CA2663893A1 - Industrial plant having an area relevant to safety - Google Patents
Industrial plant having an area relevant to safety Download PDFInfo
- Publication number
- CA2663893A1 CA2663893A1 CA002663893A CA2663893A CA2663893A1 CA 2663893 A1 CA2663893 A1 CA 2663893A1 CA 002663893 A CA002663893 A CA 002663893A CA 2663893 A CA2663893 A CA 2663893A CA 2663893 A1 CA2663893 A1 CA 2663893A1
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- Prior art keywords
- person
- safety
- industrial plant
- area
- relevant area
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 238000005096 rolling process Methods 0.000 claims abstract description 13
- 239000007788 liquid Substances 0.000 claims abstract description 7
- 239000002184 metal Substances 0.000 claims abstract description 7
- 229910052751 metal Inorganic materials 0.000 claims abstract description 7
- 238000012545 processing Methods 0.000 claims abstract description 7
- 230000005670 electromagnetic radiation Effects 0.000 claims abstract description 6
- 230000009471 action Effects 0.000 claims abstract description 5
- 238000009434 installation Methods 0.000 claims abstract description 4
- 230000004888 barrier function Effects 0.000 claims description 8
- 239000011159 matrix material Substances 0.000 claims description 7
- 239000004065 semiconductor Substances 0.000 claims description 6
- 230000001681 protective effect Effects 0.000 claims description 4
- 229910000831 Steel Inorganic materials 0.000 claims description 3
- 238000013528 artificial neural network Methods 0.000 claims description 3
- 239000003990 capacitor Substances 0.000 claims description 3
- 238000005516 engineering process Methods 0.000 claims description 3
- 238000003909 pattern recognition Methods 0.000 claims description 3
- 239000010959 steel Substances 0.000 claims description 3
- 238000011156 evaluation Methods 0.000 abstract description 3
- 230000008901 benefit Effects 0.000 description 6
- 231100001261 hazardous Toxicity 0.000 description 4
- 230000005855 radiation Effects 0.000 description 4
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 3
- 238000009749 continuous casting Methods 0.000 description 3
- 238000001514 detection method Methods 0.000 description 3
- 238000011161 development Methods 0.000 description 2
- 229910001338 liquidmetal Inorganic materials 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 230000003287 optical effect Effects 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 238000005097 cold rolling Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 238000005098 hot rolling Methods 0.000 description 1
- 238000005286 illumination Methods 0.000 description 1
- 230000006698 induction Effects 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000012544 monitoring process Methods 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 230000004044 response Effects 0.000 description 1
- 238000000638 solvent extraction Methods 0.000 description 1
- 230000001360 synchronised effect Effects 0.000 description 1
- 230000001960 triggered effect Effects 0.000 description 1
- 238000004148 unit process Methods 0.000 description 1
Classifications
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21B—MANUFACTURE OF IRON OR STEEL
- C21B7/00—Blast furnaces
- C21B7/24—Test rods or other checking devices
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
- C21C5/00—Manufacture of carbon-steel, e.g. plain mild steel, medium carbon steel or cast steel or stainless steel
- C21C5/28—Manufacture of steel in the converter
- C21C5/42—Constructional features of converters
- C21C5/46—Details or accessories
- C21C5/4673—Measuring and sampling devices
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16P—SAFETY DEVICES IN GENERAL; SAFETY DEVICES FOR PRESSES
- F16P3/00—Safety devices acting in conjunction with the control or operation of a machine; Control arrangements requiring the simultaneous use of two or more parts of the body
- F16P3/12—Safety devices acting in conjunction with the control or operation of a machine; Control arrangements requiring the simultaneous use of two or more parts of the body with means, e.g. feelers, which in case of the presence of a body part of a person in or near the danger zone influence the control or operation of the machine
- F16P3/14—Safety devices acting in conjunction with the control or operation of a machine; Control arrangements requiring the simultaneous use of two or more parts of the body with means, e.g. feelers, which in case of the presence of a body part of a person in or near the danger zone influence the control or operation of the machine the means being photocells or other devices sensitive without mechanical contact
- F16P3/142—Safety devices acting in conjunction with the control or operation of a machine; Control arrangements requiring the simultaneous use of two or more parts of the body with means, e.g. feelers, which in case of the presence of a body part of a person in or near the danger zone influence the control or operation of the machine the means being photocells or other devices sensitive without mechanical contact using image capturing devices
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16P—SAFETY DEVICES IN GENERAL; SAFETY DEVICES FOR PRESSES
- F16P3/00—Safety devices acting in conjunction with the control or operation of a machine; Control arrangements requiring the simultaneous use of two or more parts of the body
- F16P3/12—Safety devices acting in conjunction with the control or operation of a machine; Control arrangements requiring the simultaneous use of two or more parts of the body with means, e.g. feelers, which in case of the presence of a body part of a person in or near the danger zone influence the control or operation of the machine
