U.S. patent application number 14/296265 was filed with the patent office on 2015-12-10 for equipment and method for three-dimensional radiance and gas species field estimation.
The applicant listed for this patent is Honeywell International Inc.. Invention is credited to Kwong Wing Au, Stefano Bietto, Kurt Kraus, Matthew Martin, Sharath Venkatesha.
Application Number | 20150356720 14/296265 |
Document ID | / |
Family ID | 54542914 |
Filed Date | 2015-12-10 |
United States Patent
Application |
20150356720 |
Kind Code |
A1 |
Kraus; Kurt ; et
al. |
December 10, 2015 |
EQUIPMENT AND METHOD FOR THREE-DIMENSIONAL RADIANCE AND GAS SPECIES
FIELD ESTIMATION
Abstract
A process is provided for estimating a three-dimensional (3D)
radiance field of a combustion process in an enclosure. An on-line
intensity-temperature calibration is performed based on an
association between an intensity of an image pixel and an actual
temperature associated with a selected region in the enclosure. The
intensity of the corresponding image is transformed to a radiance
image based on settings of an image-capturing device and the
on-line calibration. A registration and alignment estimation of the
image is performed based on positional information of the
enclosure. The radiance image is aligned based on the registration
estimation. The 3D radiance field having voxels of the enclosure is
estimated based on a two-dimensional to 3D transforming of the
aligned radiance images.
Inventors: |
Kraus; Kurt; (Tulsa, OK)
; Au; Kwong Wing; (Bloomington, MN) ; Martin;
Matthew; (Tulsa, OK) ; Venkatesha; Sharath;
(Minnetonka, MN) ; Bietto; Stefano; (Tulsa,
OK) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Honeywell International Inc. |
Morristown |
NJ |
US |
|
|
Family ID: |
54542914 |
Appl. No.: |
14/296265 |
Filed: |
June 4, 2014 |
Current U.S.
Class: |
382/141 |
Current CPC
Class: |
G06T 7/30 20170101; G06T
2207/10048 20130101; G06T 15/08 20130101; G06T 7/85 20170101; G06T
7/0004 20130101; G06T 2200/04 20130101; G06T 2207/10012
20130101 |
International
Class: |
G06T 7/00 20060101
G06T007/00; G06T 15/08 20060101 G06T015/08 |
Claims
1. A process for estimating a three-dimensional (3D) radiance field
of a combustion process in an enclosure, comprising: performing an
on-line intensity-temperature calibration based on an association
between an intensity of an image pixel and an actual temperature
associated with a selected region in the enclosure; transforming
the intensity intensity of the corresponding image to a radiance
image based on settings of an image-capturing device and the
on-line calibration; performing a registration and alignment
estimation of the image based on positional information of the
enclosure; aligning the radiance image based on the registration
estimation; and estimating, using a computer processor, the 3D
radiance field having voxels of the enclosure based on a
two-dimensional (2D)-to-3D transforming of the aligned radiance
images.
2. The process according to claim 1, further comprising: capturing
images of selected spectral bands in the enclosure using a
plurality of image capturing devices; and estimating at least one
of the 3D radiance fields of the selected spectral bands in the
enclosure.
3. The process according to claim 1, further comprising: mapping at
least one of a temperature and a gas species, and the corresponding
intensity of the image pixel with the settings associated with the
image-capturing device; maintaining records of the
intensity-temperature calibration in a storage device; calculating
a difference between a recorded intensity-temperature calibration
value associated with the image pixel, and a current
intensity-temperature calibration value; and indicating that system
maintenance is required when the difference exceeds a predetermined
threshold.
4. The process according to claim 1, further comprising:
selectively adjusting the settings of the image-capturing device
having parameters related to at least one of a wavelength, an
aperture, a shutter, and a gain; evaluating an intensity histogram
of the corresponding image during, the transforming of the
intensity of the corresponding image to the 3D radiance field; and
adjusting the settings of the image-capturing device based on the
evaluation of the histogram.
5. The process according to claim 2, further comprising: computing
a total 3D radiance field based on a subset of the at least one 3D
radiance field associated with the settings of the image-capturing
device for estimating a radiance value of the total 3D radiance
field.
6. The process according to claim 2, further comprising: detecting
and computing a 3D gas species field of the enclosure using a
function of statistical classification, threshold values or
gradients in a subset of the at least one 3D radiance field
associated with the settings of the image-capturing device.
