Glass kiln cement kiln burner: high-temperature monitoring television

1、 Overview of High Temperature Monitoring Technology

The high-temperature industrial television monitoring system is an important component of industrial kiln automation. With the rapid development of industrial manufacturing technology in China, the increase in production, energy conservation, and reliable operation of industrial kilns are particularly important. The improvement and continuous progress of industrial automation control technology have led to the widespread use of high-temperature industrial television for monitoring industrial kilns. Significantly improved the production efficiency of industrial enterprises and the safety and service life of equipment. The high-temperature industrial television monitoring system has been widely recognized by users for its intuitive, wide observation range, and high degree of automation in monitoring the working conditions of kilns. Due to the further development of CMOS imaging technology, it is possible to monitor the working conditions inside industrial kilns clearly. High temperature industrial television equipment integrates electromechanical technology, microelectronics technology, fiber optic control signals, cooling technology, and software. It is necessary to conduct long-term tracking research and design on the production process characteristics and working conditions of kilns in order to apply the equipment in harsh high-temperature kiln environments. Especially when we use advanced vortex pure air cooling technology without water cooling, it is more widely used in areas where water resources are scarce in the north and water pipes are prone to burst in winter, where water cooling is not suitable.

2、 Product Introduction

The ZW-SL type endoscopic high-temperature industrial television equipment is a professional application for high-temperature industrial monitoring equipment in cement rotary kilns and glass melting kilns. It is suitable (with a furnace wall thickness of about 300mm) and can directly extend the camera lens into the kiln (below 2000 ℃) to continuously monitor the working status of flames and materials in real-time. The effective observation of various factors such as the flame shape of the cement plant kiln head and the combustion status of the cement kiln rotary kiln burner through this equipment has a direct effect on increasing and stabilizing production. The device has an over temperature automatic exit function.

5、 Technical characteristics

a) A comprehensive quality assurance system, with streamlined and networked management for training services, spare parts services, tracking and follow-up services.

b) Wind and water cooling technology, spiral air curtain design, unique in China

c) Triple protection technology, intelligent, and reliable operation

d) High temperature resistant all stainless steel material, molded manufacturing, cleverly designed structure, reflecting technological level

e) The image perspective can be selected based on various on-site options to obtain high-definition video effects.

f) High definition intelligent transmission system with no delay or lag in images

3、 System composition and working principle: The system mainly consists of hardware cooling protection device, control system part, image acquisition part, cooling air circuit part, and monitoring part.

1. Cooling protection device:

Overall structure; The equipment is made of special high-temperature resistant stainless steel material, which has high-strength high-temperature and corrosion resistance performance. Based on the original technology, it adopts a mold design, and the equipment has a beautiful appearance, small and lightweight.

Camera cooling protective cover: The camera probe protective cover is designed with a special spiral wind curtain structure and fluid component principle, which accelerates the rotation of compressed air inside the probe cover to improve cooling effect and effectively protect the lens and camera under high temperature. The entire structure is cleverly conceived, uniquely designed, easy to maintain, and has a long service life. In order to reduce the radiation heat from the furnace to the equipment, a 1mm pinhole lens is used, greatly reducing the radiation area. The lens is cooled by two channels of gas. And blow out the cooling gas from the front end of the protective cover, which shows better performance in high temperature resistance and dust prevention. The entire camera probe can withstand high temperatures of 2000 ℃. The camera and lens are installed inside the probe cover, and the probe goes deep into the furnace. CMOS uses a pinhole lens to capture images of the furnace, such as flames, and presents the object image to the camera, which is then converted into a network signal and transmitted to the monitor in the control room through optical fiber to achieve its monitoring function.

Extension and exit part: The initial small wheeled vehicle propulsion has been changed to metal guide rail transmission, overcoming the situation where traditional screw and nut structures are prone to deformation and jamming. At the same time, a self-locking motor is used as the power, which is flexible and free to move, making the equipment stable and reliable in and out, and can be used at any installation angle.

2. Control system part:

The control part adopts PLC programming control, with Japanese MITSUBISHI PLC with up to 14 input and output control points, imported SMC air sensors, and all cooling air pipes using fully stainless steel metal hoses that can withstand high temperatures of 450 degrees. Compared with related products in the industry, the internal configuration of the system has higher material grade, reliability, and richer performance. Users can freely program according to their own requirements to meet their needs. The response speed and protection function of the system equipment have also been fully guaranteed, and the troubleshooting of equipment faults has been simplified. As long as the fault situation at the corresponding points is checked according to the instructions, it greatly reduces the workload and labor intensity of maintenance and repair.