- F16P3/14—Safety devices acting in conjunction with the control or operation of a machine; Control arrangements requiring the simultaneous use of two or more parts of the body with means, e.g. feelers, which in case of the presence of a body part of a person in or near the danger zone influence the control or operation of the machine the means being photocells or other devices sensitive without mechanical contact
- F16P3/144—Safety devices acting in conjunction with the control or operation of a machine; Control arrangements requiring the simultaneous use of two or more parts of the body with means, e.g. feelers, which in case of the presence of a body part of a person in or near the danger zone influence the control or operation of the machine the means being photocells or other devices sensitive without mechanical contact using light grids
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D21/00—Arrangements of monitoring devices; Arrangements of safety devices
- F27D21/02—Observation or illuminating devices
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D21/00—Arrangements of monitoring devices; Arrangements of safety devices
- F27D21/04—Arrangements of indicators or alarms
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01S—RADIO DIRECTION-FINDING; RADIO NAVIGATION; DETERMINING DISTANCE OR VELOCITY BY USE OF RADIO WAVES; LOCATING OR PRESENCE-DETECTING BY USE OF THE REFLECTION OR RERADIATION OF RADIO WAVES; ANALOGOUS ARRANGEMENTS USING OTHER WAVES
- G01S17/00—Systems using the reflection or reradiation of electromagnetic waves other than radio waves, e.g. lidar systems
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01S—RADIO DIRECTION-FINDING; RADIO NAVIGATION; DETERMINING DISTANCE OR VELOCITY BY USE OF RADIO WAVES; LOCATING OR PRESENCE-DETECTING BY USE OF THE REFLECTION OR RERADIATION OF RADIO WAVES; ANALOGOUS ARRANGEMENTS USING OTHER WAVES
- G01S17/00—Systems using the reflection or reradiation of electromagnetic waves other than radio waves, e.g. lidar systems
- G01S17/02—Systems using the reflection of electromagnetic waves other than radio waves
- G01S17/04—Systems determining the presence of a target
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01S—RADIO DIRECTION-FINDING; RADIO NAVIGATION; DETERMINING DISTANCE OR VELOCITY BY USE OF RADIO WAVES; LOCATING OR PRESENCE-DETECTING BY USE OF THE REFLECTION OR RERADIATION OF RADIO WAVES; ANALOGOUS ARRANGEMENTS USING OTHER WAVES
- G01S17/00—Systems using the reflection or reradiation of electromagnetic waves other than radio waves, e.g. lidar systems
- G01S17/86—Combinations of lidar systems with systems other than lidar, radar or sonar, e.g. with direction finders
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
- C21C5/00—Manufacture of carbon-steel, e.g. plain mild steel, medium carbon steel or cast steel or stainless steel
- C21C5/52—Manufacture of steel in electric furnaces
- C21C2005/5288—Measuring or sampling devices
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/20—Recycling
Landscapes
- Engineering & Computer Science (AREA)
- General Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Remote Sensing (AREA)
- Radar, Positioning & Navigation (AREA)
- Electromagnetism (AREA)
- General Physics & Mathematics (AREA)
- Manufacturing & Machinery (AREA)
- Computer Networks & Wireless Communication (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Metallurgy (AREA)
- Quality & Reliability (AREA)
- Automation & Control Theory (AREA)
- Geophysics And Detection Of Objects (AREA)
- Alarm Systems (AREA)
- Emergency Alarm Devices (AREA)
- Image Analysis (AREA)
Abstract
The invention relates to an industrial plant (1) for producing or processing liquid, red-hot or hot metal (2, 6), particularly in a blast furnace installation or in a rolling mill, wherein a safety-relevant area (B1, B2) is formed in the direct vicinity of the liquid or red-hot metal and the presence of a person is at least periodically not allowed. A detector unit (10, 12, 14, 16A, 16B) is provided for the surveillance of said area, detecting electromagnetic radiation emitted by a present person or identifying the absence of electromagnetic radiation blocked by a present person. Furthermore, the invention provides for an evaluation unit (22) which is able to detect the presence of a person from the output data of the detector unit (10, 12, 14, 16A, 16B), and for a control unit (24) which is connected to the evaluation unit (22). If a person is present in the safety-relevant area (B1), the control unit automatically initiates an action acting against the presence of the person. By forming a plurality of safety-relevant areas (B1, B2, B3) having different danger levels, gentle stopping of the industrial plant (1) is made possible.
Description
Description Industrial plant having an area relevant to safety The invention relates to an industrial plant for producing or processing liquid, incandescent or hot metal, particularly a blast furnace installation or a rolling mill in which a safety-relevant area, in which the presence of a person is not permitted at least temporarily, is formed in the direct environment of the liquid or incandescent metal.
Devices for the surveillance of spatial areas are known, e.g.
from DE 101 63 534 Al, DE 102 21 578 Al and DE 10 2004 047022 Al.
In this context, sensors are used which provide three-dimensional information about the monitored area. The principle of the 3D
CMOS sensor is thus based on the fact that a laser and an electronic lock are exactly synchronized. The lock opens exactly with the emission of the laser pulse. The extremely short light pulse illuminates an obstacle - if present - and the reflected light pulse impinges on the 3D CMOS image converter. The sensor registers the propagation times which are evaluated as a measure of the distance and the shape of the obstacle. A light-emitting diode or a laser can be used as transmitter. One pixel of the CMOS sensor can in each case comprise one photodiode and an associated pixel capacitor which is discharged by illumination of the photodiode when the time window is open.