7. The process according to claim 1, further comprising:
determining the positional information by collecting a plurality of
reference points in the enclosure using markers recognizable by the
image-capturing device; calculating a perspective transformation of
the image based on the reference points and the corresponding image
pixels; and aligning and registering a two-dimensional (2D)
temperature image based on the perspective transformation.
8. The process according to claim 1, further comprising: computing
the 3D radiance field of the enclosure based on the aligned
radiance images using a hierarchical, multi-resolution method;
performing the hierarchical, multi-resolution method by applying a
hierarchical coarse-to-fine algorithm based on a resolution of the
selected region; and calculating inverses of matrices using a
radiative transfer equation for each resolution computation of the
selected region to compute the 3D radiance field.
9. An apparatus for estimating a three-dimensional (3D) radiance
field of a combustion process in an enclosure, the apparatus
comprising: an intensity-temperature calibration unit configured
for performing an on-line intensity-temperature calibration based
on an association between an intensity of an image pixel and an
actual temperature associated with a selected region in the
enclosure; an intensity-temperature transformation unit configured
for transforming the intensity of the corresponding image to a
radiance image based on settings of an image-capturing device and
the on-line calibration; a registration and alignment estimation
unit configured for performing a registration and alignment
estimation of the image based on positional information of the
enclosure, and aligning the radiance image based on the
registration estimation; and an estimation unit configured for
estimating, using a computer processor, the 3D radiance field
having voxels of the enclosure based on a two-dimensional
(2D)-to-3D transforming of the aligned radiance images
10. The apparatus according to claim 9, further comprising a 3D
temperature-radiance estimation unit configured for: capturing
images of selected spectral bands in the enclosure using a
plurality of image capturing devices; and estimating at least one
of the 3D radiance fields of the selected spectral bands in the
enclosure.
11. The apparatus according to claim 9, wherein the
intensity-temperature calibration unit is configured for: mapping
at least one of a temperature and a gas species, and the
corresponding intensity of the image pixel with the settings
associated with the image-capturing device; maintaining records of
the intensity-temperature calibration in a storage device;
calculating a difference between a recorded intensity-temperature
calibration value associated with the image pixel, and a current
intensity-temperature calibration value; and indicating that system
maintenance is required when the difference exceeds a predetermined
threshold.
12. The apparatus according to claim 9, wherein the
intensity-temperature transformation unit is configured for:
selectively adjusting the settings of the image-capturing device
having parameters related to at least one of a wavelength, an
aperture, a shutter, and a gain; evaluating, an intensity histogram
of the corresponding image during the transforming of the intensity
of the corresponding image to the 3D radiance field; and adjusting
the settings of the image-capturing device based on the evaluation
of the histogram.
13. The apparatus according to claim 9, wherein the estimation unit
is configured for: computing a total 3D radiance field based on a
subset of the at least one 3D radiance field associated with the
settings of the image-capturing device for estimating a radiance
value of the total 3D radiance field; and detecting and computing a
3D gas species field of the enclosure using a function of
statistical classification, threshold values or gradients in a
subset of the at least one 3D radiance field associated with the
settings of the image-capturing device.
14. The apparatus according to claim 9, wherein the registration
and alignment estimation unit is configured for: determining the
positional information by collecting a plurality of reference
points in the enclosure using markers recognizable by the
image-capturing device; calculating, a perspective transformation
of the image based on the reference points and the corresponding
image pixels; and aligning and registering a two-dimensional (2D)
temperature image based on the perspective transformation.
15. The apparatus according to claim 9, wherein the estimation unit
is configured for: computing the 3D radiance field of the enclosure
based on the aligned radiance images using a hierarchical,
multi-resolution method; performing the hierarchical,
multi-resolution method by applying a hierarchical coarse-to-fine
algorithm based on a resolution of the selected region; and
calculating inverses of matrices using a radiative transfer using
equation for each resolution computation of the selected region to
compute the 3D radiance field.
16. A non-transitory computer-readable medium storing instructions
executable by a computer processor to estimate a three-dimensional
(3D) radiance field of a combustion process in an enclosure,
comprising instructions to: perform an on-line
intensity-temperature calibration based on an association between
an intensity of an image pixel and an actual temperature associated
with a selected region in the enclosure; transform the intensity of
the corresponding image to a radiance image based on settings of an
image-capturing device and the on-line calibration; perform a
registration and alignment estimation of the image based on
positional information of the enclosure; align the radiance image
based on the registration estimation; and estimate, using a
computer processor, the 3D radiance field having voxels of the
enclosure based on a two-dimensional (2D)-to-3D transforming of the
aligned radiance images.