Using programmable PLC for on-site control. The complete automatic protection function enables the automatic protection device to activate in three states: overtemperature (temperature is set to the upper limit of protection), gas shutdown, and power outage (UPS power supply is required). The probe will automatically retreat from the furnace, and the fireproof steel plate will return to position and seal the furnace opening to prevent further accidents from spreading.

It has an automatic exit function in one of the following three situations:

When the temperature inside the probe housing exceeds the set value (≥ 55 ℃)

When the compressed air pressure is lower than the specified value (≤ 0.1Mpa)

When power outage occurs (UPS power supply needs to be set), multi-level manual control:

Press the extension button and exit button to achieve probe extension and exit functions

The probe cover can be pushed or pulled by hand to achieve extension and exit functions

Remote control function: The operator can remotely control the extension and exit of the probe cover

3. Image acquisition section:

The high-temperature camera system has an ultra wide dynamic range of brightness that cannot be compared to its domestic counterparts. It can clearly reproduce the details of combustion at each position in the furnace under various combustion conditions, from high brightness to cessation of combustion. Specially designed

A needle hole lens with independent intellectual property rights, with adjustable step length, and the lens aperture from fully open to fully closed (or from fully closed to fully open) reaching more than 5 times the same level of aperture in the same industry.

(1) Camera (self-developed high-definition transmission)

In order to improve the quality of the image and expand its applicability to illumination, we adopt advanced aperture correction (to make the image edges clear) and ultra-low illumination strong light suppression technology. Our self-developed HD high-definition transmission camera system, combined with our unique optical lens, ensures a dual guarantee of clear reproduction of every detail in the field. characteristic:

*Ultra low illumination 0.001lux

*Adopting unique TM * strong light suppression technology to completely or partially suppress strong light

*Three speed BMBTM effect optional

*Achieving high-quality images through DSP processing

*Signal to noise ratio greater than 50dB

*OSD manual control/camera settings

*Improving the Quality of Color Restoration through Color Reproduction Technology under Low Illumination

*Wide range electronic shutter, selectable from 1/50 seconds to 1/100000 seconds (10 steps)

*AC 24V line locking, ± 90 ° vertical phase adjustment

*Remote control of cameras through high-definition decoders

*Aperture correction technology makes image edges clear

*High resolution 2 million pixels

(See KS Intelligent Transmission System for details)

(2) Lens: This device adopts a high-temperature resistant pinhole lens, with an imported sapphire mirror surface and a high-temperature resistant adhesive material. In order to reduce the radiation heat from the furnace to the equipment, it greatly reduces

By reducing the radiation area, even in unexpected situations, the mirror will not burn out. This enables the pinhole lens to withstand high temperatures of 2000 ℃, much higher than the temperature resistance of the camera.

The design of the elongated pinhole lens avoids the safety hazards caused by the passive front facing of the endoscopic product camera. The protective cover of the camera probe is made of special high-temperature and corrosion-resistant materials and a special structural design, effectively protecting the high-temperature lens and camera. It is easy to maintain and has a long service life. The length of the lens can be selected according to the actual situation on site. The combination of a strong light suppression low illumination CMOS high-definition camera and our unique high-temperature lens ensures a dual guarantee of clear reproduction of every detail on site. The camera and lens are installed inside the probe cover, and the probe goes deep into the furnace. CMS uses a pinhole lens to capture images of flames and other objects in the furnace, and presents them to the camera. Then, they are converted into network signals and transmitted to the monitor in the control room through optical fiber to achieve their monitoring function.

4. Cooling air section;

This equipment adopts pure air cooling technology and forced air cooling method, which is simple to use, convenient to maintain, and not limited by regional restrictions. Considering the temperature inside the kiln of 2000 ℃ and the lens's ability to withstand high temperatures of 400 ℃, the calculation results of heat exchange and ventilation design indicate that general forced air cooling can meet the requirements. However, to further ensure the reliability of the camera system under high temperatures, the system considers a three way air supply design. Central isolation technology: In order to protect the camera in various harsh working environments, we have added an isolation ring between the lens and the camera. By using isolation rings to reduce the direct blowing of cooling airflow on the camera (as the camera is working outside the furnace, the temperature is not very high as long as it is slightly cooled), the danger of long-term deposition of water and oil components in the air on the camera and damage to the camera is avoided. The circulating water is continuously cooled through the interlayer to protect the camera and lens (added on site).

