Application of visual inspection system in coke dry quenching

1. Overview of coke dry quenching visual inspection system

The CDQ visual inspection system is a system that uses a visual camera combined with an AI algorithm to replace the human eye for measurement and judgment. It consists of a visual camera, a visual industrial computer, and visual software and auxiliary materials. In the field of dry coke quenching, typical applications are hook status, APS lock arm status detection, and coke tank positioning status on the rotating trolley. Through visual inspection technology, the hook status of the hoist during the lifting process can be detected in real-time to ensure that the hook fully enters the coke tank hanging ear during the lifting process to prevent the hook from being hung sideways or decoupled.

Real-time detection of the opening and clamping status of the APS lock arm to ensure that the status of the APS lock arm after clamping the trolley is reliable, preventing the APS from being effectively clamped and the clamping phenomenon caused by the falling off of the trolley’s clamping base.

Real-time detection determines whether the positioning state of the coke tank before lifting is reliable, and prevents accidents such as the coke tank positioning exceeding the safe range, the coke tank top being on the rotating plate positioning triangle, and other accidents causing the bottom door to open after the coke tank is lifted.

Through the AI algorithm, the normal (OK) and abnormal (NG) visual signals are converted into switching outputs. The detection system converts image information (OK, NG) into switching signals with millisecond response speed and provides them to the superior main system.

2. Development background of CDQ visual inspection system

 

The key to safely lifting a full CDQ coke tank is to rotate the coke tank in the correct positioning state after APS clamping, and the hooks on both sides effectively enter the stage of hanging lugs and close together. Looking at dry quenching coke lifting accidents, the hooks are hanging off the hook, decoupling, and the bottom door of the coke tank is opened, causing the red coke to fall to the ground. Almost without exception, they all occur at this stage, that is, below the standby position. Therefore, how to prevent similar major accidents from happening in this initial stage has always been an important topic that our colleagues in the industry have studied deeply.

 

CDQ, coke dry quenching, visual inspection system

 

3. Introduction to CDQ visual inspection system

 

The CDQ visual inspection system uses machines instead of human eyes to make measurements and judgments. Through the image capture device, the captured target is converted into an image signal and sent to a dedicated visual software processing system. It is converted into a digital signal based on pixel distribution, position status, brightness, colour and other information. The visual software system performs various operations on these signals. The operation is performed to extract the characteristics of the target, and then the on-site equipment actions are controlled based on the judgment results.

 

4. Coke dry quenching visual inspection system function

 

1) Powerful self-learning ability combined with in-depth algorithms for on-site working conditions, fully adaptable to coke dry quenching application sites;

2) Millisecond-level detection result feedback can quickly provide alarm and fault instructions to the superior system to keep abnormal conditions within a safe and controllable range;

3) Intelligent algorithm, while providing various alarm information such as camera failure, camera position deviation, network failure, etc., making the entire system more stable and reliable;

4) Flexible communication technology can provide reliable interfaces for various superior systems to facilitate expanded applications;

5) Implement network isolation between self-contained systems and superior systems to eliminate the risk of industrial control network attacks;

6) Powerful hardware configuration, the entire system almost reaches maintenance-free standards;

7) Professional control technology processing can quickly interrupt the system to ensure safety when an abnormality is detected, and can quickly resume operation even if a misjudgment occurs, without affecting CDQ production operations.

 

6. Typical applications of CDQ visual inspection system

 

(1) Visual inspection of hoist hook

Through the AI intelligent machine vision detection method, it can effectively detect and determine whether the state of the hook entering the lifting lug is reliable. Once an unexpected situation occurs such as the hook position deviating from the allowable error range, the plate hook hanging sideways, decoupling, or not entering the lifting lug, the visual inspection system converts the image information into a switching signal with a millisecond response speed and provides it to the elevator main system.

(2) APS visual inspection

Through AI intelligent machine vision detection methods, it can effectively detect and determine whether the APS state after clamping and loosening is reliable. Once unexpected situations such as unreliable clamping (especially when the trolley clamping base falls off and the APS clamp is empty) or incomplete loosening occur, the visual inspection system converts the image information into a switching signal with a millisecond response speed and provides it to the upgrade Host system.

(3) Visual inspection of coke tank positioning

Through AI intelligent machine vision inspection methods, it can effectively detect and determine whether the positioning status of the coke tank is reliable. Once an unexpected situation occurs, such as the coke tank positioning exceeding the safe range or the coke tank top being on the rotating disk positioning triangle, the visual inspection system converts the image information into a switching signal with a millisecond-level response speed and provides it to the elevator main system.

(4) Detection of the bottom door status of the coke tank and the liquid level status of the boiler drum before and after the coke is loaded, etc.

Through the AI intelligent machine vision inspection method, the status of the bottom door of the coke tank before and after the coke is loaded can also be judged, and the status of the bottom door of the coke tank after the coke is loaded into the furnace can be visually judged to prevent the bottom door from being opened when the coke is loaded into the furnace. Risks caused by opening or severely tilting the coke tank, or failing to reliably close the bottom door of the coke tank after loading the coke. In the same way, on the very critical liquid level status of the dry quenching boiler drum, visual inspection methods can be used to further improve risk prevention.

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