Modern industrial plants must be planned and operated in such a manner that the risk to persons is reduced to a minimum. As a rule, therefore, certain plant sections with high hazard potential are partitioned off or the access to some areas is blocked. For this purpose, protective grids and gates can be provided.
For the partitioning or control of hazardous areas around machines or in simple industrial plants, so-called switching mats or also optical systems, e.g. light barriers are also known. Like fences with access gates, switching mats have high constructional complexity. Optical or radiation-based systems are not taken into consideration under extreme environmental conditions.
The invention is based on the object of securing and checking a safety-relevant area in a constructionally simple manner in an industrial plant having a very strong heat emission, namely in an industrial plant for producing or processing liquid, incandescent or hot metal.
According to the invention, this object is achieved with respect to the industrial plant initially mentioned by a surveillance device for the safety-relevant area, comprising:
- a detector unit which detects electromagnetic radiation emanating from a present person or the absence of electromagnetic radiation blocked out by a present person, - an evaluating unit which detects from output data of the detector unit the presence of a person, and - a control unit connected to the evaluating unit, which, when a person is present in the safety-relevant area, automatically initiates an action acting against the presence of the person.
The inventors have recognized that a radiation-based surveillance device can guarantee the required safety for a safety-relevant area also in industrial plants having a high heat and infrared radiation emission. They are thus breaking with a technical prejudice. The experts have hitherto not considered such detector units for blast furnace installations or rolling mills. Instead, a great amount of effort is expended with mechanical access barriers now as before. The invention has the advantage that elaborate mechanical latching devices such as innumerable electrically latched gates in a fence etc. are not necessary for guaranteeing adequate safeguarding of persons.
Dispensing with or reducing the number of such protective grids and/or gates also has considerable advantages in the case of plant maintenance because these fences and gates do not then impede the access to the plant.
The detector unit is preferably based on at least one of the following detector types:
- a motion detector, - a light barrier, - a video camera or a CCD camera, - a thermal camera, - a combination of light transmitter and semiconductor matrix sensor, particularly in CMOS technology.
The combination of at least two of the aforementioned detector types in the detector unit is particularly preferred as a result of which a particularly high safety standard can be achieved.
It is also of special advantage if detector principles with different detection dimensionality are used in the detector unit such as, e.g. a one-dimensional sensor or a line scan, particularly a light barrier, and/or a two-dimensional sensor or an area scan, particularly a light curtain or a 2D camera, and/or a three-dimensional sensor, the latter comprising, in particular, a light sensor, a semiconductor matrix sensor with one photodiode per pixel and a capacitor for integrating the reflected transmitter light and a delay determining unit.
According to a particularly preferred embodiment, the detector unit is set up for generating an image from the safety-relevant area and the evaluating unit processes the image. In the image processing, an object or pattern recognition is preferably carried out, = CA 02663893 2009-01-15 preferably based on a neural network so that a person can be distinguished from a non-human object.
Apart from the detection of a hazard to persons, this also makes it possible to detect other unplanned or irregular movements, e.g. by vehicles or falling parts, in the plant.
According to a preferred development, at least one further safety-relevant area is formed in the industrial plant which differs or differ in its/their risk potential from the first-mentioned safety-relevant area wherein the further safety-relevant area or areas can be monitored separately for the presence of a person by the surveillance device. In this context, at least one of the safety-relevant areas preferably has a danger level of between "maximum hazard" and "no hazard".
According to another preferred development, the control unit is connected to a plant control device so that, when an endangered person is detected, the plant control device can automatically carry out an intervention in the plant operation which reduces the hazard, particularly in real time, online and/or without the interposition of human inputs.
In this context, it is of quite particular advantage if the intervention can be carried out with its intensity depending on the risk potential of the safety-relevant area in which the forbidden person has been detected. This advantageously results in the possibility for a "gentle" stopping of the plant, e.g.
by initially reducing the rate of rolling or throughput in a rolling mill when a person is detected in an area of medium risk potential and only reducing the rate of rolling or throughput to zero, i.e. stopping the plant, if the person penetrates the area of maximum risk potential.
In a steel mill or a blast furnace, the response to a person penetrating can consist of a delay and/or a complete interruption of an opening of the furnace.
The industrial plant also preferably has an input device for establishing a locking area by the operating personnel of a control room. The operating personnel can thus flexibly define, for instance within an area of medium risk potential, a section, the so-called locking area which temporarily has a higher or the maximum risk level, for instance because a machine with increased risk potential is temporarily stored in this area.
An exemplary embodiment of an industrial plant according to the invention will be explained in greater detail with reference to the drawing in the text which follows. The single figure shows as the industrial plant 1 a continuous-casting plant with hot rolling mill in a greatly diagrammatic form. The invention can also be applied in a cold rolling mill where the steel, e.g., is hotter than 100 C.
Liquid metal 2, e.g. iron, is conducted through a funnel mold 3 and deflection rollers from a vertical feed direction to a horizontal feed direction. In the horizontal, the ribbon 6, which is still glowing, passes through several rolling stands 5 after it has been heated in an induction furnace 7.
