A multispectral radiation thermometry platform
based on wireless data transmission
KAIHUA ZHANG,1 KUN YU,1 AND YUFANG LIU 1, 2, 3
1Henan Key Laboratory of Infrared Spectrum Measures and Applications, School of Physics, Henan Normal University, Xinxiang, Henan 453007,
PR China
2 Institute of Physics, Henan Academy of Sciences, Zhengzhou, Henan 450046, PR China
3yf-liu@htu.edu.cn
Received XX Month XXXX; revised XX Month, XXXX; accepted XX Month XXXX; posted XX Month XXXX (Doc. ID XXXXX); published XX Month XXXX
In metal smelting, precise temperature control is of vital
importance for reaction rates, efficiency, and product
quality. Traditional methods such as thermocouples have
inherent limitations, but multispectral radiation
thermometry (MRT) offers high resolution and reliability.
This paper proposes a multispectral radiation
thermometry platform featuring wireless data
transmission, which enables remote data transfer and
precise temperature measurements. The platform was
meticulously calibrated and six common emissivity
models were inverted with high accuracy. The results of
temperature measurements conducted at a copper
smelting site demonstrated an excellent degree of
agreement with those obtained using disposable
thermocouples. The platform has the potential to be
applied in harsh environments, offering a novel approach
to temperature measurement in metal smelting
processes.
In metal smelting, temperature serves as a pivotal parameter for
controlling reaction rates, enhancing production efficiency, and
ensuring product quality [1]. Accurate temperature measurement
within the smelting furnace enables precise process control, crucial
for improving production efficiency, safeguarding product quality,
and ensuring production safety [2].
Currently, widely employed temperature measurement
methods in metal smelting processes include thermocouple
thermometry and radiation thermometry [3, 4]. The advantage of
thermocouple thermometry lies in its simple structure and
measurement of the true temperature of the object. However, it
suffers from poor dynamic response, limited temperature
measurement range, high consumption, and inability to measure
temperature variations in real-time during the smelting process.
Radiation thermometry is characterized by high resolution,
sensitivity, reliability, short response time, unlimited temperature
measurement, non-contact, and non-destructive measurement
advantages, holding a significant position in the field of temperature
measurement in metal smelting. However, currently prevalent
brightness and colorimetric pyrometers fail to fundamentally
address the uncertainty caused by emissivity variations [5].
Brightness methods are greatly influenced by background thermal
radiation and medium absorption, while colorimetric methods are
stringent in the selection of two temperature measurement bands.
Multispectral radiation thermometry technology, achieving
temperature inversion independent of target emissivity, has
experienced rapid advancement [6-10]. Researchers have
proposed algorithms that assume emissivity models as a means to
overcome the challenge of unknown emissivity [11-16]. These
models typically include wavelength emissivity models [17] or
temperature emissivity models [18]. While assuming emissivity
models resolves the issue of temperature determination in the
presence of unknown emissivity, their applicability is often limited
to specific materials within specific environments. To address the
limitations of assuming emissivity models, researchers have
explored methods for processing multispectral radiation
thermometry data without assuming specific emissivity models.
These methods include the use of multi-wavelength emissivity
constraint algorithms [19], generalized inverse matrix with an
external penalty function [20], and direct processing algorithms
[21]. While these methods are effective to some extent, they are
sensitive to deviations between assumed and actual emissivity
models. Other methods based on similarity between measured and
blackbody spectral radiance intensity [22] or moving narrowband
spectral windows [23] have limitations in terms of proximity to the
object's true temperature range and real-time temperature
measurement. In recent years, neural network technology has
provided a new direction for processing multispectral radiation
thermometry data. However, these methods often require a large
number of data samples and long training times [24]. Research on
temperature measurement algorithms has enhanced the
applicability and accuracy of multispectral radiation thermometry.
However, devices used for spectral measurement and temperature
inversion typically have large volumes, posing significant challenges
for practical application in metal smelting sites.
This paper presents a multispectral radiation thermometry
platform based on wireless data transmission, which separates
spectral measurement from data processing. This enhances the
applicability of the platform in metal smelting sites. The
temperature measurement platform was meticulously calibrated,
and temperature validation experiments were conducted in the
laboratory. Finally, the device was applied for temperature
measurement at a copper smelting site to verify its applicability and
measurement accuracy.
