With the continuous advancement of the wave of industrial upgrading in the metallurgical industry, the refractory brick industry in the subdivided field has also ushered in a new opportunity, machine vision as the core technology of industrial automation has also been fully applied, and the 3D camera of Sick has shown excellent performance in the field of refractory bricks.
Refractory brick is referred to as fire brick, it is a kind of stereotyped refractory material, light refractory brick is used for thermal insulation scenes, heavy refractory bricks are mainly used for masonry steelmaking electric furnace, glass furnace, cement rotary furnace, and many construction projects; It is usually formed and calcined from bauxite or other raw materials with high oxide content, with high thermal shock stability and refractory degree above 1770 °C.
Due to its outstanding performance, it can help many special industries to work at high temperatures, so the specification testing and thermal shock stability testing of refractory bricks are very important.
Refractory brick production process
The manufacturing process is broadly divided into:
raw material
Powder preparation (crushing, crushing, screening)
Proportional ingredients
Mixing Pi mixing
Dry forming
sinter
Inspection
wrap
According to the preparation method, it can be divided into: fired bricks, unfired bricks, fused bricks, and refractory insulation bricks
According to the shape, it is divided into: standard bricks, ordinary bricks, and special bricks
According to the raw materials, it is divided into: refractory clay bricks, high-alumina bricks, silica bricks, magnesia bricks, etc
Refractory brick size detection
Application Description:
In the inspection, packaging, shipment and other links, it is necessary to verify whether the shape and size of the refractory bricks meet the specifications, and whether the length, height, width, flatness and other tests are standard; Conventional detection accuracy requires 0.02-0.1mm
Application difficulties
There are many types of materials, different sizes and colors
Problems such as black material light absorption and bright surface reflection have high requirements for camera imaging quality
A 3D camera needs to have good depth-of-field compatibility and speed advantages
The powerful, fast, and configurable RulerXR cameras from SICK are ideal for visual inspection of large sizes.
Detection of surface defects of refractory bricks
After the refractory brick is thermoformed, the performance of the refractory material to resist the sharp change of temperature without damage is called thermal shock stability; This property is also known as resistance to thermal shock or temperature slashes. As we all know, silica bricks are prone to cracks and cracking when exposed to rapid cooling and heating; Magnesia bricks are prone to peeling.
App Description:
SICK 3D cameras detect surface defects in refractory bricks: The 3D camera is equipped with a temperature fatigue tester for refractory bricks to inspect the end face of refractory bricks.
Workflow:
Grab the material into the furnace at an extreme temperature of 1500 degrees for 20-30min
Water cooling for 5-10min
The 3D camera detects the end face and determines whether the surface is peeling, so as to verify the thermal shock stability of the refractory brick
What the camera detects:
Detect the surface conditions such as 1-2mm level cracking, deformation, damage, and slag dropping on the end face
Difficulties:
There are many types of materials, various surface defects, and different conditions after illumination, and the imaging quality requirements are high
There are heating furnaces and water cooling environments around, and the environment is relatively harsh, and the stability of the camera is required
Erection space is limited and requires quick configuration
The SICK Trispector 1030 camera effectively quantifies the thermal shock stability of refractory bricks through images, and adapts them to different refractory brick materials, such as high-alumina, magnesium, and carbon, to check the quality and contribute to the new development of the industry.
Source: Sick SICK, Germany
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