CN117032135A - Quality monitoring system for ceramic fiber filter tube production - Google Patents
Quality monitoring system for ceramic fiber filter tube production Download PDFInfo
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- CN117032135A CN117032135A CN202311099513.8A CN202311099513A CN117032135A CN 117032135 A CN117032135 A CN 117032135A CN 202311099513 A CN202311099513 A CN 202311099513A CN 117032135 A CN117032135 A CN 117032135A
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/41875—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by quality surveillance of production
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/32—Operator till task planning
- G05B2219/32368—Quality control
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Abstract
The invention discloses a quality monitoring system for ceramic fiber filter tube production, and belongs to the technical field of ceramic fiber filter tube quality monitoring. The device comprises a structure acquisition module, a ruler analysis module, a fiber distribution module, a press monitoring module, an operation terminal and a database. The size and the rule value of the ceramic fiber filter tube are obtained by analyzing the corresponding size of the filter tube plan view of the ceramic fiber filter tube in the pressing process, so that the tube body and the arc bottom of the ceramic fiber filter tube in the pressing process are ensured to meet the design requirements, the size and the structure of the ceramic fiber filter tube are kept consistent within a certain range, the consistency of products is improved, the ceramic fiber filter tube is ensured to have better filtering efficiency and flow characteristics, the ceramic fiber distribution state of the ceramic fiber filter tube in the pressing process is judged, the performance of the ceramic fiber filter tube in the actual use process is further predicted, and the quality stability and the reliability of the ceramic fiber filter tube are ensured.
Description
Technical Field
The invention relates to the technical field of quality monitoring of ceramic fiber filter tubes, in particular to a quality monitoring system for ceramic fiber filter tube production.
Background
The ceramic fiber filter tube is a tubular filter made of ceramic fibers, is made of inorganic materials, has excellent high-temperature resistance, corrosion resistance and wear resistance, is generally woven by a plurality of ceramic fiber bundles or fiber belts, is processed by pressing, sintering and other processes, has higher filtering efficiency and flow processing capacity, and can effectively filter suspended matters, particles, microorganisms and other impurities.
The ceramic fiber filter tube is widely applied to various industrial fields, is used for application such as gas filtration, liquid filtration and dust removal, provides efficient filtration effect and reliable operation performance, relies on manual operation and visual inspection in the pressing process of the ceramic fiber filter tube, lacks real-time on-line monitoring and feedback system, leads to the fact that the quality problem of the ceramic fiber filter tube in the pressing process can not be found and treated in time, can not guarantee the quality and stability of the ceramic fiber filter tube in the pressing process, and increases the defective rate and production cost.
Disclosure of Invention
In order to solve the problem that the quality problem of a ceramic fiber filter tube cannot be found and processed in time due to the lack of a real-time on-line monitoring and feedback system in the pressing process of the ceramic fiber filter tube in the prior art, the embodiment of the invention provides a quality monitoring system for ceramic fiber filter tube production, which comprises the following technical scheme:
the aim of the invention can be achieved by the following technical scheme: a quality monitoring system for ceramic fiber filter tube production comprises a structure acquisition module, a ruler analysis module, a fiber distribution module, a press monitoring module, an operation terminal and a database;
the structure acquisition module is used for acquiring a filter tube plan view of the ceramic fiber filter tube in the pressing process, scanning the ceramic fiber filter tube in the pressing process through X rays to obtain a radiographic film of the ceramic fiber filter tube, putting the radiographic film into a darkroom for processing to obtain a radiographic film of a corresponding structure of the ceramic fiber filter tube, acquiring a reference gray value interval of a pressing die from a database, identifying the pressing die in the structural radiographic film according to the reference gray value interval of the pressing die, removing an image of the pressing die in the radiographic film of the corresponding structure of the ceramic fiber filter tube to obtain a plan structure diagram of the ceramic fiber filter tube, and recording the plan structure diagram as the filter tube plan view;
the ruler analysis module is used for analyzing the size of the filter tube plan to obtain ruler values of the ceramic fiber filter tubes in the pressing process, dividing the filter tube plan into an arc bottom plan and a tube plan according to the arc bottom in the filter tube plan, measuring the length of the tube body of the filter tube in the tube plan, then arranging a plurality of detection points with the same number on the inner wall and the outer wall of the tube plan of the filter tube, measuring the distance between the detection points of the inner wall and the distance between the detection points of the outer wall, analyzing according to the distance between the detection points of the inner wall and the distance between the detection points of the outer wall to obtain the pipe diameter uniformity of the ceramic fiber filter tubes in the pressing process, measuring the distance between the detection points of the inner wall and the detection points of the outer wall and analyzing to obtain the pipe wall uniformity of the ceramic fiber filter tubes in the pressing process, measuring the lengths of the inner arc and the outer arc in the arc bottom plan, establishing a two-dimensional coordinate axis based on the intersection point of the central line of the ceramic fiber filter tubes and the corresponding outer arc of the arc bottom plan in the pressing process as an origin, and analyzing to obtain the specification of the corresponding arc bottom of the ceramic fiber filter tubes in the pressing process, and obtaining the ceramic filter tubes in the pressing process by analyzing the uniformity and specification;
the fiber distribution module is used for analyzing the pipe wall in the filter pipe plan to obtain the fiber uniformity value of the ceramic fiber filter pipe in the pressing process, amplifying the filter pipe wall in the filter pipe plan by a plurality of times to obtain a pipe wall image, dividing the pipe wall image according to a set dividing area to obtain pipe wall partitions, arranging a plurality of chromaticity detection points on the pipe wall partitions, obtaining the chromaticity of the detection points, summarizing to obtain a chromaticity list, obtaining the chromaticity mode of the pipe wall partitions from the chromaticity list, and judging the ceramic fiber distribution state of the ceramic fiber filter pipe in the pressing process as a uniform state or a non-uniform state based on the chromaticity mode.