Around the continuous-casting and rolling area of the industrial plant 1, several safety-relevant areas B1, B2, B3 are formed which are monitored in each case separately by themselves by a surveillance device. The monitoring has the aim of finding out which processes occur in the respective area B1, B2, B3 and, in particular, whether a person has penetrated in PCT/EP2007/056214 - 5a -forbidden manner in the respective area B1, B2, B3, who would be exposed to an unacceptable hazard in this area. The safety-relevant areas comprise a secure area B3, a less hazardous area B2 and a very hazardous area B1.
The surveillance device, particularly for the safety-relevant areas B1 and B2, comprises a detector unit having a number of different detectors. These are a CCD camera or video camera 10 which generates a two-dimensional image (projection) of the area monitored, furthermore a three-dimensional image sensor having a combination 12 of a light transmitter and a semiconductor matrix sensor arranged in the immediate vicinity of the light transmitter, furthermore a motion detector 14 and a light barrier 16A, 16B. The motion detector 14 is based, for example, on the so-called pyroelectric effect. The light barrier can be operated with visible or invisible light. As the 3-D sensor, for example, a semiconductor matrix sensor in CMOS
technology is used such as is described, for example, in DE 10 2004 047022 Al, DE 101 63 534 Al or DE 102 21 578 Al.
Due to the interaction of these different detector types and detector principles, an evaluating unit 22 which is supplied wirelessly or in wire-connected manner with the output data of the said detectors, can detect in a particularly reliable manner the presence of a person in the safety-relevant area B1 or B2 and distinguish him for example from artifacts generated from the continuous-casting or rolling area due to interference radiation. To further secure the person detection process, an object and pattern recognition of the image generated by the detector unit also takes place in the evaluating unit 22 by means of a neural network.
The different safety-relevant areas B1, B2 can be separately monitored as images in that there is a separate camera or a separate matrix detector for each area, i.e. that the different areas Bl, B2 are defined and specified by the respective acquisition cone of the associated detectors. As an alternative, the areas Bl, B2 can be monitored jointly by a common detector, preferably a 3-D sensor, wherein the distinction whether there is an unwanted person in the area Bl or in the area B2 can then be carried out as an evaluation by means of position data which are supplied by the detector.
In a control unit 24 functionally following the evaluating unit 22, for the case where an unwanted person is detected in a safety-endangered area B1 or B2, an action acting against the presence of this person is initiated. This can consist in that the person is first warned, e.g. for a short time, by a light or tone signal, e.g. by means of a loudspeaker 26. At a higher escalation level, the control unit 24 acts directly functionally on the plant control device 30 which, together with the evaluating unit 22 and the control unit 24, is accommodated in a control room 20 of the industrial plant 1. In the case where the person, after a short audible warning time, is still located in the hazardous area Bl or B2, the mill train is stopped or the rate of throughput, respectively, is reduced. This is done without requiring an intervention by the operating personnel.
In the case where the safety-relevant areas Bl, B2 are monitored by a 3-D sensor, in particular, it is of special advantage that the operating personnel in the control room 20 can establish via an input device 40 a locking area V which is temporarily graded as having an increased risk potential. The locking area V shown can thus be temporarily graded in the risk potential of the area Bl, for example, i.e. if a person enters the locking area V, an action of the highest escalation level is immediately triggered, e.g. the immediate stopping of the rolling mill.
According to one variant, a thermal camera is used as camera, which results in the advantage that it is not only persons in unwanted areas which can be identified but also other unusual temperature variations can be detected in the industrial plant, for instance if liquid metal emerges at an unwanted location or hot iron parts have fallen down.
Devices for the surveillance of spatial areas are known, e.g.
from DE 101 63 534 Al, DE 102 21 578 Al and DE 10 2004 047022 Al.
In this context, sensors are used which provide three-dimensional information about the monitored area. The principle of the 3D
CMOS sensor is thus based on the fact that a laser and an electronic lock are exactly synchronized. The lock opens exactly with the emission of the laser pulse. The extremely short light pulse illuminates an obstacle - if present - and the reflected light pulse impinges on the 3D CMOS image converter. The sensor registers the propagation times which are evaluated as a measure of the distance and the shape of the obstacle. A light-emitting diode or a laser can be used as transmitter. One pixel of the CMOS sensor can in each case comprise one photodiode and an associated pixel capacitor which is discharged by illumination of the photodiode when the time window is open.
Modern industrial plants must be planned and operated in such a manner that the risk to persons is reduced to a minimum. As a rule, therefore, certain plant sections with high hazard potential are partitioned off or the access to some areas is blocked. For this purpose, protective grids and gates can be provided.
For the partitioning or control of hazardous areas around machines or in simple industrial plants, so-called switching mats or also optical systems, e.g. light barriers are also known. Like fences with access gates, switching mats have high constructional complexity. Optical or radiation-based systems are not taken into consideration under extreme environmental conditions.
The invention is based on the object of securing and checking a safety-relevant area in a constructionally simple manner in an industrial plant having a very strong heat emission, namely in an industrial plant for producing or processing liquid, incandescent or hot metal.