17. The medium according to claim 16, further comprising
instructions to: capture images of selected spectral bands in the
enclosure using a plurality of image capturing devices; estimate at
least one of the 3D radiance fields of the selected spectral bands
in the enclosure; map at least one of a temperature and a gas
species, and the corresponding intensity of the image pixel with
the settings associated with the image-capturing device; maintain
records of the intensity-temperature calibration in a storage
device; calculate a difference between a recorded
intensity-temperature calibration value associated with the image
pixel, and a current intensity-temperature calibration value; and
indicate that system maintenance is required when the difference
exceeds a predetermined threshold.
18. The medium according to claim 16, further comprising
instructions to: selectively adjust the settings of the
image-capturing device having parameters related to at least one of
a wavelength, an aperture, a shutter, and a gain; evaluate an
intensity histogram of the corresponding image during the
transforming of the intensity of the corresponding image to the 3D
radiance field; and adjust the settings of the image-capturing,
device based on the evaluation of the histogram.
19. The medium according to claim 16, further comprising
instructions to: compute a total 3D radiance field based on a
subset of the at least one 3D radiance field associated with the
settings of the image-capturing device for estimating a radiance
value of the total 3D radiance field; and detect and compute a 3D
gas species field of the enclosure using a function of statistical
classification, threshold values or gradients in a subset of the at
least one 3D radiance field associated with the settings of the
image-capturing device.
20. The medium according to claim 16, further comprising
instructions to: determine the positional information by collecting
a plurality of reference points in the enclosure using markers
recognizable by the image-capturing device; calculate a perspective
transformation of the image based on the reference points and the
corresponding image pixels; align and register a two-dimensional
(2D) temperature image based on the perspective transformation;
compute the 3D radiance field of the enclosure based on the aligned
radiance images using a hierarchical, multi-resolution method;
perform the hierarchical, multi-resolution method by applying a
hierarchical coarse-to-fine algorithm based on a resolution of the
selected region; and calculate inverses of matrices using a
radiative transfer equation for each resolution computation of the
selected region to compute the 3D radiance field.
Description
[0001] The present invention relates generally to a process for
estimating conditions of a combustion process, and more
particularly to a process for accurate estimation of a
three-dimensional thermal radiance field and gas species field of a
furnace enclosure.
BACKGROUND OF THE INVENTION
[0002] Accurately analyzing internal conditions of a furnace is an
essential task for an operator to better control temperatures of
different regions in a furnace enclosure for producing products
more efficiently and saving energy-related costs. Typically,
image-capturing devices, such as color cameras, infrared
spectrometers, filtered cameras, and the like, are installed in the
furnace enclosure for detecting the temperatures of the furnace
enclosure. Intensities of image pixels received from the devices
have a direct relationship with the temperatures of viewed surfaces
inside the furnace. Similarly, multi-spectral cameras have been
used to detect the temperature of a flame and gas species.
[0003] A certain method of video-based technology provides color or
intensity images to the operator allowing the operator to manually
interpret the state of the combustion process based on the images.
Another technology performs off-line intensity-temperature
calibration and maps each color image to a specific temperature
image, thereby providing a two-dimensional (2D) projection of the
temperature and/or radiance field. Other technologies, such as
laser, and acoustic, offer three-dimensional (3D) temperature
and/or radiance field estimation at specific locations inside the
furnace enclosure. However, a number of required sensors, a related
cost, and a complicated installation often make such systems
impractical in a large scale enclosure.
[0004] Another technology for video-based, three-dimensional
temperature and/or radiance field estimation applies thermal
radiation transfer equations to the temperature images. However,
this method is inefficient and inaccurate, and does not provide a
required resolution and accuracy due to complex, iterative
computations required to resolve unknown temperature and radiance
fields in the enclosure. Another reason for the inaccuracy is
attributed to poor-quality images caused by incorrect or limited
controls of the image-capturing devices. Achieving an acceptable
accuracy in high resolution and accurate alignment of the images
along with information about a physical structure of the enclosure
is essential. As discussed above, relative positions of the
image-capturing devices and imaging areas, such as enclosure walls,
often shift their alignments and thus cause significant errors.