The pressing monitoring module is used for receiving signals sent by the ruler analysis module and the fiber distribution module, identifying the signals, marking the ceramic fiber filter tube in the pressing process according to the identification result, counting the signals sent by the ruler analysis module and the fiber distribution module, generating prompt information according to the statistics result and sending the prompt information to the operation terminal;
the operation terminal is used for receiving the prompt message sent by the press working detection module and displaying the prompt message correspondingly;
the database is used for storing the size information of the standard ceramic fiber filter tube and each reference interval, wherein the size information of the standard ceramic fiber filter tube comprises a reference inner diameter, a reference outer diameter, a reference inner arc length, an outer arc length, an inner arc radian and an outer arc radian, and each reference interval comprises a reference gray value interval, a ceramic fiber chromaticity value interval and a tube wall chromaticity value interval.
Preferably, the dimensions of the filter tube plan are analyzed to obtain the ruler values of the ceramic fiber filter tube during the pressing process, and the analysis process is as follows:
obtaining a filter tube plan view, dividing the filter tube plan view according to the arc bottom in the filter tube plan view to obtain an arc bottom plan view and a tube plan view, obtaining the central line of a ceramic fiber filter tube in the pressing process, arranging a plurality of detection points with equal quantity on the inner wall and the outer wall of the filter tube plan view based on the central line according to a preset mode, numbering the inner wall detection points of the filter tube plan view as I, i=1, 2, & gt, N, numbering the outer wall detection points of the filter tube body as I, i=1, 2, & gt, wherein the value ranges of N, N and N are positive integers which are larger than 1, obtaining the inner wall symmetry detection points and the outer wall symmetry detection points of the filter tube plan view based on the inner wall detection points and the outer wall detection points of the filter tube plan view, measuring the distance between the inner wall symmetry detection points and recording as H i～i+1 The distance between the symmetrical detection points of the outer wall is measured and is recorded as H I～I+1 I1 and I2 are symmetrical detection points IN the inner wall detection points, IN and in+1 are symmetrical detection points IN the inner wall detection points, I1 and I2 are symmetrical detection points IN the inner wall detection points, IN and in+1 are symmetrical detection points IN the outer wall detection points, the reference inner diameter and the reference outer diameter of the ceramic fiber filter tube are obtained from a database, the tube diameter uniformity GJ of the ceramic fiber filter tube IN the pressing process is obtained through analysis, and the larger the tube diameter uniformity is, the more uniform the tube body of the ceramic fiber filter tube IN the pressing process is;
for the pipe body diagram of the filter pipeMeasuring the distance between the inner wall detection point and the outer wall detection point to obtain the thickness of the pipe body and recording the thickness as GH j J=1, 2,.. 1 Measuring the distance between the inner wall detection point IN and the outer wall detection point IN to obtain the thickness GH of the tube body k Summarizing the tube thicknesses to obtain a tube thickness list, screening the first tube thickness and the second tube thickness from the tube thickness list, and respectively marking the first tube thickness and the second tube thickness as GH max And GH min The pipe wall uniformity GB of the ceramic fiber filter pipe in the pressing process is obtained through analysis, and the larger the pipe wall uniformity is, the more uniform the pipe wall thickness of the ceramic fiber filter pipe in the pressing process is;
the inner arc length and the outer arc length in the arc bottom plan view are measured and respectively recorded as HC Inner part And HC Outer part Establishing a two-dimensional coordinate system by taking the intersection point of the central line of the ceramic fiber filter tube and the outer arc corresponding to the arc bottom plane graph in the pressing process as an origin, acquiring the endpoint coordinates of the inner arc corresponding to the arc bottom plane graph, obtaining the center coordinates of the inner arc according to the endpoint coordinates of the inner arc, calculating the radius of the inner arc through the center coordinates of the inner arc, obtaining the radian of the inner arc in the arc bottom plane graph based on the radius of the inner arc and the length of the inner arc, and recording the radian as rad Inner part ；
Obtaining endpoint coordinates of an outer arc corresponding to the arc bottom plan, obtaining center coordinates of the outer arc according to the endpoint coordinates of the outer arc, calculating the radius of the outer arc through the center coordinates of the outer arc, obtaining the radian of the outer arc in the arc bottom plan based on the radius of the outer arc and the length of the outer arc, and recording the radian as rad Outer part ；
Obtaining the reference inner arc length hc of the ceramic fiber filter tube from the database Inner part Length of outer arc hc Outer part RAD of inner arc Inner part And outer arc radian RAD Outer part Obtaining the standardization GF of the corresponding arc bottom of the ceramic fiber filter tube in the pressing process through standardization calculation, comparing the ruler value with a preset ruler value threshold, judging that the size state corresponding to the ceramic fiber filter tube in the pressing process is standard, generating a ruler signal, and if the ruler value is larger than the preset ruler value thresholdAnd if the gauge value is smaller than a preset ruler value threshold, judging that the size state corresponding to the ceramic fiber filter tube in the pressing process is a flaw state, generating a incomplete signal, and sending the ruler signal or the incomplete signal to a pressing monitoring module.
