DESC:NON-CONTACT SMART POSITIONING HARDWARE DEVICE FOR REAL-TIME BURNER PIPE MONITORING USING IMAGE PROCESSING WITHOUT OBJECT DETECTION MODEL TRAINING

CLAIM OF PRIORITY:
[0001] This patent application claims the priority from the provisional patent application number 202421076058 dated 8th October, 2024 titled “NON-CONTACT SMART POSITIONING HARDWARE DEVICE FOR REAL-TIME BURNER PIPE MONITORING USING IMAGE PROCESSING WITHOUT OBJECT DETECTION MODEL TRAINING”.

FIELD OF THE INVENTION
[0002] The present invention generally relates to the technical fields of industrial process monitoring and control, unsupervised learning, image analytics, non-contact sensor, real time digitalisation of kiln burner position, specifically relates to non-contact-based systems for real-time position measurement of critical components. More particularly, it pertains to a smart hardware device utilizing image processing techniques to monitor and measure the precise position and movement of a kiln burner pipe without the need for object detection model training.

BACKGROUND OF THE INVENTION
[0003] In industrial settings, precise monitoring of critical components is essential for maintaining efficiency, safety, and operational continuity. One such critical component in the operation of furnaces is the burner pipe. The position of the burner pipe significantly impacts the combustion process, thermal efficiency, and the overall reliability of the furnace. Traditional methods for monitoring the burner pipe’s position, such as contact-based sensors and manual inspections, suffer from various limitations, including noise due to uneven thermal expansion, mechanical lag, wear and tear of components, frequent calibration requirement issues, and difficulties in real-time monitoring and transmitting. Proximity of any sensor requiring a hardware which needs to be physically connected to the hot surface of the burner pipe puts special requirement of costly heat-resistant material of construction,
[0004] Existing systems like the one described in US Patent 10,823,401 focus on controlling thermal radiation within a burner system to ensure efficient combustion. While this approach is vital for managing thermal patterns, it does not address the precise monitoring of the burner pipe's position. Similarly, US Patent Application 20230329590 describes a non-contact monitoring system using depth sensing cameras, mainly intended for medical applications like monitoring a patient’s respiratory movements. Although this technology offers non-contact monitoring capabilities, it is not tailored for industrial applications like furnace burner pipe monitoring.
[0005] US20240102737 provides an imaging device integrated within a burner, which allows for visual monitoring and control of the heating process. However, this system is focused more on visual observation of the actual combustion process rather than accurate position measurement of components like the burner pipe, which is essential for effective energy transfer of the combustion heat to process material. Moreover, these conventional systems often rely on object detection models that require extensive training and calibration, adding to the complexity and lead time for deployment. There are mechanical systems connected directly, physically to the burner pipe measuring the movement of the pipe. But these are affected by the mechanical vibrations and thermal shocks present on the burner pipe during the burning operation.
[0006] Given the limitations of existing technologies, there is a need for a non-contact, high-resolution device that can accurately monitor the real-time position of a burner pipe without the need for object detection model training. Such a device should be capable of providing precise measurements that account for thermal expansion and movement of the burner pipe, thus ensuring optimal combustion and enhancing the overall efficiency and reliability of the furnace.

