CN102527969A - Automatic ladle slag outflow detection system and method thereof - Google Patents
Automatic ladle slag outflow detection system and method thereof Download PDFInfo
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Abstract
The invention discloses an automatic ladle slag outflow detection system and a method thereof. The automatic ladle slag outflow detection system comprises an audio frequency sensor, an audio frequency signal preprocessing device and a main control device. The audio frequency sensor is used for acquiring corresponding sound signals generated when molten steel and steel slag flow out of a gate and converting the sound signals into corresponding analog waveform and then outputting the analog waveform to the audio frequency signal preprocessing device. The audio frequency signal preprocessing device is used for converting the analog waveform corresponding to the molten steel and steel slag sound signals into corresponding digital signals and then outputting the digital signals to the main control device. The main control device is used for analyzing and recognizing characteristic sound spectrum of steel slag according to the digital signals corresponding to the molten steel and steel slag sound signals so as to judge whether molten steel flows into tundish contains steel slag or not. The automatic ladle slag detection system has the advantages that the time for ladle slag outflow can be determined in time accurately, and the process of pouring the tundish by molten steel of the ladle through the gate is realized under accurate control.
Description
Technical field
The present invention relates to industrial ladle roughing slag detection technique, relate in particular to the automatic checkout system and the method for bale slag-blanking.
Background technology
Ladle in the basket pouring process for preventing secondary oxidation of steel, generally adopt long nozzle protection steel stream.
In order to control tundish slag content, reduce the following quantity of slag wherein, near at the end, a lot of steel mills adopt following mode to detect the ladle roughing slag situation at steel ladle pouring.
The one, remove long nozzle in advance, according to the color of molten steel and slag, judge whether down slag through the macroscopic method of manual work.
Though this method is simple, can produce a lot of harmful effects.And owing to remove long nozzle in advance, the molten steel that big bag is cast latter stage will be by secondary oxidation.
Because molten steel and slag are red-hot state, work under bad environment, the operative employee is difficult to accurately judge whether down slag, when steel stream reaches full slag basically, just can tell down slag, closes slide gate nozzle then, and this moment, existing a large amount of slags got into tundish.For avoiding the generation of this kind situation, the operator mouth of a river of having to close in advance, especially all the more so to strict steel grade.Will cause residual steel amount rising in the ladle like this, the reduction of molten steel recovery rate.
Because of slag subjectivity under the artificial judgment is bigger, cause tundish slag amount to increase sometimes, and slag have very big erosion to the refractory material of tundish, can shorten the life-span of tundish refractory material and sliding gate slide board.In addition, the strong oxidizing property slag gets into molten steel total oxygen amount increase in the tundish, causes casting blank defect.And the steel that detects by an unaided eye for a long time flows down the slag situation, can damage or make its face to burn to operator's eyes, is unfavorable for the labour protection to the workman.
The 2nd, for improving the degree of purity of tundish molten steel, improve slab quality, reduce the residual steel amount of ladle and prolong the middle cylinder-packing refractory life-span etc., in the steel ladle pouring later stage following slag is carried out automatic Detection & Controling.
At present, the method that both at home and abroad the ladle roughing slag situation is detected automatically is a lot, as the detection method of weighing, electromagnetic detection method, ultrasonic Detection Method and infrared detection method, vibration detection method etc.Wherein obtain practical application in the many iron and steel enterprises of electromagnetic detection method and vibration detection method at home and abroad.
The electromagnetic detection method of bale slag-blanking, its principle are to utilize the different slags that detect of molten steel and slag magnetic conductivity.When high frequency electric through first coil, when hub of a spool has steel to flow through again, steel stream will have the magnetic field generation.Iron companies such as domestic Wuhan Iron and Steel Plant, Baosteel etc. are all developing and are producing as a trial.But in use expose many problems; Wherein the most outstanding a bit is, existing method need be embedded in cell winding near the steel base brick mouth of a river, and this just need transform all ladles of continuous casting workshop; And cell winding is positioned near the tapping hole; Therefore higher because of environment temperature, also can be had a strong impact on its service life, uses the expense of manufacturing and maintenance of this system all very high.