Preferably, the walls of the filter tube in plan view are analyzed as follows:
amplifying the pipe wall part in the filter pipe plan view by a plurality of times to obtain a pipe wall image, dividing the pipe wall image into a first pipe wall partition, a second pipe wall partition, a third pipe wall partition and a t pipe wall partition according to a preset dividing area, wherein the value range of t is a positive integer, uniformly detecting points are distributed in the pipe wall partition, the chromaticity value of the detecting points in the pipe wall partition is obtained, and the chromaticity value interval of ceramic fibers and the chromaticity value interval of the pipe wall are obtained from a database;
summarizing the chromaticity values of the detection points to obtain a chromaticity value list, taking the chromaticity value with the largest occurrence number as the chromaticity value mode of the pipe wall partition from the chromaticity value list, comparing the chromaticity value mode of the pipe wall partition with the chromaticity value interval of the ceramic fiber, analyzing the fiber uniformity value of the pipe wall partition if the chromaticity value mode of the pipe wall partition belongs to the chromaticity value interval of the ceramic fiber, and judging the distribution state of the ceramic fiber corresponding to the pipe wall partition as a non-uniform state if the chromaticity value mode of the pipe wall partition does not belong to the chromaticity value interval of the ceramic fiber, and generating a defective signal;
preferably, the fiber level of the pipe wall section is analyzed as follows:
comparing the chromaticity value of the detection point with the chromaticity value interval of the ceramic fiber and the chromaticity value interval of the pipe wall respectively, marking the detection point as a target point if the chromaticity value of the detection point belongs to the chromaticity value interval of the ceramic fiber, marking the detection point as a gap point if the chromaticity value of the detection point belongs to the chromaticity value interval of the pipe wall, thereby obtaining a target point and a gap point of the pipe wall partition, counting the number MBr of the target points and the number KXr of the gap points of the pipe wall partition, wherein r is the number of the pipe wall partition, and r=1, 2.
Calculating an average chromaticity value AVEr of the pipe wall partition by a mean value calculation formula, connecting adjacent void points to obtain a void area, not processing the non-adjacent void points, counting the void area of the pipe wall partition to be Sr, obtaining a fiber uniformity value XYr of the pipe wall partition by analysis, comparing the fiber uniformity value of the pipe wall partition with a preset fiber uniformity value threshold, judging that the distribution state of the pipe wall partition corresponding to ceramic fibers is a non-fiber uniformity state when the fiber uniformity value of the pipe wall partition is smaller than the preset fiber uniformity value threshold, marking the pipe wall partition as a non-fiber uniformity partition, judging that the distribution state of the pipe wall partition corresponding to ceramic fibers is a fiber uniformity state when the fiber uniformity value of the pipe wall partition is larger than the preset fiber uniformity value threshold, and marking the pipe wall partition as a fiber uniformity partition;
counting the number of non-uniform fiber partitions, dividing the number of the non-uniform fiber partitions by the number of the pipe wall partitions to obtain a non-uniform ratio, comparing the non-uniform ratio with a preset non-uniform ratio threshold, judging the ceramic fiber distribution state of the ceramic fiber filter pipe in the pressing process to be uniform when the non-uniform ratio is smaller than the preset non-uniform ratio threshold, generating a standard signal, judging the ceramic fiber distribution state of the ceramic fiber filter pipe in the pressing process to be non-uniform when the non-uniform ratio is larger than the preset non-uniform ratio threshold, generating a defective signal, and transmitting the standard signal or the defective signal to a press monitoring module;
preferably, the ceramic fiber filter tube in the pressing process is marked according to the identification result, and the marking process is as follows:
the method comprises the steps of receiving signals sent by a ruler analysis module and a fiber distribution module and identifying, when the ruler signal and the standard signal are simultaneously identified, marking a ceramic fiber filter tube in the pressing process as a qualified filter tube, when any one of a incomplete signal and an inferior signal is identified, marking the ceramic fiber filter tube in the pressing process as an inferior filter tube, and when the incomplete signal and the inferior signal are simultaneously identified, marking the ceramic fiber filter tube in the pressing process as an obsolete filter tube;
uniformly marking defective signals or defective signals as defect signals, generating defect information of defect of the filter tube size when the ceramic fiber filter tube is defective in the pressing process and the corresponding defect signals are defective signals, sending the defect information of the defective filter tube and the defect of the filter tube size as prompt information to an operation terminal, and generating defect information of non-uniform ceramic fiber distribution of the filter tube when the ceramic fiber filter tube is defective in the pressing process and the corresponding defect signals are defective signals, and sending the defect information of the defective filter tube and the ceramic fiber non-uniform distribution of the filter tube as prompt information to the operation terminal;
counting the occurrence times of incomplete signals and inferior signals respectively, generating prompt information of checking whether the pressing parameter setting is correct or not if the occurrence times of the incomplete signals are larger than the set occurrence times, generating prompt information of checking whether the ceramic fiber mixing and feeding are in accordance with the requirements if the occurrence times of the inferior signals are larger than the set occurrence times, and transmitting the prompt information to an operation terminal.