OBJECT OF THE INVENTION:
[0007] With reference to the above background explanation, the present invention of a non-contact smart positioning hardware device for real-time burner pipe monitoring using image processing without object detection model training has following objectives to solve the limitations of the conventional systems, devices and methods.
[0008] The principal objective of the invention is that by introducing a non-contact-based smart hardware device that utilizes image processing techniques to provide real-time, high-resolution position data of the burner pipe.
[0009] Another objective of the present invention is that the said device does not require any object detection model training, making it more straightforward to deploy and maintain in industrial environments.
[0010] Another objective of the present invention is that the device operates effectively under varying light conditions such as day or night, and no calibration required as long as the working environment remains consistent.
[0011] Another objective of the present invention is that the device ensures more accurate monitoring and control of critical industrial processes.
SUMMARY OF THE INVENTION
[0012] The present invention relates to a non-contact smart hardware device combined with intelligent software system designed for real-time, high-resolution monitoring of the position of a kiln burner pipe. Utilizing advanced, unsupervised image processing techniques, this device eliminates the need for object detection model training, providing an innovative solution for measuring thermal expansion and movement in the burner pipe, which are critical for maintaining optimal combustion processes and thermal efficiency in industrial furnaces.
[0013] In one aspect, the smart hardware device comprises a transmitter module and a receiver module. The transmitter module, equipped with two colour patches placed at a precise distance is tethered to the kiln burner pipe, ensuring synchronized movement between the two. The receiver module, a stationary processor-inbuilt smart hardware device housed in an enclosure, captures the image of the transmitter module and the burner pipe at configurable intervals. The device then uses a proprietary algorithm to compute the precise position and deviation of the burner pipe in both X and Y dimensions, with millimetre level accuracy and resolution.
[0014] A significant advantage of this invention is its ability to operate without requiring any external calibration (it has its inbuilt re-calibration algorithm based on reference image marks on the burner transmitter device), provided that the working environment remains unchanged, within the prescribed view of the camera in the receiver device. The device is capable of functioning effectively in various lighting conditions (has its own inbuilt image correction module to remove any unfocussed area, alignment, detect and reject any image with external disturbance etc.), covering a displacement range of 0 to 500 mm in both X and Y directions. Additionally, the system's design ensures that both the transmitter and receiver can remain in place during plant emergencies or maintenance, minimizing downtime and enhancing operational efficiency.
[0015] In another aspect, the device’s output can be integrated into Distributed Control Systems (DCS), and/or possible option to send the readings of the kiln position directly to the cloud server (using the available data network) or in-built SIM, enabling continuous monitoring of the kiln burner position. This integration allows operators, process team to take corrective actions as needed, leading to improved plant reliability and reduced stoppage times.
[0016] Further advantages of the present invention include its low lead time for installation due to the elimination of object detection model training, and its adaptability to varying distances between the transmitter and receiver, ensuring precise positional readings under different operational conditions. The invention represents a significant advancement in the field of industrial process monitoring, offering a robust, reliable, and easy-to-deploy solution for maintaining the efficiency and safety of furnace operations.
[0017] In yet another aspects and advantages of the present disclosure will become apparent to those skilled in this art from the following detailed description, wherein only illustrative embodiments of the present disclosure are shown and described. The present disclosure is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, and its several details are capable of modifications in various obvious respects, all without departing from the disclosure. Accordingly, the drawings, description and examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
[0018] The systems, methods and apparatus disclosed herein may be implemented in any means for achieving various aspects. Other features will be apparent from the accompanying drawings and from the detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS:
[0019] So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may have been referred by embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments. These and other features, benefits, and advantages of the present invention will become apparent by reference to the following text figure, with like reference numbers referring to like structures across the views, wherein:
[0020] Figure 1 illustrates a non-contact-based smart hardware device that utilizes image processing techniques to provide real-time, high-resolution position data of the burner pipe, according to the present invention.
[0021] Figure 2 illustrates transmitter image marks which are used to self-calibrate the resolution or pixel to distance ratio, according to the present invention.
[0022] Figure 3 illustrates a real assembly and fixture as installed at the plant with the burner pipe assembly, according to the present invention.
[0023] Figure 4 shows the information flow and position detection workflow, according to the present invention.
[0024] Figure 5A is a process flow of a non-contact smart positioning hardware device for real-time burner pipe monitoring using image processing without object detection model training, according to the present invention.
[0025] Figure 5B is a continuation of process flow from Figure 5A of the non-contact smart positioning hardware device for real-time burner pipe monitoring using image processing without object detection model training, according to the present invention.
[0026] Other features of the present embodiments will be apparent from the accompanying drawings and from the detailed description that follows.