[0005] A certain method uses multi-spectral imaging technology for
the detection of the gas composition in an open environment. This
method only detects the presence or absence of certain gases along
a viewing path, but cannot provide the distribution of gas species
in a three dimension field.
[0006] Therefore, there is a need for an improved method of
estimating and detecting temperature and radiance fields of the
enclosure without generating substantial errors or variations
during the combustion process of the furnace. Further, the
estimation of gas species field provides the operator a better tool
to improve the efficiency of the furnace enclosure.
BRIEF SUMMARY OF THE INVENTION
[0007] The present invention is directed to a process for
estimating and detecting three-dimensional temperature, radiance
and gas species fields of a furnace enclosure based on a set of
multi-spectral images captured by a plurality of multi-spectral
image-capturing devices.
[0008] An important feature of certain embodiments is that the
present process solves the problem of real-time visualization,
simulation and understanding of the combustion process in large
scale enclosure. The present process measures and indicates
chemical species and concentrations within an enclosure. Such
species information is used to selectively control the combustion
process by modulation or manipulation of input fuel sources,
combustion air sources, or mechanical features of an associated
burner or furnace based on indications from three-dimensional
optical spectral observations.
[0009] For example, a fuel/air ratio of a combustion system may be
adjusted. Exact locations or regions within n enclosure can be
determined, which contain the largest amounts of specific
pollutants or other combustion process intermediate reactants. A
burner operation or design may be modulated or modified to optimize
a specific desired response based on the determination. The desired
responses may include basic flame detection, reduction or
minimization of pollutants, optimization of the fuel/air ratio for
maximum fuel efficiency or other process needs, such as
optimization of radiant heat flux profile from a burner flame, or
maximization of specific reaction processes using a closed-loop
fuel/air ratio control of sub-stoichiometric combustion.
[0010] In practice, the present process may be applied to any
combustion enclosure, whose flames are generated by, for example,
premix, diffusion mix, solid fuel, liquid fuel, and gaseous fuel
used in industrial, residential, commercial, or power burners,
flares, or thermal oxidizers. It is also contemplated that the
present process may be used to validate and/or optimize indications
resulting from computational models of physical systems.
Specifically, in certain embodiments, the present process observes
a physical enclosure, and corresponding computational model input
parameters are adjusted to conform to the physical
observations.
[0011] Another important feature of certain embodiments is that the
present process utilizes an may of optical spectral detectors, such
as the multi-spectral image-capturing devices or cameras, disposed
in array alignment surrounding the enclosure. By surrounding the
furnace in the array alignment, tomographic reconstruction,
triangulation, or other processing, techniques can be used to
establish three-dimensional concentrations and spatial physical
locations of various combustion intermediate or final products. The
intermediate or final products include chemical radicals and
molecules, such as OH, NO, NOx, CO, CO.sub.2, N, N.sub.2, O.sub.2,
O, H, H.sub.2, H.sub.2O, C, S, SO, SO.sub.2, and SO.sub.3.
[0012] An advantage of the detectors arranged in the array
alignment is that high resolution of the resulting image and data
may be derived based on the images obtained from the detectors.
Since multiple detectors are arranged in a spaced pattern array
configuration, failures of one or more detectors due to breakage,
fouling, blocked field of view or other similar defects, only
affect a part of the array, and the remaining, functional detectors
continue to provide images and associated data. Each detector
detects an intensity of various light emissions from atomic or
molecular species residing in the enclosure across a predetermined
span of a light spectrum. Each atomic particle is blown to emit at
a specific frequency. Since the particle's light emission frequency
is unique and identifiable from those of other resident or
potentially resident particles, an individual constituent can be
automatically identified by a computer processer. Based on the
intensity of the frequency of detected radiance, an associated
degree of concentration or relative location can be inferred using
the computer processer.