The invention has the beneficial effects that:
1. the size and the rule value of the ceramic fiber filter tube are obtained by analyzing the corresponding size of the filter tube plan of the ceramic fiber filter tube in the pressing process, so that the tube body and the arc bottom of the ceramic fiber filter tube in the pressing process meet the design requirements, the size and the structure of the ceramic fiber filter tube are kept consistent within a certain range, the consistency of products is improved, and the ceramic fiber filter tube is further ensured to have better filtering efficiency and flow characteristics;
2. the ceramic fiber distribution state of the ceramic fiber filter tube in the pressing process is judged by the filter tube, so that the uniformity and the density distribution situation of the ceramic fiber filter tube corresponding to the ceramic fiber in the pressing process are known, the performance of the ceramic fiber filter tube in the actual use process is further predicted, and the quality stability and the reliability of the ceramic fiber filter tube are ensured;
3. according to the prompt information generated by the convincing signal, the quality of the ceramic fiber filter tube is rapidly judged according to the marking result of the ceramic fiber filter tube, the problems existing in the pressing process and the pretreatment process before pressing are timely found according to the prompt information, the process parameters of the pressing process and the process parameters before pressing are adjusted, the quality of the ceramic fiber filter tube is improved, further, the obsolete filter tube is not subjected to the subsequent process, the obsolete filter tube is prevented from occupying production resources, and the production cost of the ceramic fiber filter tube is saved.
Drawings
The invention is further described below with reference to the accompanying drawings.
Fig. 1 is a system block diagram of the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Referring to fig. 1, the present invention is a quality monitoring system for ceramic fiber filter tube production, comprising: the device comprises a structure acquisition module, a ruler and gauge analysis module, a fiber distribution module, a press working monitoring module, an operation terminal and a database.
The structure acquisition module acquires a filter tube plan view of the ceramic fiber filter tube in the pressing process, scans the ceramic fiber filter tube in the pressing process through X rays to obtain a radiographic film of the ceramic fiber filter tube, places the radiographic film into a darkroom for processing to obtain a radiographic film of a corresponding structure of the ceramic fiber filter tube, acquires a reference gray value interval of a pressing die from a database, identifies the pressing die in the structural radiographic film according to the reference gray value interval of the pressing die, eliminates an image of the pressing die in the radiographic film of the corresponding structure of the ceramic fiber filter tube to obtain a plan structure diagram of the ceramic fiber filter tube, and records the plan structure diagram as the filter tube plan view.
The ruler-gauge analysis module analyzes the size of the filter tube plan to obtain ruler-gauge values of the ceramic fiber filter tube in the pressing process, and the analysis process is as follows:
in the present invention, the ceramic fiber filter tube is a cylindrical filter tube.
Obtaining a filter tube plan, dividing the filter tube plan according to the arc bottom in the filter tube plan to obtain an arc bottom plan and a tube plan, and obtaining the central line of the ceramic fiber filter tube in the pressing process, and the baseArranging a plurality of detection points with the same quantity on the inner wall and the outer wall of the pipe body plan of the filter pipe in a preset mode on the central line, numbering the inner wall detection points of the pipe body plan of the filter pipe as I, i=1, 2, & N, numbering the outer wall detection points of the pipe body of the filter pipe as I, i=1, 2, & N, N and N are positive integers with the value ranges of more than 1, obtaining inner wall symmetrical detection points and outer wall symmetrical detection points of the pipe body plan of the filter pipe based on the inner wall detection points and the outer wall detection points of the pipe body plan of the filter pipe, measuring the distance between the inner wall symmetrical detection points and recording the distance as H i～i+1 The distance between the symmetrical detection points of the outer wall is measured and is recorded as H I～I+1 I1 and I2 are symmetrical detection points IN the inner wall detection points, IN and in+1 are symmetrical detection points IN the inner wall detection points, and similarly, I1 and I2 are symmetrical detection points IN the inner wall detection points, IN and in+1 are symmetrical detection points IN the outer wall detection points, and the reference inner diameter and the reference outer diameter of the ceramic fiber filter tube are obtained from a database and are represented by the formula:
calculating to obtain the pipe diameter uniformity GJ of the ceramic fiber filter pipe in the pressing process, wherein R1 is a reference inner diameter, R2 is a reference outer diameter, deltaD 1 is an inner diameter allowance, deltaD 2 is an outer diameter allowance, a1 is a preset inner diameter weight factor, a2 is a preset outer diameter weight factor, and the larger the pipe diameter uniformity is, the more uniform the pipe body of the ceramic fiber filter pipe in the pressing process is.
It should be noted that, a plurality of detection points with the same number are arranged on the inner wall and the outer wall of the pipe body plan of the filter pipe according to a preset mode based on the central line, wherein the preset mode is as follows: the central line is taken as the central axis of the filter tube body plan, and a plurality of detection points with the same number are distributed on the inner wall and the outer wall of the filter tube body plan in an axisymmetric mode.
Measuring the distance between the inner wall detection point and the outer wall detection point of the pipe body diagram of the filter pipe to obtain the thickness of the pipe body and recording the thickness as GH j J=1, 2,..Obtaining the thickness GH of the pipe body 1 Measuring the distance between the inner wall detection point IN and the outer wall detection point IN to obtain the thickness GH of the tube body k Summarizing the tube thicknesses to obtain a tube thickness list, screening the first tube thickness and the second tube thickness from the tube thickness list, and respectively marking the first tube thickness and the second tube thickness as GH max And GH min By the formula:
calculating to obtain the pipe wall uniformity GB, ρ of the ceramic fiber filter pipe in the pressing process as a constant, wherein the ρ is 0.00142, a3 is a preset first weight factor of pipe wall uniformity, a4 is a preset second weight factor of pipe wall uniformity, deltaD 3 is a preset pipe wall allowance, and the larger the pipe wall uniformity is, the more uniform the pipe wall thickness of the ceramic fiber filter pipe in the pressing process is.