According to the invention, this object is achieved with respect to the industrial plant initially mentioned by a surveillance device for the safety-relevant area, comprising:
- a detector unit which detects electromagnetic radiation emanating from a present person or the absence of electromagnetic radiation blocked out by a present person, - an evaluating unit which detects from output data of the detector unit the presence of a person, and - a control unit connected to the evaluating unit, which, when a person is present in the safety-relevant area, automatically initiates an action acting against the presence of the person.
The inventors have recognized that a radiation-based surveillance device can guarantee the required safety for a safety-relevant area also in industrial plants having a high heat and infrared radiation emission. They are thus breaking with a technical prejudice. The experts have hitherto not considered such detector units for blast furnace installations or rolling mills. Instead, a great amount of effort is expended with mechanical access barriers now as before. The invention has the advantage that elaborate mechanical latching devices such as innumerable electrically latched gates in a fence etc. are not necessary for guaranteeing adequate safeguarding of persons.
Dispensing with or reducing the number of such protective grids and/or gates also has considerable advantages in the case of plant maintenance because these fences and gates do not then impede the access to the plant.
The detector unit is preferably based on at least one of the following detector types:
- a motion detector, - a light barrier, - a video camera or a CCD camera, - a thermal camera, - a combination of light transmitter and semiconductor matrix sensor, particularly in CMOS technology.
The combination of at least two of the aforementioned detector types in the detector unit is particularly preferred as a result of which a particularly high safety standard can be achieved.
It is also of special advantage if detector principles with different detection dimensionality are used in the detector unit such as, e.g. a one-dimensional sensor or a line scan, particularly a light barrier, and/or a two-dimensional sensor or an area scan, particularly a light curtain or a 2D camera, and/or a three-dimensional sensor, the latter comprising, in particular, a light sensor, a semiconductor matrix sensor with one photodiode per pixel and a capacitor for integrating the reflected transmitter light and a delay determining unit.
According to a particularly preferred embodiment, the detector unit is set up for generating an image from the safety-relevant area and the evaluating unit processes the image. In the image processing, an object or pattern recognition is preferably carried out, = CA 02663893 2009-01-15 preferably based on a neural network so that a person can be distinguished from a non-human object.
Apart from the detection of a hazard to persons, this also makes it possible to detect other unplanned or irregular movements, e.g. by vehicles or falling parts, in the plant.
According to a preferred development, at least one further safety-relevant area is formed in the industrial plant which differs or differ in its/their risk potential from the first-mentioned safety-relevant area wherein the further safety-relevant area or areas can be monitored separately for the presence of a person by the surveillance device. In this context, at least one of the safety-relevant areas preferably has a danger level of between "maximum hazard" and "no hazard".
According to another preferred development, the control unit is connected to a plant control device so that, when an endangered person is detected, the plant control device can automatically carry out an intervention in the plant operation which reduces the hazard, particularly in real time, online and/or without the interposition of human inputs.
In this context, it is of quite particular advantage if the intervention can be carried out with its intensity depending on the risk potential of the safety-relevant area in which the forbidden person has been detected. This advantageously results in the possibility for a "gentle" stopping of the plant, e.g.
by initially reducing the rate of rolling or throughput in a rolling mill when a person is detected in an area of medium risk potential and only reducing the rate of rolling or throughput to zero, i.e. stopping the plant, if the person penetrates the area of maximum risk potential.
In a steel mill or a blast furnace, the response to a person penetrating can consist of a delay and/or a complete interruption of an opening of the furnace.
The industrial plant also preferably has an input device for establishing a locking area by the operating personnel of a control room. The operating personnel can thus flexibly define, for instance within an area of medium risk potential, a section, the so-called locking area which temporarily has a higher or the maximum risk level, for instance because a machine with increased risk potential is temporarily stored in this area.
An exemplary embodiment of an industrial plant according to the invention will be explained in greater detail with reference to the drawing in the text which follows. The single figure shows as the industrial plant 1 a continuous-casting plant with hot rolling mill in a greatly diagrammatic form. The invention can also be applied in a cold rolling mill where the steel, e.g., is hotter than 100 C.
Liquid metal 2, e.g. iron, is conducted through a funnel mold 3 and deflection rollers from a vertical feed direction to a horizontal feed direction. In the horizontal, the ribbon 6, which is still glowing, passes through several rolling stands 5 after it has been heated in an induction furnace 7.
Around the continuous-casting and rolling area of the industrial plant 1, several safety-relevant areas B1, B2, B3 are formed which are monitored in each case separately by themselves by a surveillance device. The monitoring has the aim of finding out which processes occur in the respective area B1, B2, B3 and, in particular, whether a person has penetrated in PCT/EP2007/056214 - 5a -forbidden manner in the respective area B1, B2, B3, who would be exposed to an unacceptable hazard in this area. The safety-relevant areas comprise a secure area B3, a less hazardous area B2 and a very hazardous area B1.
The surveillance device, particularly for the safety-relevant areas B1 and B2, comprises a detector unit having a number of different detectors. These are a CCD camera or video camera 10 which generates a two-dimensional image (projection) of the area monitored, furthermore a three-dimensional image sensor having a combination 12 of a light transmitter and a semiconductor matrix sensor arranged in the immediate vicinity of the light transmitter, furthermore a motion detector 14 and a light barrier 16A, 16B. The motion detector 14 is based, for example, on the so-called pyroelectric effect. The light barrier can be operated with visible or invisible light. As the 3-D sensor, for example, a semiconductor matrix sensor in CMOS
technology is used such as is described, for example, in DE 10 2004 047022 Al, DE 101 63 534 Al or DE 102 21 578 Al.