[0013] By computationally employing tomographic reconstruction,
triangulation, or other suitable processing techniques to combine
the data from an array of detectors, three-dimensional geometric
and spatial properties of various species or atomic particles
molecules can be determined. Another advantage of certain
embodiments of the present process is that the determination of the
location and concentration of various chemical constituents within
the enclosure is performed in real-time and on-line to modulate
input streams or mechanical aspects of the burners/flame for
optimization of desired properties of the radiance and gas species
fields in the enclosure. The foregoing and other aspects and
features of the present invention will become apparent to those of
reasonable skill in the art from the following detailed
description, as considered in conjunction with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 illustrates an exemplary use of the present process
in a camera system configuration;
[0015] FIG. 2 illustrates an exemplary system for a 3D radiance
field and gas species field estimation using the camera system
shown in FIG. 1;
[0016] FIG. 3 is a functional block diagram of the present process
featuring functional units in accordance with an embodiment of the
present disclosure;
[0017] FIG. 4 illustrates an exemplary output of the 3D thermal
radiance field estimation from the system shown in FIG. 2; and
[0018] FIG. 5 illustrates an exemplary output of the 3D gas species
field estimation from the system shown FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
[0019] Referring now to FIG. 1, an exemplary estimation unit 10
using an embodiment of the present process is provided for
accurately estimating a three-dimensional temperature and thermal
radiance field of a combustion process inside a large scale
enclosure 12, such as an industrial furnace. As used herein, the
term "unit" may refer to, be part of, or include an Application
Specific Integrated Circuit (ASIC), an electronic, circuit, a
computer processor (shared, dedicated, or group) and/or memory
shared, dedicated, or group) that executes one or more software or
firmware programs, a combinational logic circuit, and/or other
suitable components that provide the described functionality. Thus,
while this disclosure includes particular examples and arrangements
of the units, the scope of the present process should not be so
limited since other modifications will become apparent to the
skilled practitioner.
[0020] The estimation unit 10 is coupled to a server or computing
device 14 (including a, e.g., database and video serve and is
programmed to perform tasks and display relevant data for different
functional units via, a network 16. It is contemplated that other
suitable networks can be used, such as a corporate Intranet, a
local area network (LAN) or a wide area network (WAN), and the
like, using dial-in connections, cable modems, high-speed ISDN
lines, and other types of communication methods known in the art.
All relevant information can be stored in the databases for
retrieval by the estimation unit 10 or the computing device 14
(e.g., as a data storage device and/or a machine readable data
storage medium carrying computer programs).
[0021] A plurality of image-capturing devices 18 are mounted around
the enclosure 12 (with two devices 18 being shown in this example,
but with additional devices being included, if desired). The
image-capturing devices have the ability to capture the response in
one or multiple parts of the electromagnetic spectrum including
visible, ultra-violet, near infrared (NIR), mid wave infrared
(MWIR) and long wave infrared (LWIR). The devices can be configured
to capture data in specific spectrum bands as required by detection
of targeted gas species (e.g., detect presence of carbon monoxide).
In addition, the devices can be auto-configured to detect a
specific range of temperatures or radiance field. Further, each of
the image capturing devices can be individually configured for a
specific spectrum band to increase the efficiency of the system and
enable detection of multiple gas species in one or different
regions of the furnace. Each image-capturing device 18 can be
liquid-cooled by directing the inflow of cold coolant C.sub.IN to
the device, and delivering the outflow of warm coolant C.sub.OUT
from device to an outlet.
[0022] Each of the image-capturing devices 18 captures image
sequences covering a selected interior portion or region of the
enclosure 12 for which a temperature-radiance field and gas species
field are to be estimated. A plurality of temperature sensors 20,
such as thermal couples or pyrometers, which are each observable by
one or more image-capturing devices 18, are placed inside the
enclosure 12. Optional markers 22, which are within a field of view
(FOV) of the image-capturing devices 18, may also be placed inside
the enclosure 12.
[0023] Cables 24 (or other signal transferring means, such as
wireless communication) connect the image-capturing devices 18 and
the temperature sensors 20 to the computing device 14, which may
also have digitization, storage, and user interface capabilities.
The computing device 14 receives temperature outputs or signals
from the temperature sensors 20 and image sequences from the
image-capturing devices 18 to set proper parameters of the
image-capturing devices for performing subsequent calibration,
registration and estimating, temperature-radiance field of the
selected region.
[0024] It is an important task for an operator to optimally set the
parameters related to the combustion process for maximum product
maximum energy efficiency, and minimum flue gas consumed. Often,
the operator selectively controls the combustion process based on a
visual estimation of a state of the process at specific locations
inside the enclosure 12. Acquiring the states of the process
necessitates the knowledge of the three-dimensional temperature and
radiance field inside the enclosure 12.
[0025] In one embodiment, three-dimensional temperature and
radiance fields are computed from a set of images, which are
captured by optimally placed image-capturing devices 18 in the
enclosure 12. As shown in FIG. 1, the plurality of image-capturing
devices 18 are disposed in the enclosure 12, and the plurality of
thermal couples or pyrometers 20 are disposed at selected locations
of the enclosure for collecting data. The estimation unit 10
calculates and determines the temperature and radiance fields of
the selected regions of the enclosure 12 based on the collected
data.