The schematic diagram of the multispectral radiation
temperature measurement platform is shown in Fig. 1. The
platform comprises four main components: an optical signal
acquisition module, a multispectral signal transmission module, an
ATK-ESP8266 WiFi transmission module, and the TLink cloud
platform. The optical signal acquisition module is responsible for
capturing the thermal radiation signal of the measured object and
converting it into electrical signals. The multispectral signal
transmission module is responsible for exporting the data collected
by the fiber optic spectrometer. The ATK-ESP8266 WiFi
transmission module uploads the collected multispectral data to the
TLink cloud platform, where it is imported into the data processing
equipment.
Fig. 1. The schematic diagram of the MRT platform.
The sample is subjected to heating via a silicon carbide heating
element. This is encapsulated in a cylindrical cavity constructed
from glass fiber insulation material. The furnace surface is covered
with a high-temperature and high thermal conductivity alumina
ceramic plate, while the outer layer is covered with ceramic fiber
insulation material. The sample is placed on the alumina ceramic
plate, and heating is applied through heat transfer. The heating
system employs a high-precision proportional-integral-derivative
(PID) controller for temperature control, and the sample
temperature is monitored using an S-type thermocouple. The
maximum temperature of the furnace can reach 1473 K.
The optical signal acquisition module comprises an optical
system and a fiber optic spectrometer. The radiation emitted by the
target is initially focused by the concave mirror onto the right-angle
mirror, and then converged by the right-angle mirror into the fiber
optic port. Finally, the radiation is transmitted through the optical
fiber to the fiber optic spectrometer for measurement. The fiber
optic spectrometer employed in this setup is the NIR25S from Idea
Optics. The system incorporates a high-speed linear array InGaAs
detector as the optoelectronic sensor and integrates a step filter to
eliminate higher-order diffraction, enabling the acquisition of
radiation signals in the spectral range of 0.9-2.5 μm. The spectral
radiation data of the target, measured by the fiber optic
spectrometer, is uploaded to the TLink cloud platform through the
data transmission and data transmitting modules. A remote
computer downloads the data in real-time and feeds it back to the
data processing system for temperature inversion. The
temperature inversion method utilized in the temperature
measurement platform adheres to the approach detailed in our
earlier publication [25]. The computer computes the average
temperature inversion and ultimately outputs the inferred
temperature of the target.
As the output of the fiber optic spectrometer is voltage-related
electrical signal data, calibration of the spectrometer is necessary
prior to temperature inversion of the data obtained. This calibration
process involves converting the output electrical signal data to a
data type related to the radiant energy of the object under
measurement. The calibration of the spectrometer necessitates the
utilization of a multi-temperature calibration method proposed in
our previous study [26].
In order to employ the multi-temperature calibration method, it
is necessary to measure the spectral signals of the blackbody
furnace at multiple temperature points. As a case in point, we may
cite the selection of the British ISOTECH high-temperature
blackbody furnace, model R970. The blackbody furnace has an
effective emissivity exceeding 0.995 over a temperature range of
423 K to 1473 K. The temperature of the blackbody furnace is set by
a controller, while an independent indicator displays the actual
radiation temperature. The sensor of this independent indicator is
installed inside the blackbody chamber, which has a diameter of 20
mm and a depth of 65 mm. At temperature intervals of 50 K, ranging
from 873 K to 1173 K, the blackbody radiation signals were
measured, and subsequently, the spectral response curve and
background radiation curve of the MRT platform were calculated
using the multi-temperature calibration theory, as depicted in
Figure 2. Prior to the occurrence of temperature inversion, it is of
the utmost importance to convert the electrical signal data
outputted by the fiber optic spectrometer into radiation energy
signals associated with the target under measurement, based on the
aforementioned calibration results.
Fig. 2. The response function and background radiation of the MRT
platform..
In order to assess the time response characteristics and
temperature inversion performance of the MRT platform,
simulations were initially conducted employing six emissivity
models. Utilizing the Planck formula, spectral radiance values were
computed for various temperatures based on these emissivity
functions, as depicted in Figure 3. Subsequently, the calculated
spectral data was transmitted to the Tlink cloud platform as a signal,
where a remote computer downloaded the data and executed
temperature inversion for the six model materials utilizing a data
processing method reliant on Euclidean distance optimization. This
comprehensive analysis enabled an evaluation of the platform's
capabilities across different emissivity scenarios, thereby
contributing to a deeper understanding of its performance under
various conditions.
