A system for monitoring fuel consumption in a rotary kiln includes IR sensors and computing systems. The computing systems: obtain a sequence of images; determine a map of temperature values of the infrared images in the sequence of infrared images; obtain a digital model of fuel consumption in relation to temperature values of the rotary kiln, wherein the digital model of the fuel consumption is based on a measured infrared temperature for the infrared images; determine the fuel consumption of the rotary kiln based on the measured infrared temperature with the digital model of the fuel consumption; and provide the fuel consumption in a fuel consumption report. The computing systems: analyze the fuel consumption of the kiln; obtain a correlation factor for the fuel consumption that identifies an amount of carbon dioxide emissions; and determine the emissions for the fuel consumption.
F27B 7/42 - Arrangement of controlling, monitoring, alarm or like devices
G01J 5/48 - ThermographyTechniques using wholly visual means
H04N 23/23 - Cameras or camera modules comprising electronic image sensorsControl thereof for generating image signals from infrared radiation only from thermal infrared radiation
2.
ROTARY KILN MONITORING SYSTEMS FOR FUEL CONSUMPTION AND EMISSIONS
A system for monitoring fuel consumption in a rotary kiln includes IR sensors and computing systems. The computing systems: obtain a sequence of images; determine a map of temperature values of the infrared images in the sequence of infrared images; obtain a digital model of fuel consumption in relation to temperature values of the rotary kiln, wherein the digital model of the fuel consumption is based on a measured infrared temperature for the infrared images; determine the fuel consumption of the rotary kiln based on the measured infrared temperature with the digital model of the fuel consumption; and provide the fuel consumption in a fuel consumption report. The computing systems: analyze the fuel consumption of the kiln; obtain a correlation factor for the fuel consumption that identifies an amount of carbon dioxide emissions; and determine the emissions for the fuel consumption.
A system for monitoring a coating layer in a rotary kiln includes an infrared sensor and a computing system configured to: obtain a digital model of a coating layer of a rotary kiln, wherein the digital model of the coating layer is based on a coating thickness correlated with a measured infrared temperature for each coating layer region of interest; obtain infrared data of the rotary kiln with the at least one infrared imaging sensor; determine the measured infrared temperature for each coating layer region of interest; determine a coating layer thickness of a first coating layer region of interest in the coating layer based on the measured infrared temperature assigned to the first coating layer region of interest with the digital model of the coating layer; and provide the coating layer thickness of the first coating region of interest in a coating layer thickness report.
A system for monitoring a coating layer in a rotary kiln includes an infrared sensor and a computing system configured to: obtain a digital model of a coating layer of a rotary kiln, wherein the digital model of the coating layer is based on a coating thickness correlated with a measured infrared temperature for each coating layer region of interest; obtain infrared data of the rotary kiln with the at least one infrared imaging sensor; determine the measured infrared temperature for each coating layer region of interest; determine a coating layer thickness of a first coating layer region of interest in the coating layer based on the measured infrared temperature assigned to the first coating layer region of interest with the digital model of the coating layer; and provide the coating layer thickness of the first coating region of interest in a coating layer thickness report.
F27B 7/42 - Arrangement of controlling, monitoring, alarm or like devices
G01J 5/48 - ThermographyTechniques using wholly visual means
H04N 23/23 - Cameras or camera modules comprising electronic image sensorsControl thereof for generating image signals from infrared radiation only from thermal infrared radiation
5.
ROTARY KILN BRICK LAYER THERMAL MONITORING SYSTEMS
A system for monitoring brick in a rotary kiln includes an infrared sensor and a computing system configured to: obtain a digital model of a brick layer of a rotary kiln having a plurality of bricks, wherein the digital model of the brick layer is based on a measured brick thickness correlated with a measured infrared temperature for each brick; obtain infrared data of the rotary kiln with the at least one infrared imaging sensor; determine the measured infrared temperature for each brick; determine a brick thickness of a first brick in the brick layer of the rotary kiln based on the measured infrared temperature assigned to the first brick with the digital model of the brick layer; and provide the brick thickness of the first brick in a brick thickness report.