The vibration detection method of bale slag-blanking, its initial origin of practice is in the scene of pouring molten steel.In casting process, the variation of the ladle long nozzle motion arm vibration that veteran operative employee can experience through casting latter stage and, judge ladle thus and whether descend slag prior to visual observation.A large amount of field experiences has proved that also the molten steel and the slag amount that flow in vibration and the long nozzle of motion arm are closely related.In fact, flow into from ladle the process of tundish at molten steel, the long nozzle pipe can produce stronger vibration with the motion arm that is attached thereto, and mouth of a river aperture is big more, makes molten steel flow big more, then vibrates with regard to Shaoxing opera strong; And slag proportion approximately is 1/3rd of molten steel, therefore will inevitably be variant by the vibration that slag flows and the clean steel water flows causes.Therefore, should be able to detect the situation of change of MOLTEN STEEL FLOW state in the long nozzle in theory indirectly through the vibration of detecting operation arm.
The core of the vibration detection method of above-mentioned bale slag-blanking is analysis and the processing to vibration signal, promptly and accurately to judge in the steel stream whether be mixed with slag, and therefrom extracts the slag characteristic parameter, sends and sees the slag signal.Because the vibration situation more complicated in the casting process, the factor that influences the motion arm vibration is a lot, and for example, the aperture of steel ladle sliding water gap is to the influence of vibration signal; The impact that whole ladle turret is brought in the seat ladle process in steel ladle pouring latter stage is to the influence of motion arm vibration; The certain operations environment, is thrown away heat preserving agent etc. at dross around going up and down, heat up water mouthful such as: the switch mouth of a river, ladle, all can bring influence to the motion arm vibration; Because of motion arm structure difference causes system's carry-over factor different, make the system that only depends on the vibration signal monitoring be difficult to be provided with this carry-over factor, so performance difference is huge in the different system of motion arm structure.
Therefore, in the vibration signal that collects through motion arm,,, control thereby can't pour into a mould big bag according to this judgement if vibration signal, can't judge whether big bag descend slag without processing owing to comprised a large amount of and the irrelevant information of slag characteristic.
Can know that in sum there is the problem that is difficult to overcome in the whole bag of tricks that existing ladle roughing slag situation automatically detects in practical application, will inevitably have influence on the judgement of bale slag-blanking and the control of slide gate nozzle.
Summary of the invention
Technical problem to be solved by this invention provides a kind of automatic checkout system and method for bale slag-blanking, can judge bale slag-blanking in time, exactly.
In order to solve the problems of the technologies described above, the invention provides a kind of automatic checkout system of bale slag-blanking, comprise the audio sensor, audio signal pretreatment unit and the master control set that connect successively, wherein:
Audio sensor, corresponding voice signal when being used to gather molten steel and slag and flowing out the mouth of a river, and convert corresponding analog waveform to and export the audio signal pretreatment unit to;
The audio signal pretreatment unit is used for converting the analog waveform corresponding to molten steel and slag voice signal to digital signal corresponding and exports master control set to;
Master control set is used for from analyzing the characteristic sound spectrum of identification slag corresponding to the data signal of molten steel and slag voice signal, thereby judges to flow into whether contain slag in the molten steel in the tundish.
Preferably,
Audio sensor is installed on the mechanical arm that contacts with the mouth of a river and away from the inside or the outside of the mouth of a river one end, through this mechanical arm collected sound signal; Or be installed on the ground Board position that carries tundish, through direct contact collected sound signal; Perhaps utilizing high directional microphone to point to mouth of a river protective sleeve gathers via airborne voice signal; Convert the voice signal of gathering the output of to correspondent voltage waveform.
Preferably,
The audio signal pretreatment unit will carry out preparatory processing and amplifying corresponding to the voltage waveform of molten steel and slag voice signal through automatic gain control amplifier; Through wave filter the voltage waveform of preparatory amplification is carried out Filtering Processing, will convert corresponding data signal output through the voltage waveform of Filtering Processing to through analog-digital converter.