DETAILED DESCRIPTION OF THE INVENTION:
[0027] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and the following description. Numerous variations, changes and substitution may occur to those skilled in the art without departing from the invention. It should be understood that various alternatives to the embodiments of the present disclosure herein may be employed.
[0028] At the outset, for ease of reference, certain terms used in this application and their meanings as used in this context are set forth. To the extent a term used herein is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in at least one printed publication or issued patent. Further, the present techniques are not limited by the usage of the terms shown below, as all equivalents, synonyms, new developments, and terms or techniques that serve the same or a similar purpose are considered to be within the scope of the present claims.
[0029] The articles “a” and “an” as used herein mean one or more when applied to any feature in embodiments of the present invention described in the specification and claims. The use of “a” and “an” does not limit the meaning to a single feature unless such a limit is specifically stated. The article “the” preceding singular or plural nouns or noun phrases denotes a particular specified feature or one or more particular specified features and may have a singular or plural connotation depending upon the context in which it is used. The adjective “any” means one, some, or all indiscriminately of whatever quantity.
[0030] The present invention relates to a non-contact smart hardware device designed to monitor the real-time position of a kiln burner pipe using advanced image processing techniques. The device ensures high-resolution, accurate measurements that are essential for optimizing the combustion process, enhancing thermal efficiency, and ensuring the reliability of the furnace system.
[0031] Figure 1 illustrates a non-contact-based smart hardware device (100) that utilizes image processing techniques to provide real-time, high-resolution position data of the burner pipe, according to the present invention.

REFERENCE NUMERALS:
Kiln burner pipe (102)
Transmitter module (104)
Receiver module (106)
Direction of motion of pipe (108)
[0032] As illustrated in the accompanying Figure 1, the system consists of two primary components such as a Transmitter or Transmitter module (104) and a Receiver or Receiver module (106). The Transmitter (104) is affixed to the kiln burner pipe (102), and the Receiver (106) is positioned at a distance, aligned in such a way that it faces the transmitter (104). The configuration of these components enables the device to accurately monitor the position and movement of the burner pipe (102) without physical contact.
[0033] In one or more embodiments, the Transmitter (104) is a crucial part of the system, designed or structured to move synchronously with the kiln burner pipe (102). The Transmitter (104) includes two color patches that are placed at a precise distance from each other on a flat surface. In an aspect, the two-color patches are placed at a distance of 100mm. In another aspect, the two-color patches are placed at a distance of 150mm. This Transmitter (104) is securely tethered to the kiln burner pipe (102) so that any movement or thermal expansion of the pipe is directly reflected by the movement of the Transmitter (104). The precise placement of the color patches allows the system to measure positional changes in both the X and Y axes.
[0034] In one or more embodiments, the Receiver (106) is a stationary unit that houses a smart hardware device (100) with a built-in processor. It is equipped with various auxiliary components, including a camera for capturing images of the Transmitter (104), a light adjustment mechanism to ensure optimal image quality under varying light conditions, a display screen, and control buttons for user interaction. The Receiver (106) is powered by an external power source and is encased within an enclosure to protect it from environmental factors.
[0035] In one or more embodiments, during operation, the Receiver (106) continuously captures images of the Transmitter (104) and the kiln burner pipe (102) at configurable intervals. In an aspect, the Receiver (106) captures images of the Transmitter (104) and the kiln burner pipe (102) at an interval of 60 seconds. In another aspect, depending on the process requirements the Receiver (106) captures images of the Transmitter (104) and the kiln burner pipe (102) at an interval of 120 seconds. The captured images are processed using a proprietary algorithm embedded within the Receiver's processor. This algorithm analyzes the position of the color patches on the Transmitter (104) and calculates the relative displacement of the kiln burner pipe (102) with high precision. The displacement is expressed in terms of X and Y coordinates, providing accurate real-time data on the position of the burner pipe (102).
[0036] In one or more embodiments, when the reset button on the Receiver (106) is pressed, the current position of the Transmitter (104) is set as the reference point (0, 0). All subsequent positional data is calculated relative to this reference point, allowing for precise tracking of the burner pipe’s (102) movement over time. The device (100) operates effectively under varying light conditions, making it suitable for use in both day and night shifts without requiring additional calibration, provided that the working environment remains constant.
[0037] Figure 2 illustrates transmitter image marks which are used to self-calibrate the resolution or pixel to distance ratio, according to the present invention.
REFERENCE NUMERALS:
Reference center point and linear displacement (202)
Angular movement sideways (204)
Angular movement up and down (206)