The first tube thickness is the maximum value in the tube thickness list, and the second tube thickness is the minimum value in the tube thickness list. The larger the uniformity of the tube wall, the more uniform the tube wall thickness of the ceramic fiber filter tube in the pressing process.
The invention ensures that the size and the structure of the ceramic fiber filter tube are consistent within a certain range by judging whether the inner diameter, the outer diameter and the tube wall thickness of the ceramic fiber filter tube meet the requirements in the pressing process, improves the consistency of products, and further ensures that the ceramic fiber filter tube has better filtering efficiency and flow characteristics.
The inner arc length and the outer arc length in the arc bottom plan view are measured and respectively recorded as HC Inner part And HC Outer part Establishing a two-dimensional coordinate system by taking the intersection point of the central line of the ceramic fiber filter tube and the outer arc corresponding to the arc bottom plane graph in the pressing process as an origin, acquiring the endpoint coordinates of the inner arc corresponding to the arc bottom plane graph, obtaining the center coordinates of the inner arc according to the endpoint coordinates of the inner arc, calculating the radius of the inner arc through the center coordinates of the inner arc, obtaining the radian of the inner arc in the arc bottom plane graph based on the radius of the inner arc and the length of the inner arc, and recording the radian as rad Inner part 。
Obtaining the corresponding outer of the arc bottom planThe end point coordinates of the outer arc, the center coordinates of the outer arc are obtained according to the end point coordinates of the outer arc, the radius of the outer arc is calculated through the center coordinates of the outer arc, the radian of the outer arc in the arc bottom plan is obtained based on the radius of the outer arc and the length of the outer arc, and the radian is recorded as rad Outer part 。
Obtaining the reference inner arc length hc of the ceramic fiber filter tube from the database Inner part Length of outer arc hc Outer part RAD of inner arc Inner part And outer arc radian RAD Outer part By the canonical degree calculation formula:
GF＝(1/|HC inner part -hc Inner part |+1)×a5+(1/|HC Outer part -hc Outer part |+1)×a6+(1/|rad Inner part -RAD Inner part
|+1)×a7+(1/|rad Outer part -RAD Outer part |+1)×a8
Calculating to obtain the rule value of the ceramic fiber filter tube in the pressing process, wherein the rule value is calculated by a formula CG=GJ×b1+GB×b2+GF×b3, b1 is a preset tube diameter uniformity conversion factor, b2 is a preset tube wall uniformity conversion factor, b3 is a preset rule conversion factor, comparing the rule value with a preset rule value threshold, judging that the size state corresponding to the ceramic fiber filter tube in the pressing process is a standard state if the rule value is larger than the preset rule value threshold, generating a rule signal, judging that the size state corresponding to the ceramic fiber filter tube in the pressing process is a defect state if the rule value is smaller than the preset rule value threshold, and transmitting the rule signal or the defect signal to a pressure engineering monitoring module.
According to the invention, the arc bottom of the ceramic fiber filter tube in the pressing process is analyzed, so that the inner and outer radians of the arc bottom meet the requirements, the phenomenon that fluid is biased or dead angle in the filter tube due to the fact that the inner and outer radians are not standard is avoided, the filtering efficiency of the ceramic fiber filter tube is improved, and the service life of the ceramic fiber filter tube is prolonged.
The fiber distribution module analyzes the pipe wall in the filter pipe plan to obtain the fiber uniformity value of the ceramic fiber filter pipe in the pressing process, and the analysis process is as follows:
amplifying the pipe wall part in the filter pipe plan view by a plurality of times to obtain a pipe wall image, dividing the pipe wall image into a first pipe wall partition, a second pipe wall partition, a first pipe wall partition, a third pipe wall partition and a t pipe wall partition according to a preset dividing area, wherein the value range of t is a positive integer, uniformly detecting points are distributed in the pipe wall partition, the chromaticity values of the detecting points in the pipe wall partition are obtained, and the chromaticity value interval of the ceramic fiber and the chromaticity value interval of the pipe wall are obtained from a database.
Summarizing the chromaticity values of the detection points to obtain a chromaticity value list, counting the chromaticity value with the largest occurrence number from the chromaticity value list as the chromaticity value mode of the pipe wall partition, comparing the chromaticity value mode of the pipe wall partition with the chromaticity value interval of the ceramic fiber, judging the distribution state of the ceramic fiber corresponding to the pipe wall partition as a non-uniform state if the chromaticity value mode of the pipe wall partition does not belong to the chromaticity value interval of the ceramic fiber, generating a defective signal, comparing the chromaticity value of the detection point with the chromaticity value interval of the ceramic fiber and the chromaticity value interval of the pipe wall if the chromaticity value mode of the pipe wall partition belongs to the chromaticity value interval of the ceramic fiber, marking the detection point as a target point if the chromaticity value of the detection point belongs to the chromaticity value interval of the pipe wall, marking the detection point as a gap point if the chromaticity value of the detection point belongs to the chromaticity value interval of the pipe wall, thereby obtaining the target point and the gap point of the pipe wall partition, counting the number MBr of the target point of the pipe wall partition and the gap point number KXr, r being the number of the pipe wall partition, r=1, 2.