Fig. 3. The calculated spectral data and emissivity of six models.
Fig. 4. The relative error and response time of inversion results for different
numbers of wavelengths.
Figure 4 presents the relative error and response time of
inversion results for different numbers of wavelengths. It can be
observed that an increase in the number of wavelengths
corresponds to a gradual decrease in relative error, although this is
accompanied by an increase in response time. This trade-off
emphasizes the critical importance of striking a balance between
accuracy and efficiency in temperature inversion processes. It
highlights the necessity of thoughtfully selecting the number of
wavelengths, considering factors such as measurement accuracy
requirements and operational efficiency. Furthermore, while a
greater number of wavelengths may enhance accuracy, it may also
introduce greater complexity in equipment setup and data
processing. Therefore, a comprehensive evaluation of various
factors is necessary in practical temperature measurement
applications. This nuanced understanding aids in optimizing
temperature measurement processes to meet specific industrial
requirements effectively.
To validate the performance of a multispectral temperature
measurement platform under real-world conditions, a copper
smelting facility in China was selected as the testing ground. During
the experiments, the platform's front-end equipment was precisely
aligned with the liquid metal surface within an industrial copper
smelting crucible to capture real-time spectral data of the molten
copper. Continuous flushing of protective gas over the
measurement area was employed to mitigate oxidation of the
molten copper, ensuring data fidelity. Subsequently, temperature
spectral data were retrieved and processed at the backend with
minimal latency, facilitating near real-time temperature assessment.
Additionally, periodic measurements using industrial-grade
disposable thermocouples were performed to corroborate the
accuracy of the collected data. A comparative analysis between the
temperature platform's readings and those obtained from the
thermocouples, as depicted in Figure 5, was conducted. A
meticulous experimental design and thorough data analysis were
employed to conduct a comprehensive evaluation of the
multispectral temperature measurement platform's efficacy in
industrial copper smelting environments. This endeavor not only
underscores the platform's potential in industrial applications but
also highlights avenues for further enhancement and optimization.
Fig. 5. Comparison of real-time temperature measurement data from the
MRT platform with disposable thermocouple measurements.
According to the data presented in Figure 5, the inverse data from
the temperature measurement platform shows good consistency
with the measurements from the disposable thermocouple,
indicating that the temperature platform data meets the
requirements for industrial temperature measurement. However,
there are certain deviations between the two, primarily due to
several factors. Firstly, industrial sites often contain significant
amounts of smoke and water vapor, and the temperature
measurement platform has not been adequately calibrated for
these real-world conditions. Future work should involve the
introduction of online calibration or elimination algorithms to
enhance temperature accuracy. Secondly, the surface of molten
copper is prone to oxidation. Although oxidized substances are
swept away from the measurement area by the protective gas, the
short integration time of spectral acquisition may still allow the
radiation spectrum of oxidized substances to enter the optical path,
thereby affecting the accuracy of the target radiation spectrum.
The development of a multispectral radiation thermometry
platform based on wireless data transmission represents a
significant advancement in temperature measurement technology
for metal smelting applications. By separating spectral
measurement from data processing, the platform offers enhanced
accuracy and efficiency, overcoming limitations associated with
traditional temperature measurement methods. Calibration
experiments confirmed the platform's reliability, while validation
tests conducted at a copper smelting facility demonstrated its
effectiveness in real-world operating conditions. Despite certain
deviations observed between the platform's readings and those
obtained from thermocouples, the platform's performance met the
requirements for industrial temperature measurement. Future
research directions include refining calibration algorithms and
optimizing spectral measurement techniques to further enhance
the platform's accuracy and applicability in metal smelting
environments.
Funding. National Natural Science Foundation of China (U23A20377),
Henan Provincial Joint Fund for Science and Technology Research and
Development Program (225200810077), Program for Innovative Research
Team (in Science and Technology) in University of Henan Province
(23IRTSTHN013), and Natural Science Foundation of Henan province
(222300420011, 222300420209).
Disclosures. The authors declare no conflicts of interest.
Data availability. Data underlying the results presented in this paper are
not publicly available at this time but may be obtained from the authors upon
reasonable request.
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