infrared image information of each polar plate identified after scanning are sent to the handheld control terminal.
3. The infrared intelligent inspection method for the electrolytic cell according to claim 2, characterized in that: the intelligent robot is an automatic tracking trolley, and the automatic tracking travelling crane track is positioned above the electrolytic cell.
4. The infrared intelligent inspection method for the electrolytic cell according to claim 3, characterized in that: the infrared scanner comprises a wide-angle camera, the travelling rail is a single straight line, the transverse boundary of the electrolytic cell is located in the shooting range of the wide-angle camera, and the longitudinal boundary of the electrolytic cell is located under the single straight line.
5. The infrared intelligent inspection method for the electrolytic cell according to claim 3, characterized in that: the power supply mode of the intelligent robot is a rail power supply mode.
6. The infrared intelligent inspection method for the electrolytic cells according to claim 1, wherein the step S02 specifically comprises: and a temperature early warning value is preset in the background, the infrared image information is converted into corresponding temperature information, when the temperature information exceeds the temperature early warning value, the polar plate in the region is judged to be a short-circuit polar plate, and the temperature information and the position information of the short-circuit polar plate are recorded.
7. The infrared intelligent inspection method for the electrolytic cell according to claim 1, characterized in that: the expansion corrosion comprises two parts of expansion treatment and corrosion treatment, wherein the expansion treatment comprises expansion of a local highlight area in the infrared image information, the corrosion treatment comprises reduction of the local highlight area in the infrared image information, and the times of the expansion treatment and the corrosion treatment are the same.
8. The infrared intelligent inspection method for the electrolytic cell according to claim 1, characterized in that: the characteristic quantity of the electrolytic cell comprises a plurality of rectangular small areas formed by dividing the passing area of the electrolytic cell, and each rectangular small area corresponds to one polar plate one by one.
9. The infrared intelligent inspection method for the electrolytic cells according to claim 1, wherein the step S2 specifically comprises: the method comprises the steps of presetting time intervals between two adjacent shooting, receiving infrared image information sent from different time periods by a background for storage, and analyzing and predicting temperature change trend according to the linear change rule of historical infrared image information so as to early warn the position of a short-circuit polar plate in advance.
10. The infrared intelligent inspection method for the electrolytic cells according to claim 1, wherein the step S3 specifically comprises: the alarm information comprises temperature information and position information of all short-circuit pole plates in the electrolytic bath and prompts shutdown.
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| CN111893550A (en)* | 2020-08-10 | 2020-11-06 | 扬州市景杨表面工程有限公司 | Intelligent electroplating process chain for electronic components |
| CN112526391A (en)* | 2020-11-26 | 2021-03-19 | 湖南傲英创视信息科技有限公司 | Electrolytic cell fault detection system and method |
| CN113362275A (en)* | 2021-04-13 | 2021-09-07 | 武汉船用电力推进装置研究所（中国船舶重工集团公司第七一二研究所） | Electrolytic tank fault polar plate identification method |
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| CN117031258A (en)* | 2023-06-27 | 2023-11-10 | 三门三友科技股份有限公司 | Method for realizing fault detection system of electrolytic circuit based on temperature and monitoring method thereof |
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