A non-transitory computer readable media can cause the imaging analysis computer to: obtain a 3D model of a preheater level of the preheater; obtain at least one infrared image of a fixed field of view of the preheater level of the preheater; analyze all pixels in the fixed field of view of the at least one infrared image for each pixel temperature; generate a 2D temperature model of the preheater level; overlaying the 2D temperature model over the 3D model to generate a virtual 3D preheater level temperature model; and provide a visual representation of the virtual 3D preheater level temperature model.
G06T 19/20 - Editing of 3D images, e.g. changing shapes or colours, aligning objects or positioning parts
G08B 7/06 - Signalling systems according to more than one of groups Personal calling systems according to more than one of groups using electric transmission
G01J 5/48 - ThermographyTechniques using wholly visual means
G08B 3/10 - Audible signalling systemsAudible personal calling systems using electric transmissionAudible signalling systemsAudible personal calling systems using electromagnetic transmission
G08B 5/22 - Visible signalling systems, e.g. personal calling systems, remote indication of seats occupied using electric transmissionVisible signalling systems, e.g. personal calling systems, remote indication of seats occupied using electromagnetic transmission
7.
METHODS OF ROTARY KILN THERMAL MONITORING AND COOLING
A system for monitoring brick in a rotary kiln includes an infrared sensor and a computing system configured to: obtain a digital model of a brick layer of a rotary kiln having a plurality of bricks, wherein the digital model of the brick layer is based on a measured brick thickness correlated with a measured infrared temperature for each brick; obtain infrared data of the rotary kiln with the at least one infrared imaging sensor; determine the measured infrared temperature for each brick; determine a brick thickness of a first brick in the brick layer of the rotary kiln based on the measured infrared temperature assigned to the first brick with the digital model of the brick layer; and provide the brick thickness of the first brick in a brick thickness report.
F27D 21/00 - Arrangement of monitoring devicesArrangement of safety devices
G01B 11/02 - Measuring arrangements characterised by the use of optical techniques for measuring length, width, or thickness
H04N 23/23 - Cameras or camera modules comprising electronic image sensorsControl thereof for generating image signals from infrared radiation only from thermal infrared radiation
G01J 5/60 - Radiation pyrometry, e.g. infrared or optical thermometry using determination of colour temperature
G06V 10/75 - Organisation of the matching processes, e.g. simultaneous or sequential comparisons of image or video featuresCoarse-fine approaches, e.g. multi-scale approachesImage or video pattern matchingProximity measures in feature spaces using context analysisSelection of dictionaries
G01J 5/00 - Radiation pyrometry, e.g. infrared or optical thermometry
8.
Rotary kiln brick layer thermal monitoring systems
A system for monitoring brick in a rotary kiln includes an infrared sensor and a computing system configured to: obtain a digital model of a brick layer of a rotary kiln having a plurality of bricks, wherein the digital model of the brick layer is based on a measured brick thickness correlated with a measured infrared temperature for each brick; obtain infrared data of the rotary kiln with the at least one infrared imaging sensor; determine the measured infrared temperature for each brick; determine a brick thickness of a first brick in the brick layer of the rotary kiln based on the measured infrared temperature assigned to the first brick with the digital model of the brick layer; and provide the brick thickness of the first brick in a brick thickness report.
G06V 10/75 - Organisation of the matching processes, e.g. simultaneous or sequential comparisons of image or video featuresCoarse-fine approaches, e.g. multi-scale approachesImage or video pattern matchingProximity measures in feature spaces using context analysisSelection of dictionaries
H04N 23/23 - Cameras or camera modules comprising electronic image sensorsControl thereof for generating image signals from infrared radiation only from thermal infrared radiation
9.
ROTARY KILN THERMAL MONITORING AND COOLING SYSTEMS
A system for detecting an hotspots can include: at least one infrared imaging sensor; and an imaging analysis computer operably coupled with the at least one infrared imaging sensor. The imaging analysis computer can be configured to control any infrared imaging sensor and acquire infrared images therefrom at any rate and in any duration. The imaging analysis computer can be configured to analyze the infrared images in order to detect temperatures and identify hotspots. The temperature and hotspot information can be used to control a cooling system that can spray water on and around hotspots for temperature control.