Due to the interaction of these different detector types and detector principles, an evaluating unit 22 which is supplied wirelessly or in wire-connected manner with the output data of the said detectors, can detect in a particularly reliable manner the presence of a person in the safety-relevant area B1 or B2 and distinguish him for example from artifacts generated from the continuous-casting or rolling area due to interference radiation. To further secure the person detection process, an object and pattern recognition of the image generated by the detector unit also takes place in the evaluating unit 22 by means of a neural network.
The different safety-relevant areas B1, B2 can be separately monitored as images in that there is a separate camera or a separate matrix detector for each area, i.e. that the different areas Bl, B2 are defined and specified by the respective acquisition cone of the associated detectors. As an alternative, the areas Bl, B2 can be monitored jointly by a common detector, preferably a 3-D sensor, wherein the distinction whether there is an unwanted person in the area Bl or in the area B2 can then be carried out as an evaluation by means of position data which are supplied by the detector.
In a control unit 24 functionally following the evaluating unit 22, for the case where an unwanted person is detected in a safety-endangered area B1 or B2, an action acting against the presence of this person is initiated. This can consist in that the person is first warned, e.g. for a short time, by a light or tone signal, e.g. by means of a loudspeaker 26. At a higher escalation level, the control unit 24 acts directly functionally on the plant control device 30 which, together with the evaluating unit 22 and the control unit 24, is accommodated in a control room 20 of the industrial plant 1. In the case where the person, after a short audible warning time, is still located in the hazardous area Bl or B2, the mill train is stopped or the rate of throughput, respectively, is reduced. This is done without requiring an intervention by the operating personnel.
In the case where the safety-relevant areas Bl, B2 are monitored by a 3-D sensor, in particular, it is of special advantage that the operating personnel in the control room 20 can establish via an input device 40 a locking area V which is temporarily graded as having an increased risk potential. The locking area V shown can thus be temporarily graded in the risk potential of the area Bl, for example, i.e. if a person enters the locking area V, an action of the highest escalation level is immediately triggered, e.g. the immediate stopping of the rolling mill.
According to one variant, a thermal camera is used as camera, which results in the advantage that it is not only persons in unwanted areas which can be identified but also other unusual temperature variations can be detected in the industrial plant, for instance if liquid metal emerges at an unwanted location or hot iron parts have fallen down.
Claims (11)
1. An industrial plant (1) for producing or processing liquid or incandescent metal (2, 6), particularly a blast furnace installation or rolling mill in which a safety-relevant area (B1), in which the presence of a person is not permitted at least temporarily, is formed in the direct environment of the liquid or incandescent metal (2), characterized by a surveillance device for the safety-relevant area, comprising:
a) a detector unit (10, 12, 14, 16A, 16B) which detects electromagnetic radiation emanating from a present person or the absence of electromagnetic radiation blocked out by a present person, wherein the detector unit (10, 12, 14, 16A, 16B) is based on a combination of at least two of the following detector types:
- a motion detector (14), - a light barrier (16A, 16B), - a video camera (10) or a CCD camera, - a thermal camera, - a combination (12) of light transmitter and semiconductor matrix sensor, particularly in CMOS
technology, b) an evaluating unit (22) which detects from output data of the detector unit (10, 12, 14, 16A, 16B) the presence of a person, and c) a control unit (24) connected to the evaluating unit (22), which, when a person is present in the safety-relevant area (B1), automatically initiates an action acting against the presence of the person, and d) a plant control device (30) which is connected to the control unit (24) in such a manner that when an endangered person is detected, the plant control device (30) can automatically carry out an intervention in the -9a-plant operation which reduces the hazard, particularly in real time.
a) a detector unit (10, 12, 14, 16A, 16B) which detects electromagnetic radiation emanating from a present person or the absence of electromagnetic radiation blocked out by a present person, wherein the detector unit (10, 12, 14, 16A, 16B) is based on a combination of at least two of the following detector types:
- a motion detector (14), - a light barrier (16A, 16B), - a video camera (10) or a CCD camera, - a thermal camera, - a combination (12) of light transmitter and semiconductor matrix sensor, particularly in CMOS
technology, b) an evaluating unit (22) which detects from output data of the detector unit (10, 12, 14, 16A, 16B) the presence of a person, and c) a control unit (24) connected to the evaluating unit (22), which, when a person is present in the safety-relevant area (B1), automatically initiates an action acting against the presence of the person, and d) a plant control device (30) which is connected to the control unit (24) in such a manner that when an endangered person is detected, the plant control device (30) can automatically carry out an intervention in the -9a-plant operation which reduces the hazard, particularly in real time.
2. The industrial plant (1) as claimed in claim 1, characterized in that the detector unit (10, 12, 14, 16A, 16B) is based on at least one and preferably on a combination of several of the following detector principles:
- 1-D sensor or line scan, particularly light barrier (16A, 16B), - 2-D sensor or area scan, particularly light curtain or 2D camera, - 3-D sensor, particularly comprising a light transmitter, a semiconductor matrix sensor with one photodiode and one capacitor per pixel for integrating the reflected transmitter light and a delay determining unit.