Preferably,
Master control set will carry out digital filtering corresponding to the data signal of molten steel and slag voice signal to be handled; The data signal of handling through digital filtering is carried out vectorization to be handled; Analyze said vectorization process result, identify the characteristic sound spectrum of slag.
Preferably,
When master control set contains slag in the molten steel of judging big bag inflow tundish, send alarm signal; And/or send the control signal of closing the mouth of a river, pour into a mould from the mouth of a river to stop molten steel.
Preferably,
Near the molten steel casting image at this mouth of a river of the camera acquisition of installing the mouth of a river in data signal that master control set is weighed with reference to the big bag of wrapping the big bag LOAD CELLS sensing of installation greatly and the tundish; Reject and judge the interfering signal that whether contains slag in the molten steel that flow into tundish, thereby improve the accuracy of judging.
In order to solve the problems of the technologies described above, the invention provides a kind of automatic testing method of bale slag-blanking, comprising:
Corresponding voice signal when gathering the molten steel and the slag outflow mouth of a river through audio sensor, and convert corresponding analog waveform output to;
Convert the analog waveform of audio sensor output to digital signal corresponding;
From characteristic sound spectrum, thereby judge to flow into whether contain slag in the molten steel in the tundish corresponding to analysis identification slag the data signal of molten steel and slag voice signal.
Preferably, corresponding voice signal when gathering the molten steel and the slag outflow mouth of a river through audio sensor, and convert corresponding analog waveform output to, specifically comprise:
Be installed on the mechanical arm that contacts with the mouth of a river and, gather said voice signal through mechanical arm away from the inside or the outside audio sensor of the mouth of a river one end; Or be installed on the audio sensor of the ground Board position that carries tundish, through direct contact collected sound signal; Or utilize high directional microphone to point to mouth of a river protective sleeve and gather via airborne voice signal;
Audio sensor or microphone convert the voice signal of gathering the output of to correspondent voltage waveform.
Preferably, the analog waveform that audio sensor is exported converts digital signal corresponding to, specifically comprises:
To carry out preparatory processing and amplifying corresponding to the voltage waveform of molten steel and slag voice signal through automatic gain control amplifier; Through wave filter the voltage waveform of preparatory amplification is carried out Filtering Processing, will convert corresponding data signal through the voltage waveform of Filtering Processing to through analog-digital converter.
Preferably, the characteristic sound spectrum from corresponding to analysis identification slag the data signal of molten steel and slag voice signal specifically comprises:
To carry out digital filtering corresponding to the data signal of molten steel and slag voice signal handles;
The data signal of handling through digital filtering is carried out vectorization to be handled;
Analyze the vectorization process result, identify the characteristic sound spectrum of slag.
Preferably, this method also comprises:
When in the molten steel of judging big bag inflow tundish, containing slag, send alarm signal; And/or send the control signal of closing the mouth of a river, stop pour steel and/or stop pour steel with caution.
Preferably, also comprise:
Near the molten steel casting image at this mouth of a river of the camera acquisition of installing the mouth of a river in data signal of weighing with reference to the big bag of wrapping the big bag LOAD CELLS sensing of installation greatly and the tundish; Reject and judge the interfering signal that whether contains slag in the molten steel that flow into tundish, thereby improve the accuracy of judging.
The present invention utilizes that the proportion of slag and molten steel is different can to cause different these principles of the two noise that through the mouth of a river time, produces; And utilize voice signal can propagate this advantage effectively because of attenuation coefficient is little through firm mechanical arm; Pick up the voice signal on the mechanical arm through highly sensitive audio detection device, collect data signal corresponding to voice signal through pretreatment unit processing and amplifying and analog-to-digital conversion; Through the data signal of gathering is carried out a series of subsequent treatment, tell the characteristic sound spectrum of slag, thereby judge the moment of bale slag-blanking in time, exactly, and realize thus of the accurate control of big Baogang water through mouth of a river cast tundish.