A system for measuring temperatures of a preheater of a rotary kiln can include: at least one infrared imaging sensor for each level of the preheater; and an imaging analysis computer operably coupled with the at least one infrared imaging sensor of each level of the preheater. The imaging analysis computer can be configured to: obtain a 3D model of a preheater level of the preheater; obtain at least one infrared image of a fixed field of view of the preheater level of the preheater; analyze all pixels in the fixed field of view of the at least one infrared image for each pixel temperature; generate a 2D temperature model of the preheater level; overlaying the 2D temperature model over the 3D model to generate a virtual 3D preheater level temperature model; and providing a visual representation of the virtual 3D preheater level temperature model.
A system for detecting an hotspots can include: at least one infrared imaging sensor; and an imaging analysis computer operably coupled with the at least one infrared imaging sensor. The imaging analysis computer can be configured to control any infrared imaging sensor and acquire infrared images therefrom at any rate and in any duration. The imaging analysis computer can be configured to analyze the infrared images in order to detect temperatures and identify hotspots. The temperature and hotspot information can be used to control a cooling system that can spray water on and around hotspots for temperature control.
G01J 5/00 - Radiation pyrometry, e.g. infrared or optical thermometry
G08B 7/06 - Signalling systems according to more than one of groups Personal calling systems according to more than one of groups using electric transmission
G08B 3/10 - Audible signalling systemsAudible personal calling systems using electric transmissionAudible signalling systemsAudible personal calling systems using electromagnetic transmission
G08B 5/22 - Visible signalling systems, e.g. personal calling systems, remote indication of seats occupied using electric transmissionVisible signalling systems, e.g. personal calling systems, remote indication of seats occupied using electromagnetic transmission
A system for measuring temperatures of a preheater of a rotary kiln can include: at least one infrared imaging sensor for each level of the preheater; and an imaging analysis computer operably coupled with the at least one infrared imaging sensor of each level of the preheater. The imaging analysis computer can be configured to: obtain a 3D model of a preheater level of the preheater; obtain at least one infrared image of a fixed field of view of the preheater level of the preheater; analyze all pixels in the fixed field of view of the at least one infrared image for each pixel temperature; generate a 2D temperature model of the preheater level; overlaying the 2D temperature model over the 3D model to generate a virtual 3D preheater level temperature model; and providing a visual representation of the virtual 3D preheater level temperature model.
G01J 5/00 - Radiation pyrometry, e.g. infrared or optical thermometry
G08B 7/06 - Signalling systems according to more than one of groups Personal calling systems according to more than one of groups using electric transmission
G08B 3/10 - Audible signalling systemsAudible personal calling systems using electric transmissionAudible signalling systemsAudible personal calling systems using electromagnetic transmission
G08B 5/22 - Visible signalling systems, e.g. personal calling systems, remote indication of seats occupied using electric transmissionVisible signalling systems, e.g. personal calling systems, remote indication of seats occupied using electromagnetic transmission
Methods and systems for monitoring an industrial process are disclosed. Some aspects of the system arrange multiple imaging sensors to image machinery associated with an industrial process. Regions of interest within images acquired by the multiple imaging sensors may be monitored for abnormal thermal conditions, and alerts generated as needed. Alerts may also be generated if temperatures within a region of interest exceed thresholds associated with that region of interest. Each region of interest may be independently monitored and have individualized alerting thresholds. In some aspects, images from the multiple imaging sensors may be stitched together, with the regions of interest based on the stitched image. In other aspects, regions of interest within images from separate imaging sensors may be linked together so as to share at least common alerting thresholds.
A system for detecting an oil leak can include: at least one infrared imaging sensor; and an imaging analysis computer operably coupled with the at least one infrared imaging sensor. The imaging analysis computer can be configured to control any infrared imaging sensor and acquire infrared images therefrom at any rate and in any duration. The imaging analysis computer can be configured to analyze the infrared images in order to detect an oil leak. The imaging analysis computer can be configured to detect oil on a surface (e.g., solid surface or water surface) where oil should not be (or is not present in a baseline) in order to determine that there is an oil leak in the vicinity.