[0026] Referring now to FIG. 2, a schematic flow diagram of the
three-dimensional radiance and gas species field estimation system
illustrates its high level processes and the outputs of each
process. The estimation unit 10, also known as a 3D radiance field
estimator 11, computes the three-dimensional radiance fields of the
furnace enclosure. Each three-dimensional radiance field
corresponds to a particular spectral wavelength .lamda..sub.i.
Having received the multi-spectral images from the multi-spectral
image capturing devices 18, the 3D radiance field estimator 11
segregates the multi-spectral images into groups of images, each
group corresponds to images of a spectral wavelength,
.lamda..sub.i. Using each group of images of a spectral wavelength,
.lamda..sub.i, the 3D radiance field estimation process, which is
discussed below with respect to FIG. 3, generates a 3D radiance
field at wavelength, .lamda..sub.i. As a result, groups of 3D
radiance fields at wavelengths, .lamda..sub.1,2,3, . . . , n, 40,
42, 44, . . . , 46 are generated. The different wavelengths may
correspond to spectral bands in the visible spectrum, e.g., red,
blue and green or other spectral bands of the ultra-violet,
mid-wave infrared and long-wave infrared spectra.
[0027] Each of the 3D radiance fields 40, 42, 44, 46 consists of
the voxels, 48, 47, 41 and 49 respectively. A 3D radiance field is
composed of voxels. A voxel represents a 3D volume region in the
furnace enclosure. Each voxel has an estimated value of the
radiance at the wavelength .lamda..sub.i in a corresponding volume.
A 3D total radiance field estimator 50 combines two or more outputs
of 3D radiance fields at different wavelengths. The result is a
total 3D radiance field 54. For example, the total radiance can be
computed in the visible spectrum by summing the radiance fields
from red, green and blue wavelengths. Further details are described
below with respect FIG. 4. A 3D gas species field estimator 52
detects the presence of gas species and computes their radiance in
each of the voxels. The output of the unit 52 is a
three-dimensional gas species field 56. Further details are
described below with respect to FIG. 5.
[0028] Referring now to FIG. 3, an explanation will be provided of
how the estimation unit 10, of this embodiment, computes a 3D
radiance field from a group of images at spectral wavelength
.lamda..sub.i. Included in the estimation unit 10 are an
intensity-temperature calibration unit 26, an intensity-temperature
transformation unit 28, a registration and alignment estimation
unit 30, a motion-connected temperature estimation unit 32, a 3D
temperature-radiance estimation unit 34 and a 3D model of the
furnace enclosure 36.
[0029] Intensities of the image pixels received from the
image-capturing devices 18 are directly related to the temperatures
of viewed surfaces in the enclosure 12. Calibration is performed to
establish this relationship between the temperatures and
intensities. According to Stefan-Boltzmann law, the radiant flux is
proportional to the fourth power of the temperature. Thus a
transformation from image intensity to radiance can be established
based on the intensity to temperature relationship. Herein
temperature and radiance are used interchangeably.
[0030] Conventional calibrations were performed based on an
infrequent and inadequately updated off-line process. However, the
image-capturing device response could become unstable in
high-temperature, dynamic operating conditions. Consequently, the
unstable response would render errors related to
intensity-temperature transformation due to the stale off-line
calibration.
[0031] On the other hand, in one preferred embodiment of the
present device and method, thermal couples or pyrometers 20 are
placed at selected locations in the enclosure 12 to be viewed or
read by the image-capturing devices 18. The intensity-temperature
calibration unit 26 performs an on-line calibration determining a
relationship between an intensity of an image pixel and an actual
temperature, which is established by using polynomial regression
mapping temperature outputs and the corresponding pixel intensities
from the image-capturing devices 18 with associated device
settings.
[0032] The intensity-temperature calibration unit 26 also maintains
records of the intensity-temperature calibration in a storage
device, and compares the calibration data on-line during the
combustion process. As the responses from the image-capturing
devices 18 become degraded, or the lenses of the devices become
dirty, current intensity-temperature calibration values differ from
original or initial values in record. The intensity-temperature
calibration unit 26 calculates the difference between the original
value and the current values. When the difference exceeds a
predetermined threshold, such as 15%, the intensity-temperature
calibration unit 26 flags a maintenance request indicator to signal
that system maintenance is required. The predetermined threshold
can vary depending on the application, and can be edited b the
operator.