The present invention collects voice signal faint on the mechanical arm more easily with respect to the vibration detection method, can not influence the collection to voice signal because of the difference of mechanical arm structure; Adopt AGC to amplify the voice signal of collection in advance, the overshoot that the impact that can avoid happening suddenly causes; Audio signal is detected, be prone to by the standard voice signals storage, and be convenient to the playback analysis, and can make full use of the audio analysis storehouse and speech recognition technology is accurately differentiated slag characteristic sound spectrum.
Description of drawings
Fig. 1 is the structured flowchart of the automatic checkout system embodiment of bale slag-blanking of the present invention;
Fig. 2 is the flow chart of the automatic testing method embodiment of bale slag-blanking of the present invention.
The specific embodiment
Below in conjunction with accompanying drawing and preferred embodiment technical scheme of the present invention is at length set forth.The embodiment that below gives an example only is used for explanation and explains the present invention, and does not constitute the restriction to technical scheme of the present invention.
As shown in Figure 1, be the structure of the automatic checkout system embodiment of bale slag-blanking provided by the invention, comprise the audio sensor, audio signal pretreatment unit and the master control set that connect successively, wherein:
Audio sensor, corresponding voice signal when being used to gather molten steel and slag and flowing out the mouth of a river, and convert corresponding analog waveform to and export the audio signal pretreatment unit to;
Above-mentioned audio sensor can be installed on inside or the outside of mechanical arm away from the mouth of a river one end, and is as shown in Figure 1, through the mechanical arm collected sound signal; Or be installed on the ground Board position that carries tundish, through direct contact collected sound signal, perhaps utilize high directional microphone to point to mouth of a river protective sleeve and gather via airborne voice signal.
Audio sensor for example converts the voice signal of gathering the output of to correspondent voltage waveform.Perhaps, in another embodiment, audio sensor also can convert the voice signal of gathering to corresponding current waveform output.
The audio signal pretreatment unit is used for converting the analog waveform corresponding to molten steel and slag voice signal to digital signal corresponding and exports master control set to;
The audio signal pretreatment unit is through automatic gain control (AGC; Auto-Gain Control) amplifier will carry out preparatory processing and amplifying corresponding to the voltage waveform of molten steel and slag voice signal; Through wave filter the voltage waveform that amplifies is carried out Filtering Processing; The voltage waveform of filtering is converted to the data signal output of correspondence through analog-digital converter (ADC, Analog Digital Converter).
Master control set is used for from analyzing the characteristic sound spectrum of identification slag corresponding to the data signal of molten steel and slag voice signal, thereby judges to flow into whether contain slag in the molten steel in the tundish.
Master control set will carry out digital filtering corresponding to the data signal of molten steel and slag voice signal to be handled, and the data signal of handling through digital filtering is carried out vectorization handle, and analyzes the result of warp-wise quantification treatment, identifies the characteristic sound spectrum of slag.
For example, master control set carries out this data signal the digital filtering processing of time domain and frequency domain; Handle carry out vectorization through the data signal of digital filtering through wavelet algorithm; Analyze the vectorization process result through neuroid, identify the characteristic sound spectrum of slag.
When master control set contains slag in the molten steel of judging big bag inflow tundish, send alarm signal, and/or send the control signal of closing slide gate nozzle, continue to pour into a mould from slide gate nozzle to stop molten steel.
The present invention except master control set from corresponding to the characteristic sound spectrum of analyzing the identification slag the data signal of molten steel and slag voice signal, also be aided with molten steel casting image that near install the mouth of a river in data signal that the big bag of big bag LOAD CELLS (not shown) sensing of wrapping installation greatly weighs and the tundish video camera (not shown) gathers this mouth of a river to master control set;
The data signal that master control set is weighed with reference to big bag and to molten steel casting and following slag image recognition is rejected and is judged the interfering signal that whether contains slag in the molten steel that flow into tundish, thereby improves the accuracy of judgement.
The present invention is directed to said system embodiment, the automatic testing method embodiment of bale slag-blanking correspondingly also is provided, its flow process is as shown in Figure 2, comprises the steps:
210: the voice signal when through audio sensor the molten steel that collects and slag being flowed out the mouth of a river converts analog waveform to;
Audio sensor can be installed on inside or the outside of mechanical arm away from the mouth of a river one end, picks up voice signal through mechanical arm; Or be installed on tundish ground Board position and pick up voice signal through direct contact, perhaps utilize high directional microphone to point to mouth of a river protective sleeve and gather via airborne voice signal.