A system for detecting a gas leak can include: at least one infrared imaging sensor; and an imaging analysis computer operably coupled with the at least one infrared imaging sensor. The imaging analysis computer can be configured to control any infrared imaging sensor and acquire infrared images therefrom at any rate and in any duration. The imaging analysis computer can be configured to analyze the infrared images in order to detect a gas leak. The imaging analysis computer can be configured to detect a gas where gas should not be (or is not present in a baseline) in order to determine that there is a gas leak in the vicinity. The gas can be a hydrocarbon gas or carbon monoxide, or other.
A system for detecting a gas leak can include: at least one infrared imaging sensor; and an imaging analysis computer operably coupled with the at least one infrared imaging sensor. The imaging analysis computer can be configured to control any infrared imaging sensor and acquire infrared images therefrom at any rate and in any duration. The imaging analysis computer can be configured to analyze the infrared images in order to detect a gas leak. The imaging analysis computer can be configured to detect a gas where gas should not be (or is not present in a baseline) in order to determine that there is a gas leak in the vicinity. The gas can be a hydrocarbon gas or carbon monoxide, or other.
G01J 5/00 - Radiation pyrometry, e.g. infrared or optical thermometry
G01J 5/10 - Radiation pyrometry, e.g. infrared or optical thermometry using electric radiation detectors
G01M 3/00 - Investigating fluid tightness of structures
G01M 3/38 - Investigating fluid tightness of structures by using light
G01N 21/31 - Investigating relative effect of material at wavelengths characteristic of specific elements or molecules, e.g. atomic absorption spectrometry
17.
INFRARED IMAGING SYSTEMS AND METHODS FOR OIL LEAK DETECTION
A system for detecting an oil leak can include: at least one infrared imaging sensor; and an imaging analysis computer operably coupled with the at least one infrared imaging sensor. The imaging analysis computer can be configured to control any infrared imaging sensor and acquire infrared images therefrom at any rate and in any duration. The imaging analysis computer can be configured to analyze the infrared images in order to detect an oil leak. The imaging analysis computer can be configured to detect oil on a surface (e.g., solid surface or water surface) where oil should not be (or is not present in a baseline) in order to determine that there is an oil leak in the vicinity.
H04N 3/09 - Scanning details of television systemsCombination thereof with generation of supply voltages by optical-mechanical means only having a moving reflector for electromagnetic radiation in the invisible region, e.g. infrared
H04N 5/341 - Extracting pixel data from an image sensor by controlling scanning circuits, e.g. by modifying the number of pixels having been sampled or to be sampled
G01N 25/18 - Investigating or analysing materials by the use of thermal means by investigating thermal conductivity
Methods and systems for monitoring an industrial process are disclosed. Some aspects of the system arrange multiple imaging sensors to image machinery associated with an industrial process. Regions of interest within images acquired by the multiple imaging sensors may be monitored for abnormal thermal conditions, and alerts generated as needed. Alerts may also be generated if temperatures within a region of interest exceed thresholds associated with that region of interest. Each region of interest may be independently monitored and have individualized alerting thresholds. In some aspects, images from the multiple imaging sensors may be stitched together, with the regions of interest based on the stitched image. In other aspects, regions of interest within images from separate imaging sensors may be linked together so as to share at least common alerting thresholds.
Methods and systems for tank level management are disclosed. In some aspects, one or more regions of interest are defined within an image acquired from an imaging sensor. Histograms of pixel values within each region of interest are generated, and thresholds delineating two groups of similar pixel values within each region of interest are determined. In some aspects, the tank level within each region of interest is based on the corresponding threshold. In some aspects, rows of pixel values within each region of interest are thresholded. The thresholded rows may be used to determine the tank level within the region. Some aspects determine whether the pixel values are bimodal based on the generated histogram. Unimodal pixel values may represent either an empty or full tank. A similarity to preconfigured values associated with full or empty tank conditions may facilitate identification of whether the tank is full or empty.
G06K 9/00 - Methods or arrangements for reading or recognising printed or written characters or for recognising patterns, e.g. fingerprints
G01F 23/00 - Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm
G06K 9/46 - Extraction of features or characteristics of the image
patents