[0038] Particularly, Figure 2 illustrates transmitter image marks which are used to self-calibrate the resolution or pixel to distance ratio, and then detect the movement of the burner and benchmark with the zero position to detect the exact position and movement of the burner pipe (102) in X&Y direction. The AKXA algorithm processes these images to determine the pipe’s position and deviation with millimeter accuracy. The movement the kiln burner pipe (102) is detected based on the image mark’s relative positions such as reference center point and linear displacement (202), angular movement sideways (204) and angular movement up and down (206) as shown in Figure 2.
[0039] Figure 3 illustrates a real assembly and fixture as installed at the plant with the burner pipe assembly, according to the present invention. The hardware can be seen the figure to give the idea of non-contact nature of the receiver from the burner transmitter.
[0040] Figure 4 shows the information flow and position detection workflow, according to the present invention. This logic and steps are used to arrive at the current position of the burner in X and Y direction, repeated every 60 – 120 seconds depending on the set scanning time. The algorithm is employed in every iteration to achieve the real time position of the burner pipe in X and Y direction with reference to the standard position of color patches.
[0041] Figure 5A is a process flow of a non-contact smart positioning hardware device for real-time burner pipe monitoring using image processing without object detection model training, according to the present invention.
[0042] Particularly, Figure 5A illustrates from the staring process which initiates at step 502. At step 504, the method includes synchronizing a transmitter module movement with a movement of kiln burner pipe. At step 506, configuring a camera of receiver module for capturing images received from of the transmitter module and the kiln burner pipe at predetermined intervals. At step 508, configuring a processor of the receiver module for analyzing the captured images and determining the position of the transmitter module in X and Y coordinates based on the relative position of the color patches. At step 510, transmitting the determined position data by an output interface to an external system for monitoring and control.
[0043] Figure 5B is a continuation of process flow from Figure 5A of the non-contact smart positioning hardware device for real-time burner pipe monitoring using image processing without object detection model training, according to the present invention.
[0044] Particularly, Figure 5B illustrates a continuation of process flow from Figure 5A continues from step 512, the method includes configuring a reset mechanism to set the current position of the transmitter module as a reference point (0, 0) upon activation for calculating subsequent kiln burner pipe positions in X-Y coordinates. At step 514, wherein, the said device is configured to provide accurate position monitoring across a displacement range from 0 to 500 mm in both X and Y directions. At step 516, wherein the transmitter module consists of at least two-color patches spaced at a precise distance on a flat surface and wherein, the transmitter module being securely tethered to the kiln burner pipe. At step 518, wherein the stationary receiver module, including camera, light adjustment system, display screen and control buttons, captures images of the transmitter module and burner pipe at configurable intervals and the method terminates at step 520.
MAIN ADVANTAGES ASSOCIATED WITH THE PRESENT INVENTION:
? No Calibration Required: The device does not require calibration (after first installation and one time configuration of position markings using a “self-calibration” algorithm in the receiver), making it easy to install and maintain, especially in environments where operational conditions remain consistent.
? High-Resolution Monitoring: The system provides millimeter-level accuracy in detecting the position of the burner pipe, ensuring optimal combustion and thermal efficiency.
? Non-Contact Operation: The non-contact design eliminates wear and tear, ensuring long-term reliability and reducing the need for frequent maintenance.
? Versatility in Lighting Conditions: The device is capable of functioning under various lighting conditions, eliminating the need for additional lighting adjustments or compensations.
? Integration with DCS: The output from the Receiver can be integrated into Distributed Control Systems (DCS) or transmitted directly to the cloud server for IoT applications, for continuous monitoring, allowing operators to take timely corrective actions and reduce plant stoppages.
? This advanced monitoring device represents a significant improvement over traditional contact-based or manual monitoring systems, offering a robust, reliable, and easy-to-deploy solution for maintaining the efficiency and safety of industrial furnace operations.
? The invention is essential for ensuring optimal combustion, thermal efficiency, and reliability of furnaces by accurately detecting positional changes caused by thermal expansion or other factors.

