Real-time concentration detection of Al dust using GRU-based Kalman filtering approach

Kalman filter algorithms have been widely used in dust environment concentration detection systems. However, in industrial environments, methods such as KF and median filtering usually require about 10 s of detection time, which cannot meet the requirements of online real-time detection. For this reason, this present study proposes a framework that combines a gated recirculation unit (GRU) with the KF method to achieve online real-time detection of dust concentration. In this framework, the GRU is mainly responsible for handling dynamic and nonlinear characteristics and capturing instantaneous concentration trends. On the other hand, the Kalman filter utilizes its superior state estimation capability to provide more accurate system state estimation by fusing real-time predictions from GRU and sensor measurements. The results show that the KFGRU method is superior to the conventional linear filtering method with a response time of less than 2 s and can detect dust concentration online in real-time. In terms of prediction accuracy, the deviation value of the curve processed by the KFGRU method is only 0.334, which is a significant breakthrough compared with the Kalman filter algorithm 0.755, the sliding average method 0.843, and the median filter method 0.849 (the smaller the deviation value, the higher the prediction accuracy). This study provides a comprehensive and innovative approach for dust concentration monitoring in dust reduction and explosion suppression systems, which not only meets the real-time requirement but also makes important progress in explosion safety management. This will provide more reliable and advanced technical support for dust control and safety in industrial production processes.