[0033] Based on the intensity-temperature calibration, the
intensity-temperature transformation unit 28 transforms the
intensities of the corresponding images to the temperature values
based on the device settings and the image pixels. An exemplary
intensity-temperature calibration unit 26 and the
intensity-temperature transformation unit 28 are disclosed in
commonly assigned U.S. Patent Application No. ______ (Attorney
Docket No. 5066.116930), which is incorporated by reference in its
entirety.
[0034] A dynamic range of image pixel values is limited to a number
of bits per pixel. However, the temperature of the combustion
process can reach up to 2500.degree. F. or 1400.degree. C. To cover
an entire temperature range (e.g., 0-2500.degree. F. or
0-1400.degree. C.) the device parameters or settings, such as
aperture, shutter, and gain can be selectively set and adjusted.
During this intensity-temperature transformation, an intensity
histogram of the image is evaluated by the intensity-temperature
transformation unit 28. If the histogram is skewed or becomes
uneven at a low or high end, the intensity-temperature
transformation unit 28 makes appropriate changes in the parameters
or settings of the image-capturing devices 18. This enables
acquisition of the images with an optimal intensity range under the
current operating conditions.
[0035] Unwanted movement of the image-capturing devices and imaging
areas often occurs in the furnace enclosure 12. Specifically, in an
industrial environment, vibrations and shakings of furnace walls
can be caused by adjacent pieces of equipment that are frequently
in contact with the furnace during operation. Since a temperature
field computation relies on an accurate line of sight association
with the physical structure, significant errors result if a
relative motion of the image-capturing device 18 is not correctly
set and adjusted. The accurate line of sight requirement is
especially important for a high resolution temperature field
computation. Correction of these unwanted movements is accomplished
by the registration and alignment estimation unit 30 and the
motion-corrected temperature estimation unit 32.
[0036] The registration and alignment estimation unit 30 computes a
registration alignment estimation for each of the multispectral
image capturing devices 18 viewing a physical enclosure 12.
Characteristic features that are distinct and easily recognizable
in the multispectral image, such as view ports and corners of the
furnace enclosure 12, are initially selected and subsequently
detected. Their positional information in the image is associated
with the three-dimensional geometrical coordinates of the
enclosure, which can be determined from a 3D model 36. As mentioned
above, it is preferred that readily recognizable markers 22, such
as triangular ceramic tiles, are placed in the enclosure 12.
Geometrical locations of these characteristic features also
constitute reference points of the furnace enclosure 12.
Corresponding pixel coordinates in the multi-spectral images are
correlated with the geometrical locations of these markers 22.
[0037] The registration and alignment estimation unit 30 calculates
a perspective transformation of the multi-spectral images based on
these two sets of data, i.e., the geometrical reference points and
the corresponding image pixel locations. After an application of
the transformation on the temperature images, two-dimensional (2D)
temperature images are aligned and registered by the registration
and alignment estimation unit 30.
[0038] The motion-corrected temperature estimation unit 32 performs
the perspective transformation on the temperature image, which is
computed from the intensity-temperature transformation unit 28,
such that the geometrical reference points and the corresponding
image pixel locations are in alignment. In other words, the same
pixel location represents the same physical location of the furnace
a sequence of images. The correct temperatures of the furnace area
are easily determined based on the corresponding image pixels even
under relative motion of the image capturing devices 18. The output
is a registered temperature image.
[0039] The 3D temperature-radiance estimation unit 34 applies a
hierarchical, multi-resolution method to compute a
three-dimensional temperature-radiance field of the furnace
enclosure 12 based on the registered two-dimensional temperature
images. When an operator is interested in certain areas or volumes
in the enclosure 12 (e.g., the burners, or pipes), higher
resolution is needed in the interested areas, but lower resolution
is sufficient for the uninterested areas. For example, a
hierarchical coarse-to-fine algorithm can be used to achieve or
perform this multi-resolution method. An exemplary hierarchical,
multi-resolution method is disclosed in commonly assigned U.S.
patent application Ser. No. 14/177,005, which is incorporated by
reference in its entirety.