Audio sensor for example converts the voice signal of gathering the output of to correspondent voltage waveform.
220: convert the analog waveform of the voice signal of audio sensor output to digital signal corresponding;
To carry out preparatory processing and amplifying corresponding to the voltage waveform of molten steel and slag voice signal through automatic gain control (AGC) amplifier; Through wave filter the voltage waveform that amplifies is carried out Filtering Processing, the correspondent voltage waveform transformation is become corresponding data signal through analog-digital converter (ADC).
230: will carry out digital filtering and vectorization processing corresponding to the data signal of molten steel and slag voice signal, according to the characteristic sound spectrum of vectorization interpretation of result identification slag;
To carry out digital filtering corresponding to the data signal of molten steel and slag voice signal handles;
The data signal of handling through digital filtering is carried out vectorization handle, analyze the result of warp-wise quantification treatment, identify the characteristic sound spectrum of slag.
For example, will carry out the digital filtering processing of time domain and/or frequency domain corresponding to the data signal of molten steel and slag voice signal; Handle carry out vectorization through the data signal of digital filtering through wavelet algorithm; Analyze the vectorization process result through neuroid, identify the characteristic sound spectrum of slag.
When the molten steel propagated through mechanical arm through above-mentioned audio sensor sensing and slag flow out the mouth of a river the corresponding voice signal; The molten steel casting image that also is aided with near this mouth of a river of camera acquisition of installing the mouth of a river in data signal that the big bag of big bag LOAD CELLS sensing of wrapping installation greatly weighs and the tundish; Reject and judge the interfering signal that whether contains slag in the molten steel that flow into tundish, thereby improve the accuracy of judging.
240: judging in the molten steel that flows into tundish whether contain slag, is then to carry out next step, carries out otherwise return step 230;
250: send alarm signal and/or close the control signal of slide gate nozzle, stop pouring molten steel and/or stop pouring molten steel with caution; Process ends.
In fact, circulate within a certain period of time and carry out in step 230 in the above-mentioned flow process～250th, with continuous judgement bale slag-blanking situation, and the switching at the mouth of a river carried out control corresponding.
Claims (12)
1. the automatic checkout system of a bale slag-blanking is characterized in that, comprises the audio sensor, audio signal pretreatment unit and the master control set that connect successively, wherein:
Said audio sensor, corresponding voice signal when being used to gather molten steel and slag and flowing out the mouth of a river, and convert corresponding analog waveform to and export said audio signal pretreatment unit to;
Said audio signal pretreatment unit is used for converting the analog waveform corresponding to molten steel and slag voice signal to digital signal corresponding and exports said master control set to;
Said master control set is used for discerning the characteristic sound spectrum of slag from the said data signal analysis corresponding to molten steel and slag voice signal, thereby judges to flow into whether contain slag in the molten steel in the tundish.
2. according to the described system of claim 1, it is characterized in that,
Said audio sensor is installed on the mechanical arm that contacts with the said mouth of a river and away from the inside or the outside of the said mouth of a river one end, gathers said voice signal through said mechanical arm; Or be installed on the ground Board position that carries said tundish, gather said voice signal through direct contact; Perhaps utilizing high directional microphone to point to mouth of a river protective sleeve gathers via airborne said voice signal; Convert the said voice signal of gathering the output of to correspondent voltage waveform.
3. according to the described system of claim 2, it is characterized in that,
Said audio signal pretreatment unit carries out preparatory processing and amplifying through automatic gain control amplifier with said said voltage waveform corresponding to molten steel and slag voice signal; Through wave filter the voltage waveform of preparatory amplification is carried out Filtering Processing, will convert corresponding data signal output through the voltage waveform of Filtering Processing to through analog-digital converter.
4. according to each described system of claim 1 to 3, it is characterized in that,
Said master control set carries out digital filtering with said data signal corresponding to molten steel and slag voice signal to be handled; The data signal of handling through said digital filtering is carried out vectorization to be handled; Analyze said vectorization process result, identify the characteristic sound spectrum of said slag.
