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北方工业大学硕士学位论文1基于图像处理技术的电解槽故障诊断方法研究摘要在铜电解精炼过程中，由于极板之间的距离和极板表面光洁度影响，电解过程中阴极板经常出现“结粒”现象，导致极板间发生短路故障，造成电流损失，产品质量下降，降低企业生产效率的同时还增加了电能消耗。为了提高企业生产效率，节能减耗，及时发现并排除故障可以提高电解产品的质量、减小电能损耗。目前电解企业普遍采用自动化装置进行检测，但是大部分需要依托人工巡回检测，不能及时发现故障，还有可能误判断，效率低下。本文提出了一种用红外相机监测电解槽故障的方案。由于红外相机温度测量范围宽，精度高的特点，我们将红外热像仪安装在巡检小车上，实时定位采集现场电解槽工况的红外图像，并将其传回上位机，在上位机运用数字图像处理技术进行后续的图像处理。通过对采集的电解槽红外图像进行预处理、故障查找、故障定位等操作，实现了电解槽图像的故障定位，最终结合先验知识显示故障位置，方便工作人员进行相应的操作和处理。该方法操作方便，利于推广，降低了电能浪费，提高了故障检测精度和电解产品的质量，有着很重要的现实意义。其次，由于故障检测系统在极板发生故障后报警时，故障已经产生。为了避免故障发生，造成不必要的损失，本文还研究了如何根据现场测得的极棒温度，预测故障位置的方法。将实际阴极棒抽象为导电体模型，运用COMSOL软件模拟阴极棒与周围空气间的对流换热情况。通过仿真数据研究各影响因素和电流的关系。推导出了电解槽阴极棒的温度电流模型，经过现场数据分析验证，验证了模型的有效性。关键词：电解，红外相机，故障诊断，温度电流模型，图像处理技术北方工业大学硕士学位论文2ResearchelectrolyticcellfaultdiagnosismethodbasedonimageprocessingtechnologyAbstractWetelectrolyticrefiningprocessisakeystep.Duringelectrolyticproductionprocess,theelectrolyticoftenproduceagglomeration,resultinginashortcircuitorashortcircuitfaultoccursbetweentheplates,currentlosses,decreasedproductquality,reduceproductionefficiencyalsoincreasedpowerconsumption.Inordertoimproveproductionefficiency,saveenergy,todetectandsolveproblemscanimprovethequalityoftheelectrolysisproducts.Nowadays,theenterprisedetectedwithautomaticdevice,butmostofthemneedtorelyonman,maycausewrongjudgmentsandinefficiency.Thispaperpresentsamethodwithaninfraredcameratodetect.Infraredcamerawithwidetemperaturerange,highprecision,cancompletemeasurementinarelativelyshorttime.Theinfraredcameramountedinpatrolcars,infraredimageswereacquiredbycamera,then,theinfraredimageswastransferredtocomputer,thesubsequentimageprocessingandrecognitionoperatedbyPCcombinedwithdigitalimageprocessingalgorithmstodeterminefaultlocation.Inpractice,processtheinfraredimageswecollected,thenpatrolcarinmotiontheprocessofreal-timeprocessing,faultlocationisdisplayedintroubleshootinginterface,combinedwithpriorknowledgeofthespecificlocationofthefault,intheformoftextdisplayedinthetroubleshootinginterfacefacilitatestaffappropriatehandlinganddisposal.Themethodissimple,safeandreliable,improvedfaultdetectionaccuracy,improvethequalityoftheelectrolysisproducts,reducethewasteofenergy,therebyincreasingtheproductivityoftheworkshop,hasaveryimportantpracticalsignificance.Secondly,sincethefaultdetectionsystemfailurealarmaftertheplates,thefaulthasbeengenerated.Toavoidfailure,resultinginunnecessarylosses,westudyhowthemethodaccordingtothesitemeasuredtemperatureterrificpredictthefaultlocation.Accordingtothesite'smagneticenvironment,theactualconductorabstractpremiserectangularconductormodel,usingsimulationsoftwareCOMSOLdeducedfantastictemperatureelectrolyticcellcurrentmodel,validatedbyfielddatatoverifythevalidityofthemodel.KEYWORDS：Electrolysis,infraredcameras,faultdiagnosis,imageprocessingtechnology北方工业大学硕士学位论文1目录摘要..........................................................................................................................................................................1Abstract.........................................................................................................................................................................21绪论..........................................................................................................................................................................11.1图像处理故障诊断背景...............................................................................................................................11.2电解槽检测故障诊断现状...........................................................................................................................31.3电解槽故障诊断研究内容...........................................................................................................................42基于图像的故障诊断基础......................................................................................................................................62.1红外辐射的规律...........................................................................................................................................62.2红外测温原理...............................................................................................................................................82.3红外相机的温度标定...................................................................................................................................92.3.1温度测量方法..................................................................................................................................102.3.2相机温度标定实验..........................................................................................................................112.3.3温度标定结果分析..........................................................................................................................142.4红外相机的几何标定.................................................................................................................................142.4.1几何标定原理..................................................................................................................................162