5. Filtration system: This equipment adopts secondary filtration, which mainly removes water, oil, dust, etc; The secondary filtration has automatic water removal, automatic oil removal, precision filtration, and precision oil removal, making maintenance simple and convenient.

6. Monitoring part: The camera converts the captured images into standard video signals, which are transferred by the control box and directly sent to the monitor in the central control room. The monitor can display the combustion details of each position in the furnace clearly on the full screen. In the process of long-distance (special circumstances) fiber optic signal transmission, in order to ensure signal anti-interference and reduce signal attenuation, fiber optic transmission should be used. Fiber optic transmission not only has good anti-interference ability, but also can increase transmission distance.

7. Installation features: Due to the special extended lens design of this equipment, it can be directly inserted into the kiln for observation, eliminating the tedious process of opening the bell mouth due to insufficient visual angle. In addition, the extension and exit parts are driven by metal guide rails with self-locking motors, ensuring smooth and reliable extension and exit of the equipment, allowing it to be used at any installation angle. Overcoming the limitation of deliberately selecting points for installation angles. Installation method: direct view installation, side view installation, and vertical inverted installation.

7、 The operation and maintenance part of the system: Due to the use of PLC programmable control in this equipment, daily operation and maintenance are relatively simple and easy to do. However, the following two points need to be noted:

A. Installation pipeline requirements: Cooling air shall be provided by a separate compressed air pipeline, and no other gas equipment shall be connected to the compressed air pipeline of the industrial television system to ensure stable cooling air pressure and meet the requirements. The cooling air shall not contain any water, oil or other impurities to avoid affecting the gas consumption of the industrial television system. During installation, certain protective measures should be taken (such as adding a thermal insulation protective plate on the side of the transmission device) to prevent the kiln head from turning back and the burner from burning the pipeline and equipment.

B. Daily maintenance requirements: (1) When the equipment is put into use, daily maintenance mainly involves simple maintenance of the air circuit and lens. For the air circuit, it is necessary to regularly and timely (once a day to ensure safe operation of the equipment) check the air pressure and oil discharge, and the air pressure should not be lower than the pressure required for normal operation of the equipment.

Lens section; When there is dust on the surface of the lens during use, the external lens can be removed and wiped for cleaning. When wiping, professional wiping paper or medical cotton ball should be dipped in a small amount of water to wipe in one direction. It is strictly prohibited to wipe the inner lens. If the problem cannot be solved by wiping the outer lens, the lens can be sent to our company for professional wiping and cleaning.

(2) Maintenance and repair; Key inspections should be conducted to ensure that the functions and wiring connections of the travel switch, temperature sensor, temperature digital display meter, and pressure control meter are intact, and the probe cover extension and exit control function should be complete. During the shutdown maintenance period, regular inspections and lubrication work should be carried out on all mechanical mechanisms of the automatic exit device to ensure the flexible and reliable operation of the transmission device.

(3) Service commitment: Fast service. If there is a problem with the equipment, we will arrive at the site within 24 hours after receiving the notice to solve the problem or propose a solution. During the warranty period of the equipment, any quality issues with the product itself will be repaired or replaced by us for free; After the project is completed and the equipment is put into use, we will regularly conduct follow-up visits to users to track their usage, and conduct on-site maintenance of the system equipment, providing technical support and guarantee work.

8、 Environmental parameters and technical indicators for system use

Compressed air:

·Inlet pressure: 0.2-0.7Mpa

·Inlet temperature: ≤ 35 ℃

·Flow rate: 0.1-0.4M3/min Working environment:

·Dust: ＜ 200g/M3

Noise: ＜ 150db Environmental temperature:

Automatic exit device: -10 ℃ -90 ℃ (excluding probe cover)

Control system: -10 ℃ -70 ℃

Camera: ＜ 400 ℃

Furnace temperature: ＜ 2000 ℃

Furnace wall temperature: ＜ 300 ℃ Camera parameters:

Scanning method: PAL system 625 rows/50 fields

Video output: 1Vp-p synchronous positive polarity 75 Ω

Signal to noise ratio: not less than 42db

System image quality: Level 5 (normal situation)

Brightness discrimination level: ≥ 8 levels

Clarity: 480 lines

Sensitivity: 0.8Lx (F1.4)

Reaction time: 1ms

Vibration resistance level: can withstand all conditions except earthquakes and unexpected situations

Exit stroke: 520mm

Time between failures: 2500

Working voltage: AC220V Frequency 50HZ Consumption power: 120W

Protection level: IP65

For more technical details, please call (WeChat synchronization): 15713691937.

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