Calculating the average chromaticity value AVEr of the pipe wall partition by using a mean value calculation formula, connecting adjacent void points to obtain a void area, and counting the void area of the pipe wall partition as Sr by using the formula:
XYr＝(MBr/MBr+KXr)×c1+(1/AVEr-ave+0.00113)×c2+(Sr/SS)×c3
calculating to obtain the fiber uniformity value of the pipe wall partition, ave is a preset average chromaticity value, SS is a preset partition area, c1 is a preset target point number weight factor, c2 is a preset average chromaticity value weight factor, c3 is a preset gap area weight factor, comparing the fiber uniformity value of the pipe wall partition with a preset fiber uniformity value threshold, when the fiber uniformity value of the pipe wall partition is smaller than the preset fiber uniformity value threshold, indicating the non-uniformity of the ceramic fiber distribution in the pipe wall partition, judging the distribution state of the pipe wall partition corresponding to the ceramic fiber as the non-fiber uniformity state, marking the pipe wall partition as the non-fiber uniformity partition, when the fiber uniformity value of the pipe wall partition is larger than the preset fiber uniformity value threshold, indicating the distribution uniformity of the ceramic fiber in the pipe wall partition, judging the distribution state of the pipe wall partition corresponding to the ceramic fiber uniformity state, and marking the pipe wall partition as the fiber uniformity partition.
Counting the number of non-uniform fiber partitions, dividing the number of the non-uniform fiber partitions by the number of the pipe wall partitions to obtain a non-uniform ratio, comparing the non-uniform ratio with a preset non-uniform ratio threshold, when the non-uniform ratio is smaller than the preset non-uniform ratio threshold, indicating that the number of the uniform fiber partitions in the pipe wall partitions is large, judging that the ceramic fiber distribution state of the ceramic fiber filter pipe in the pressing process is uniform, generating a standard signal, when the non-uniform ratio is larger than the preset non-uniform ratio threshold, indicating that the number of the non-uniform fiber partitions in the pipe wall partitions is large, judging that the ceramic fiber distribution state of the ceramic fiber filter pipe in the pressing process is non-uniform, generating a defective signal, and transmitting the standard signal or the defective signal to a pressing monitoring module.
According to the invention, the distribution state of the ceramic fibers corresponding to the ceramic fiber filter tube in the pressing process is analyzed, so that the uniformity and the density distribution condition of the ceramic fibers corresponding to the ceramic fiber filter tube in the pressing process are known, the performance of the ceramic fiber filter tube in the actual use process is further predicted, and the quality stability and the reliability of the ceramic fiber filter tube are ensured.
The press monitoring module receives signals sent by the ruler analysis module and the fiber distribution module and identifies the signals, and the identification process is as follows:
and receiving signals sent by the ruler analysis module and the fiber distribution module and identifying, when the ruler signal and the standard signal are simultaneously identified, indicating that the size requirement and the ceramic fiber distribution requirement of the ceramic fiber filter tubes in the pressing process are all up to the standard, marking the ceramic fiber filter tubes in the pressing process as qualified filter tubes, marking the ceramic fiber filter tubes in the pressing process as defective filter tubes when any one of defective signals and defective signals is identified, and marking the ceramic fiber filter tubes in the pressing process as obsolete filter tubes when the defective signals and the defective signals are simultaneously identified.
Uniformly marking defective signals or defective signals as defect signals, generating defect information of defect of the filter tube size when the ceramic fiber filter tube is defective in the pressing process and the corresponding defect signals are defective signals, sending the defect information of the defective filter tube and the defect of the filter tube size as prompt information to an operation terminal, and generating defect information of non-uniform ceramic fiber distribution of the filter tube when the ceramic fiber filter tube is defective in the pressing process and the corresponding defect signals are defective signals, and sending the defect information of the defective filter tube and the ceramic fiber non-uniform distribution of the filter tube as prompt information to the operation terminal.
Counting the occurrence times of incomplete signals and inferior signals respectively, generating prompt information of checking whether the pressing parameter setting is correct or not if the occurrence times of the incomplete signals are larger than the set occurrence times, generating prompt information of checking whether the ceramic fiber mixing and feeding are in accordance with the requirements if the occurrence times of the inferior signals are larger than the set occurrence times, and transmitting the prompt information to an operation terminal.
According to the invention, the prompt information is generated according to the defect signals, so that operators can know the problems of the ceramic fiber filter tube in the pressing process in real time, judge the quality of the ceramic fiber filter tube according to the marking result of the ceramic fiber filter tube, timely find the problems in the pressing process and the pretreatment process before pressing aiming at the prompt information, adjust the process parameters in the pressing process and the pretreatment process before pressing, improve the quality of the ceramic fiber filter tube, and further, avoid the occupation of production resources by the obsolete filter tube for the obsolete filter tube, and save the production cost of the ceramic fiber filter tube.
The operation terminal receives the prompt message sent by the press working detection module and displays the prompt message correspondingly.
The database stores size information of the standard ceramic fiber filter tube and each reference interval, wherein the size information of the standard ceramic fiber filter tube comprises a reference inner diameter, a reference outer diameter, a reference inner arc length, an outer arc length, an inner arc radian and an outer arc radian, and each reference interval comprises a reference gray value interval, a ceramic fiber chromaticity value interval and a tube wall chromaticity value interval.