- 1-D sensor or line scan, particularly light barrier (16A, 16B), - 2-D sensor or area scan, particularly light curtain or 2D camera, - 3-D sensor, particularly comprising a light transmitter, a semiconductor matrix sensor with one photodiode and one capacitor per pixel for integrating the reflected transmitter light and a delay determining unit.
3. The industrial plant (1) as claimed in claim 1 or 2, characterized in that the detector unit (10, 12) generates an image from the safety-relevant area (B1) and that the evaluating unit (22) carries out image processing.
4. The industrial plant (1) as claimed in one of claims 1 to 3, characterized in that the image processing carries out object or pattern recognition, preferably on the basis of a neural network, so that a person can be distinguished from a non-human object.
5. The industrial plant (1) as claimed in one of claims 1 to 4, characterized in that there are no protective grids or fences or that there are fewer protective grids or fences for securing the safety-relevant area (B1) than would be necessary for ensuring adequate or prescribed safety without surveillance device.
6. The industrial plant (1) as claimed in one of claims 1 to 5, characterized in that at least one further safety-relevant area (B2, B3) is formed which differs or differ in its/their risk potential from the first-mentioned safety-relevant area (B1) and that the further safety-relevant area or areas (B2, B3) can be monitored separately for the presence of a person by the surveillance device.
7. The industrial plant (1) as claimed in claim 6, characterized in that at least one of the safety-relevant areas (B2) has a danger level of between "maximum hazard"
and "no hazard".
and "no hazard".
8. The industrial plant (1) as claimed in claim 7, characterized in that the intervention can be carried out with its intensity depending on the risk potential of the safety-relevant area (B1, B2, B3) in which the forbidden person has been detected.
9. The industrial plant (1) as claimed in one of claims 1 to 8, characterized in that the intervention, in the case of a rolling mill, includes a reduction of the rate of rolling or of throughput and/or a stopping of the mill train (5).
10. The industrial plant (1) as claimed in one of claims 1 to 8, characterized in that the intervention includes in the case of a steel mill or blast furnace a delay and/or an interruption of an opening of the furnace.
11. The industrial plant (1) as claimed in one of claims 1 to 10, characterized by an input device (40) for establishing a locking area (V) by the operating personnel of a control room (20).
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE102006032955.4 | 2006-07-17 | ||
| DE102006032955A DE102006032955A1 (en) | 2006-07-17 | 2006-07-17 | Industrial plant with a safety relevant area |
| PCT/EP2007/056214 WO2008009536A1 (en) | 2006-07-17 | 2007-06-21 | Industrial plant having safety-relevant area |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2663893A1 true CA2663893A1 (en) | 2008-01-24 |
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| CA002663893A Abandoned CA2663893A1 (en) | 2006-07-17 | 2007-06-21 | Industrial plant having an area relevant to safety |
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| EP (1) | EP2041324B1 (en) |
| KR (1) | KR20090033392A (en) |
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| BR (1) | BRPI0714388B1 (en) |
| CA (1) | CA2663893A1 (en) |
| DE (1) | DE102006032955A1 (en) |
| MX (1) | MX2009000617A (en) |
| PL (1) | PL2041324T3 (en) |
| RU (1) | RU2439163C2 (en) |
| UA (1) | UA98939C2 (en) |
| WO (1) | WO2008009536A1 (en) |
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| DE102008013431A1 (en) * | 2008-03-10 | 2009-05-07 | Siemens Aktiengesellschaft | Machine safety-oriented stopping procedure, involves releasing turn-off impulse in case of endangerment to persons, and stopping machine within maximum deceleration time during operation of machine |
| US8284895B1 (en) * | 2008-08-18 | 2012-10-09 | The United States Of America, As Represented By The Secretary Of Agriculture | One dimensional linescan X-ray detector |
| WO2011090485A1 (en) * | 2010-01-22 | 2011-07-28 | Aramark Uniform & Career Apparel Group, Inc. | Personnel key tracking system |
| DE102010030667A1 (en) | 2010-06-29 | 2011-12-29 | Siemens Aktiengesellschaft | Device for monitoring a position and / or a movement of at least one object with respect to a predetermined area, in particular danger area, a plant and installation with a plurality of devices |
| US9517617B2 (en) * | 2012-10-17 | 2016-12-13 | M&R Printing Equipment, Inc. | Printing machine safety system |
| CN102915027B (en) * | 2012-11-16 | 2014-08-13 | 武汉钢铁(集团)公司 | Blast furnace smelting expert system built based on pattern recognition technology and method thereof |