[0040] For example, the 3D temperature-radiance estimation unit 34
calculates the 3D temperature field based on a coarse resolution
(e.g., a 1 cubic feet) as mentioned above. The next resolution 3D
temperature field (e.g., 0.125 cubic feet) may then be computed
from the results of the initial resolution. The temperature field
with fine resolution can be iteratively computed. However, only
areas of interest and associated voxels need to be traversed down
the hierarchy to the fine resolution. Inverses of matrices
calculated using a radiative transfer equation are required in each
resolution computation. An important aspect of this hierarchical,
multi-resolution method is that computational time can be
significantly saved during computation, and thus can be used as a
real-time, on-line application. The above 3D radiance field
estimator 11 is applied to groups of spectral images at wavelength
X resulting in y 3D radiance fields, each at a specific wavelength
.lamda..sub.i.
[0041] Referring again to FIG. 2, the 3D total radiance field
estimator 50 combines one or more 3D radiance fields to form a
total radiance field of a broader spectrum, including, for example,
visible or mid-wave infrared. Depending on the application, one of
several combination methods, such as weighted sum, sum of
interpolation and extrapolation, can be applied. Weight sum method
computes the total radiance as the sum of the products of radiance
at wavelength .lamda..sub.i and weight w.sub.i. For example, the
visible spectrum radiance is often computed by a weighted sum of
red, green and blue radiances. Sum of interpolation and
extrapolation method first extrapolate or interpolate radiance at
other wavelengths and then sum all the original, interpolated and
extrapolated radiances. The result is the total 3D radiance field
54, which is further described in FIG. 4.
[0042] As shown in FIG. 4, voxels 60, 62., 64, 66 and 68 are
examples of different voxels in the total radiance field. It can be
seen that the voxel 62 is of a smaller size compared to the voxel
60. The voxel 60 is estimated to have a radiance value of R.sub.1.
Similarly, voxels 64 and 68 are shown to have output radiance
estimates of R.sub.2 and R.sub.3, respectively. Each voxel, e.g.,
voxel 66, has a radiance output value of R.sub.n.
[0043] Referring again to FIG. 2, the 3D gas species field
estimator 52 detects and computes the composition of different
gases in the furnace enclosure based on groups of 3D radiance
fields at a selected wavelength .lamda..sub.i. Radiance of each
voxel in a radiance field at the wavelength is contributed from
that of the gas species and an in that voxel. Spatial and temporal
filtering is applied to each voxel to estimate and remove its
radiance due to air. The residual radiance is due to the gas
species. A radiance feature vector is generated from the
corresponding voxels in the groups of radiance fields. For example,
the residual radiance from voxels 48, 47, 41, and 49 forms a
radiance feature vector. Classification method, such as a support
vector machine, random forest, Bayesian model, determines the
presence or absence of the target gas species. The radiance of the
gas species in the output voxel can be estimated from the strength
of the radiance feature vector. Compiling the results from each
voxel creates the 3D gas species field 56.
[0044] In another embodiment, the 3D gas species field 56 can he
computed with a function of a threshold value or gradient in
selected 3D radiance fields of specific wavelengths .lamda..sub.i.
For example, a voxel having high radiance or high radiance gradient
relative to the average of its surrounding voxels in the visible
spectrum and that same voxels having threshold value or gradient
value in the blue wavelength implies the presence of hydroxyl in
that voxel. A voxel having high radiance or high radiance gradient
relative to the average of its surrounding voxels in the visible
spectrum and that same voxels having threshold value or gradient
value in the green wavelength implies hydrogen combustion in that
voxel. A voxel having high radiance or high radiance gradient
relative to the average of its surrounding voxels in the visible
spectrum and that same voxels having threshold value or gradient
value in the yellow wavelength (combination of red and green
wavelengths) implies carbon cracking within a flame in that voxel.
The resulting functional values can be used directly or correlated
with a data table of known concentrations relative to the signal
strength of the function.
[0045] Referring now to FIG. 5, the output 3D gas species field 56
is described in greater detail. Voxels 70, 72, 74, and 76 have
different gas species as detected by the 3D gas species field
estimator 52. Same gas species often occurs at groups of voxels,
such as a region 78, which is a region consisting of e.g., CH.sub.4
(methane). A voxel in the 3D gas species field may not have a gas
species. It may have only air in that voxel. Accurate detection of
gas composition and concentrations help optimize the burner
efficiency and increase the total system yield.
[0046] While a particular embodiment of the present estimation
process has been described herein, it will be appreciated by those
skilled in the art that changes and modifications may be made
thereto without departing from the invention in its broader aspects
and as set forth in the following claims.
* * * * *