The foregoing is merely illustrative and explanatory of the invention, as it is apparent to those skilled in the art that various modifications and additions can be made to the specific embodiments described or in a similar manner without departing from the structure of the invention or beyond the scope of the invention as defined in the appended claims.
Claims (7)
1. The quality monitoring system for ceramic fiber filter tube production comprises an operation terminal and a database, and is characterized by further comprising a structure acquisition module, a ruler analysis module, a fiber distribution module and a press monitoring module;
the structure acquisition module is used for acquiring a filter tube plan view of the ceramic fiber filter tube in the pressing process, scanning the ceramic fiber filter tube in the pressing process through X rays to obtain a radiographic film of the ceramic fiber filter tube, processing the radiographic film of the ceramic fiber filter tube to obtain a radiographic film of a corresponding structure of the ceramic fiber filter tube, acquiring a reference gray value interval of a pressing die from a database, identifying the pressing die based on the reference gray value interval, removing an image of the pressing die in the radiographic film of the corresponding structure of the ceramic fiber filter tube to obtain a plan structure view of the ceramic fiber filter tube, and recording the plan structure view as the filter tube plan view;
the ruler analysis module is used for analyzing the size of the filter tube plan to obtain the ruler value of the ceramic fiber filter tube in the pressing process, dividing the filter tube plan into an arc bottom plan and a tube body plan according to the arc bottom in the filter tube plan, arranging a plurality of detection points with the same number on the inner wall and the outer wall of the filter tube body plan, measuring the distance between the inner wall detection points and the distance between the outer wall detection points, analyzing according to the distance between the inner wall detection points and the distance between the outer wall detection points to obtain the tube diameter uniformity of the ceramic fiber filter tube in the pressing process, measuring the distance between the inner wall detection points and the outer wall detection points and analyzing to obtain the tube wall uniformity of the ceramic fiber filter tube in the pressing process, and further analyzing to obtain the ruler value of the ceramic fiber filter tube in the pressing process;
the fiber distribution module is used for analyzing the pipe wall in the filter pipe plan to obtain the fiber uniformity value of the ceramic fiber filter pipe in the pressing process, amplifying the filter pipe wall in the filter pipe plan by a plurality of times to obtain a pipe wall image, dividing the pipe wall image according to a set dividing area to obtain pipe wall partitions, arranging a plurality of chromaticity detection points on the pipe wall partitions, further analyzing the pipe wall partition based on the chromaticity detection points to obtain the fiber uniformity value of the pipe wall partitions, and judging the distribution state of ceramic fibers corresponding to the pipe wall partitions as a uniform state or a non-uniform state according to the fiber uniformity value of the pipe wall partitions;
the pressing monitoring module is used for receiving signals sent by the ruler analysis module and the fiber distribution module, identifying the signals, marking the ceramic fiber filter tube in the pressing process according to the identification result, counting the signals sent by the ruler analysis module and the fiber distribution module, generating prompt information according to the statistics result and sending the prompt information to the operation terminal;
the operation terminal is used for receiving the prompt message sent by the press working detection module and displaying the prompt message correspondingly;
the database is used for storing the size information of the standard ceramic fiber filter tube and each reference interval.
2. The quality monitoring system for ceramic fiber filter tube production according to claim 1, wherein the size of the filter tube plan is analyzed to obtain the ruler value of the ceramic fiber filter tube in the pressing process, and the analysis process is as follows:
obtaining a filter tube plan, dividing the filter tube plan according to the arc bottom in the filter tube plan to obtain an arc bottom plan and a tube plan, obtaining the central line of the ceramic fiber filter tube in the pressing process, arranging a plurality of detection points with the same number on the inner wall and the outer wall of the filter tube plan according to a preset mode based on the central line, obtaining inner wall symmetrical detection points and outer wall symmetrical detection points of the filter tube plan based on the inner wall detection points and the outer wall detection points of the filter tube plan, measuring the distance between the inner wall symmetrical detection points, measuring the distance between the outer wall symmetrical detection points, and obtaining the pipe diameter uniformity of the ceramic fiber filter tube in the pressing process through analysis;
measuring the distance between an inner wall detection point and an outer wall detection point of a filter tube body diagram to obtain tube body thickness, summarizing the tube body thickness to obtain a tube body thickness list, screening the first tube body thickness and the second tube body thickness from the tube body thickness list, and analyzing to obtain the tube wall uniformity of the ceramic fiber filter tube in the pressing process;
and analyzing the arc bottom plan to obtain the standardization of the ceramic fiber filter tube corresponding to the arc bottom in the pressing process.
3. The quality monitoring system for ceramic fiber filter tube production according to claim 2, wherein the analysis of the arc bottom plan is as follows:
measuring the length of an inner arc and the length of an outer arc in an arc bottom plan, establishing a two-dimensional coordinate system by taking the intersection point of the central line of the ceramic fiber filter tube and the corresponding outer arc of the arc bottom plan in the pressing process as an origin, acquiring the endpoint coordinates of the inner arc corresponding to the arc bottom plan, obtaining the center coordinates of the inner arc according to the endpoint coordinates of the inner arc, calculating the radius of the inner arc through the center coordinates of the inner arc, and obtaining the radian of the inner arc in the arc bottom plan based on the radius of the inner arc and the length of the inner arc;
obtaining endpoint coordinates of an outer arc corresponding to the arc bottom plan, obtaining center coordinates of the outer arc according to the endpoint coordinates of the outer arc, calculating the radius of the outer arc through the center coordinates of the outer arc, and obtaining the radian of the outer arc in the arc bottom plan based on the radius of the outer arc and the length of the outer arc;
the method comprises the steps of obtaining reference inner arc length, outer arc length, inner arc radian and outer arc radian of a ceramic fiber filter tube from a database, obtaining the standardization of the ceramic fiber filter tube corresponding to an arc bottom in the pressing process through standardization calculation, obtaining the ruler value of the ceramic fiber filter tube in the pressing process based on tube diameter uniformity, tube wall uniformity and standardization calculation, comparing the ruler value with a preset ruler value threshold, judging the size state of the ceramic fiber filter tube in the pressing process as a standard state or a flaw state according to a comparison result, and generating a corresponding signal according to the standard state or the flaw state and sending the corresponding signal to a pressing monitoring module.