| US9393695B2 (en) * | 2013-02-27 | 2016-07-19 | Rockwell Automation Technologies, Inc. | Recognition-based industrial automation control with person and object discrimination |
| EP2835699B1 (en) * | 2013-08-09 | 2015-05-06 | Sick Ag | Method and device for configuring and/or programming a safety controller |
| EP2937745B1 (en) * | 2014-04-25 | 2016-10-05 | Sick Ag | Safety control system for safe operation of a technical installation and method for operating the safety control system |
| DE102014117508A1 (en) * | 2014-11-28 | 2016-06-02 | Skidata Ag | Method for optimizing customer support when operating access control or payment devices |
| WO2016139147A1 (en) * | 2015-03-04 | 2016-09-09 | Abb Ag | Safety control system and method of operation of a safety control system |
| CN106287188A (en) * | 2015-06-29 | 2017-01-04 | 上海宝钢工业技术服务有限公司 | The security protection system of operating plant equipment |
| US11622555B2 (en) | 2016-04-18 | 2023-04-11 | Faunaphotonics Agriculture & Environmental A/S | Optical remote sensing systems for aerial and aquatic fauna, and use thereof |
| RU2732484C2 (en) * | 2018-11-19 | 2020-09-17 | Общество с ограниченной ответственностью "Электронные системы" | Method for remote control of safety of operational actions on electrical installation and software and hardware system for its implementation |
| DE202022103234U1 (en) | 2022-06-08 | 2023-09-20 | Leuze Electronic Gmbh + Co. Kg | Monitoring facility |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| WO1988008546A1 (en) * | 1987-05-01 | 1988-11-03 | The Broken Hill Proprietary Company Limited | Monitoring of objects in an optically dense atmosphere |
| DE19527832C2 (en) * | 1995-07-29 | 2002-11-21 | Werner & Pfleiderer Lebensmitt | Method for operating a device for loading and emptying industrial ovens |
| EP1159636B1 (en) * | 1999-03-18 | 2003-05-28 | Siemens Aktiengesellschaft | Resoluting range finding device |
| JP3972064B2 (en) * | 1999-04-02 | 2007-09-05 | 独立行政法人労働安全衛生総合研究所 | Sensor device and safety device |
| EP1113214A1 (en) * | 1999-12-28 | 2001-07-04 | Infineon Technologies AG | Light curtain system for establishing a protective light curtain, tool and system for processing objects and method for loading/unloading a tool |
| DE10026305A1 (en) * | 2000-05-26 | 2001-11-29 | Sick Ag | Opto-electronic device for monitoring protection region, has image determination unit which picks-up planar or spatial image of monitoring regions that lay near and outside the protection region |
| DE10163534A1 (en) * | 2001-12-21 | 2003-07-10 | Siemens Ag | Device for monitoring areas of space |
| DE10221578A1 (en) * | 2002-05-08 | 2003-11-27 | Siemens Ag | Dangerous area surveillance sensor has 3D-CMOS sensor with pulsed laser light source |
| US6779760B2 (en) * | 2002-12-19 | 2004-08-24 | Taiwan Semiconductor Manufacturing Co., Ltd | Safety system for overhead transport vehicle |
| WO2004084556A1 (en) * | 2003-03-20 | 2004-09-30 | Inventio Ag | Monitoring a lift area by means of a 3d sensor |
| AT413453B (en) * | 2003-11-21 | 2006-03-15 | Riegl Laser Measurement Sys | DEVICE FOR RECORDING AN OBJECT ROOM |
| DE102004047022A1 (en) * | 2004-09-28 | 2006-04-06 | Siemens Ag | Device for monitoring room areas |
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2006
- 2006-07-17 DE DE102006032955A patent/DE102006032955A1/en not_active Withdrawn
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2007
- 2007-06-21 BR BRPI0714388-5A patent/BRPI0714388B1/en not_active IP Right Cessation
- 2007-06-21 CA CA002663893A patent/CA2663893A1/en not_active Abandoned
- 2007-06-21 UA UAA200900293A patent/UA98939C2/en unknown
- 2007-06-21 RU RU2009105244/02A patent/RU2439163C2/en active
- 2007-06-21 KR KR1020097003244A patent/KR20090033392A/en not_active Application Discontinuation
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- 2007-06-21 PL PL07786792T patent/PL2041324T3/en unknown
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- 2007-06-21 EP EP07786792.7A patent/EP2041324B1/en active Active
- 2007-06-21 CN CN2007800272004A patent/CN101490283B/en not_active Expired - Fee Related
- 2007-06-21 US US12/373,735 patent/US20090315229A1/en not_active Abandoned
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| BRPI0714388B1 (en) | 2015-08-18 |
| CN101490283B (en) | 2012-08-01 |
| US20090315229A1 (en) | 2009-12-24 |
| RU2439163C2 (en) | 2012-01-10 |
| KR20090033392A (en) | 2009-04-02 |
| WO2008009536A1 (en) | 2008-01-24 |
| RU2009105244A (en) | 2010-08-27 |
| EP2041324B1 (en) | 2013-07-31 |
| MX2009000617A (en) | 2009-01-29 |
| CN101490283A (en) | 2009-07-22 |
| PL2041324T3 (en) | 2013-12-31 |
| BRPI0714388A2 (en) | 2013-02-19 |
| UA98939C2 (en) | 2012-07-10 |
| EP2041324A1 (en) | 2009-04-01 |
| DE102006032955A1 (en) | 2008-02-07 |
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| Date | Code | Title | Description |
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| EEER | Examination request | ||
| FZDE | Discontinued |
Effective date: 20140623 |