5. according to each described system of claim 1 to 3, it is characterized in that,
When said master control set contains slag in the molten steel of judging said big bag inflow tundish, send alarm signal; And/or send the control signal of closing the said mouth of a river, pour into a mould from the said mouth of a river to stop molten steel.
6. according to each described system of claim 1 to 3, it is characterized in that,
Near the molten steel casting image at this mouth of a river of the camera acquisition of installing the mouth of a river in data signal that the big bag that the big bag LOAD CELLS sensing of installation is wrapped in said master control set reference is greatly weighed and the tundish; Reject said judgement and flow in the molten steel of tundish whether contain the interfering signal of slag, thereby improve the accuracy of said judgement.
7. the automatic testing method of a bale slag-blanking comprises:
Corresponding voice signal when gathering the molten steel and the slag outflow mouth of a river through audio sensor, and convert corresponding analog waveform output to;
Convert the said analog waveform of said audio sensor output to digital signal corresponding;
From characteristic sound spectrum, thereby judge to flow into whether contain slag in the molten steel in the tundish corresponding to analysis identification slag the said data signal of said molten steel and slag voice signal.
8. according to the described method of claim 7, it is characterized in that, corresponding voice signal when gathering the molten steel and the slag outflow mouth of a river through audio sensor, and convert corresponding analog waveform output to, specifically comprise:
Be installed on the mechanical arm that contacts with the said mouth of a river and, gather said voice signal through said mechanical arm away from the inside or the outside said audio sensor of the said mouth of a river one end; Or be installed on the said audio sensor of the ground Board position that carries said tundish, gather said voice signal through direct contact; Or utilize high directional microphone to point to mouth of a river protective sleeve and gather via airborne said voice signal;
The said voice signal that said audio sensor or said microphone will be gathered converts the output of correspondent voltage waveform to.
9. according to the described method of claim 8, it is characterized in that the said analog waveform that said audio sensor is exported converts digital signal corresponding to, specifically comprises:
To carry out preparatory processing and amplifying corresponding to the said voltage waveform of molten steel and slag voice signal through automatic gain control amplifier; Through wave filter the voltage waveform of preparatory amplification is carried out Filtering Processing, will convert corresponding data signal through the voltage waveform of Filtering Processing to through analog-digital converter.
10. according to each described method of claim 7 to 9, it is characterized in that the characteristic sound spectrum from corresponding to analysis identification slag the said data signal of said molten steel and slag voice signal specifically comprises:
Said data signal corresponding to molten steel and slag voice signal is carried out digital filtering to be handled;
The data signal of handling through said digital filtering is carried out vectorization to be handled;
Analyze said vectorization process result, identify the characteristic sound spectrum of said slag.
11. according to each described method of claim 7 to 9, it is characterized in that, also comprise:
When in the molten steel of judging said big bag inflow tundish, containing slag, send alarm signal; And/or send the control signal of closing the said mouth of a river, stop pour steel and/or stop pour steel with caution.
12. according to each described method of claim 7 to 9, it is characterized in that, also comprise:
Near the molten steel casting image at this mouth of a river of the camera acquisition of installing the mouth of a river in data signal of weighing with reference to the big bag of wrapping the big bag LOAD CELLS sensing of installation greatly and the tundish; Reject said judgement and flow in the molten steel of tundish whether contain the interfering signal of slag, thereby improve the accuracy of said judgement.
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Cited By (2)
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| CN109239193A (en) * | 2018-10-26 | 2019-01-18 | 山东钢铁股份有限公司 | A method of for detecting converter slag |
| CN113634727A (en) * | 2021-07-19 | 2021-11-12 | 盐城市联鑫钢铁有限公司 | Automatic closing method and system for ladle sliding nozzle |
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| CN113634727A (en) * | 2021-07-19 | 2021-11-12 | 盐城市联鑫钢铁有限公司 | Automatic closing method and system for ladle sliding nozzle |
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Application publication date: 20120704 |