4. The quality monitoring system for ceramic fiber filter tube production according to claim 1, wherein the analysis of the tube wall in the filter tube plan view is as follows:
amplifying the pipe wall part in the filter pipe plan view by a plurality of times to obtain a pipe wall image, dividing the pipe wall image into a first pipe wall partition, a second pipe wall partition, a third pipe wall partition and a t pipe wall partition according to a preset dividing area, distributing uniform detection points in the pipe wall partition, acquiring chromaticity values of the detection points in the pipe wall partition, and acquiring a chromaticity value interval of ceramic fibers and a chromaticity value interval of the pipe wall from a database;
collecting the chromaticity values of the detection points to obtain a chromaticity value list, counting the chromaticity value with the largest occurrence number from the chromaticity value list as the chromaticity value mode of the pipe wall partition, comparing the chromaticity value mode of the pipe wall partition with the chromaticity value interval of the ceramic fiber, analyzing the fiber uniformity value of the pipe wall partition if the chromaticity value mode of the pipe wall partition belongs to the chromaticity value interval of the ceramic fiber, otherwise judging the distribution state of the ceramic fiber corresponding to the pipe wall partition as a non-uniform state, and generating a defective signal.
5. The quality monitoring system for ceramic fiber filter tube production according to claim 4, wherein the analysis of the fiber uniformity value of the pipe wall partition is as follows:
comparing the chromaticity value of the detection point with the chromaticity value interval of the ceramic fiber and the chromaticity value interval of the pipe wall respectively, marking the detection point as a target point if the chromaticity value of the detection point belongs to the chromaticity value interval of the ceramic fiber, marking the detection point as a gap point if the chromaticity value of the detection point belongs to the chromaticity value interval of the pipe wall, thereby obtaining a target point and a gap point of the pipe wall partition, and counting the number of the target points and the number of the gap points of the pipe wall partition;
calculating to obtain an average chromaticity value of the pipe wall partition by a mean value calculation formula, connecting adjacent void points to obtain a void area, counting the void area of the pipe wall partition, analyzing to obtain a fiber uniformity value of the pipe wall partition, comparing the fiber uniformity value of the pipe wall partition with a preset fiber uniformity value threshold, judging that the distribution state of the ceramic fibers corresponding to the pipe wall partition is a non-fiber uniformity state when the fiber uniformity value of the pipe wall partition is smaller than the preset fiber uniformity value threshold, marking the pipe wall partition as the non-fiber uniformity partition, otherwise, judging that the distribution state of the ceramic fibers corresponding to the pipe wall partition is a fiber uniformity state, and marking the pipe wall partition as the fiber uniformity partition;
counting the number of non-uniform fiber partitions, dividing the number of the non-uniform fiber partitions by the number of the pipe wall partitions to obtain a non-uniform ratio, comparing the non-uniform ratio with a preset non-uniform ratio threshold, judging the ceramic fiber distribution state of the ceramic fiber filter pipe in the pressing process as a uniform state or a non-uniform state according to a comparison result, and generating a corresponding signal from the uniform state or the non-uniform state and sending the corresponding signal to a pressing monitoring module.
6. The quality monitoring system for ceramic fiber filter tube production according to claim 1, wherein the ceramic fiber filter tube in the pressing process is marked according to the identification result, and the marking process is as follows:
the method comprises the steps of receiving signals sent by a ruler analysis module and a fiber distribution module and identifying, when the ruler signal and the standard signal are simultaneously identified, marking a ceramic fiber filter tube in the pressing process as a qualified filter tube, when any one of a incomplete signal and an inferior signal is identified, marking the ceramic fiber filter tube in the pressing process as an inferior filter tube, and when the incomplete signal and the inferior signal are simultaneously identified, marking the ceramic fiber filter tube in the pressing process as an obsolete filter tube;
and uniformly marking the incomplete signals or the defective signals as defect signals, generating prompt information according to the defect signals, and sending the prompt information to the operation terminal.
7. The quality monitoring system for ceramic fiber filter tube production according to claim 6, wherein the generating process of the prompt message according to the defect signal is as follows:
when the ceramic fiber filter tube is a defective filter tube and the corresponding defect signal is a defective signal in the pressing process, corresponding prompt information is generated, and when the ceramic fiber filter tube is a defective filter tube and the corresponding defect signal is a defective signal in the pressing process, the corresponding prompt information is generated and sent to an operation terminal;
counting the occurrence times of the incomplete signal and the defective signal respectively, comparing the occurrence times of the incomplete signal and the defective signal with the set occurrence times respectively, generating prompt information according to the comparison result, and sending the prompt information to the operation terminal.
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