[0045] Additionally, while the constructional and operational process described above and illustrated in the drawings is shown as a sequence of steps, this was done solely for the sake of illustration. Accordingly, it is contemplated that some constructional and operational steps may be added, some constructional steps may be omitted, the order of the constructional steps may be re-arranged, and/or some constructional steps may be performed simultaneously.

[0046] Although embodiments have been described with reference to specific example embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the system and method described herein. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense.

[0047] Many alterations and modifications of the present invention will no doubt become apparent to a person of ordinary skill in the art after having read the foregoing description. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. It is to be understood that the description above contains many specifications these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the personally preferred embodiments of this invention. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents rather than by the examples given. ,CLAIMS:WE CLAIM:
1. A non-contact smart positioning hardware device for real-time burner pipe monitoring through an image processing, comprising:
a kiln burner pipe (102);
a transmitter module (104);
a receiver module (106);
Characterized in that,
the transmitter module (104) consists of at least two-color patches spaced at a distance on a flat surface;
the transmitter module (104) being securely tethered to the kiln burner pipe (102) such that movement of the transmitter (104) is synchronized with the movement of the kiln burner pipe (102);
a receiver module (106) comprising:
a camera is configured to capture images received from of the transmitter module (104) and the kiln burner pipe (102) at predetermined intervals;
a processor is configured to analyze the captured images and determine the position of the transmitter module (104) in X and Y coordinates based on the relative position of the color patches;
an output interface for transmitting the determined position data to an external system for monitoring and control;
a reset mechanism is configured to set the current position of the transmitter module (104) as a reference point (0, 0) upon activation that calculates subsequent kiln burner pipe (102) positions in X-Y coordinates; and
said device (100) is configured to provide accurate position monitoring across a displacement range from 0 to 500 mm in both X and Y directions.
2. The non-contact smart hardware device for real-time burner pipe monitoring as claimed in claim 1, wherein the receiver module (106) consisting of the camera and the processor is communicatively coupled to the transmitter module (104) through the network for image data transmission.

3. The non-contact smart hardware device for real-time burner pipe monitoring as claimed in claim 1, wherein the stationary receiver module (106), including camera, light adjustment system, display screen and control buttons, captures images of the transmitter module (104) and burner pipe (102) at configurable intervals.

4. The non-contact smart hardware device for real-time burner pipe monitoring as claimed in claim 1, wherein the device (100) is configured to operate with an inbuilt re-calibration system based on reference image marks on the burner transmitter device under consistent environmental conditions.

5. The non-contact smart hardware device for real-time burner pipe monitoring as claimed in claim 1, wherein the receiver module (106) is powered by an external power source and encased within an enclosure to protect from environmental factors.

6. A method for real-time burner pipe monitoring through an image processing by non-contact smart positioning hardware device, comprises the steps of:
synchronizing a transmitter module (104) movement with a movement of kiln burner pipe (102);
configuring a camera of receiver module (106) for capturing images received from of the transmitter module (104) and the kiln burner pipe (102) at predetermined intervals;
configuring a processor of the receiver module (106) for analyzing the captured images and determining the position of the transmitter module (104) in X and Y coordinates based on the relative position of the color patches;
transmitting the determined position data by an output interface to an external system for monitoring and control;
configuring a reset mechanism to set the current position of the transmitter module (104) as a reference point (0, 0) upon activation for calculating subsequent kiln burner pipe (102) positions in X-Y coordinates; and
wherein, the said device (100) is configured to provide accurate position monitoring across a displacement range from 0 to 500 mm in both X and Y directions.

7. The method as claimed in claim 6, wherein the transmitter module (104) consists of at least two-color patches spaced at a distance on a flat surface and wherein, the transmitter module (104) being securely tethered to the kiln burner pipe (102).

8. The method as claimed in claim 6, wherein the stationary receiver module (106), including camera, light adjustment system, display screen and control buttons, captures images of the transmitter module (104) and burner pipe (102) at configurable intervals.

9. The method as claimed in claim 6, wherein the device is configured to operate with an inbuilt re-calibration system based on reference image marks on the burner transmitter device under consistent environmental conditions.

10. The method as claimed in claim 6, wherein the receiver module (106) consisting of the camera and the processor is communicatively coupled to the transmitter module (104) through the network for image data transmission.