CN102534097A - Converter tapping monitoring control system based on thermal image processing - Google Patents
Converter tapping monitoring control system based on thermal image processing Download PDFInfo
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- CN102534097A CN102534097A CN2012100545201A CN201210054520A CN102534097A CN 102534097 A CN102534097 A CN 102534097A CN 2012100545201 A CN2012100545201 A CN 2012100545201A CN 201210054520 A CN201210054520 A CN 201210054520A CN 102534097 A CN102534097 A CN 102534097A
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Abstract
The invention relates to the field of automation control of ferrous metallurgy and aims at providing a converter tapping monitoring control system based on thermal image processing. The converter tapping monitoring control system comprises a far infrared data collecting module, an industrial field control unit, an industrial field auxiliary unit and a system control unit, wherein the far infrared data collecting module is connected with a far infrared thermal imaging instrument; the system control unit comprises a split mounting type indoor control cabinet; and functional devices such as an industrial grade liquid crystal display device, an industrial grade personal computer, an industrial field processing control unit, a power source management unit and an electrical control unit are integrated inside the split mounting type indoor control cabinet. For the converter tapping monitoring control system, the component-based module design and encapsulation are adopted, the system cohesion is increased, and the coupling between modules is reduced so that the converter tapping monitoring control system can be reconstructed according to different continuous casting production conditions and process requirements. The converter tapping monitoring control system is convenient to install and maintain and has no influence on steel-making production as the original equipment is not transformed; and the converter tapping monitoring control system has the advantages of non-contact type detection, automatic regulation of internal temperature, automatic dust removal, sealing protection of a metal housing and long service life.
Description
Technical field
The present invention relates to the ferrous metallurgy automation control area, especially relate to a kind of converter tapping monitor control system of handling based on heat picture.
Background technology
In the STEELMAKING PRODUCTION process, must be strict the following quantity of slag during control converter tapping, if when converter tapping pushing off the slag inefficacy or effect are undesirable; Can cause ladle top slag to increase; In the refining procedure in step of back, with consuming more reductor ladle slag is carried out the deoxidation modification, increase the refining cost.Simultaneously, the following quantity of slag is excessive, and molten steel rephosphorization, Hui Meng very easily takes place and returns silicon in refining process, molten steel composition control difficulty.During liquid steel refining, the oxygen in the ladle slag is diffused in the molten steel, causes composition such as Al, Si scaling loss and secondary oxidation of steel in the molten steel, in steel, forms new inclusion, pollutes molten steel, worsens steel quality.Following quantity of slag when therefore, steelmaking process should reduce tapping as far as possible.The following quantity of slag of general requirement ton steel is controlled at below 4～6kg and is advisable at present.
Minimizing tapping slag down can bring following benefit: the quantity of slag under directly reducing; Reduce reductor and alloy consumption, the economical with materials cost; Improve the molten steel purity, reduce rephosphorization sulphur, reduce the degree of oxidation of molten steel in the ladle, improve the quality of products; Minimizing is to the erosion of refractorily lined, prolongs furnace lining work-ing life; Reduce tap hole, inner nozzle wearing and tearing, prolong tap hole, inner nozzle work-ing life.
The slag detection mode has three kinds under the converter that at present national each big steel mill mainly adopts: artificial visually examine's method, coil detect, infrared thermal imagery detects.
Artificial visually examine's method is to use maximum a kind of detection methods; But because sensitivity is low; The result receives operator's experience and emotion influence bigger, thus improve steel quality and the angle of practicing thrift the steel cost consider need be more accurate and the stable detection mode to replace manual work.
The coil detection method adopts high-temperature material that elementary, secondary two coils are isolated, and according to the specific conductivity of slag in the beam specific conductivity far below molten steel, the difference of measuring EM field detects slag down.This kind method detection sensitivity is artificial high, but measures for deflection type, and coil working is unstable in the hot environment life-span, and the spare part expense is high.
The infrared detection method is different with the infrared emittance of slag according to molten steel, latter stage steel stream is shone in tapping through thermal infrared imager to obtain molten steel slag mixed flow image, draws the ratio that slag accounts for steel stream through video processnig algorithms and judges the method for slag down.Infrared detection technology obtains widespread use in industry spot in recent years more and more, because infrared detection has the noncontact characteristic, has remarkable advantages to the high temperature occasion of smelting iron and steel.Characteristics such as the infrared detection method has highly sensitive, and fitting operation is simple, safeguards easily, and running cost is low progressively become the main means that slag detects under the converter tapping.
Slag detects and is based in the particular range of wavelengths under the infrared method converter; The infrared signature of molten steel and slag has and designs than these characteristics of big-difference; So add different alloys and different smelting technologyes in the molten steel, all can cause the significant difference of the infrared signature of molten steel and slag.Aspect detection system, the configuration of the different parameters of thermal infrared imager, particularly the type selecting of infrared filter directly has influence on the differentiation effect of molten steel and slag; In addition, the image analysis algorithm part of detection software also need customize to the infrared radiation characteristic situation of subject.In addition, also there is following problems in existing infrared slag detection system down: system architecture designs for non-structured, is difficult to carry out reconstruction and optimization according to different continuous casting working conditions and process requirements; In the Image Dynamic treating processes, resolving power is non-adjustable, thereby causes its recognition rate to be difficult to be guaranteed.
Summary of the invention
The technical problem that the present invention will solve is, overcomes deficiency of the prior art, and a kind of converter tapping monitor control system of handling based on heat picture is provided.
For solving its technical problem, the technical scheme that the present invention adopted is:
A kind of converter tapping monitor control system of handling based on heat picture is provided; Comprise the far infrared data acquisition module (IVS) that is connected to far infrared thermal imager, also comprise industry spot control unit (IFCU), industry spot auxiliary unit (IFAU) and system control unit (IMCU);
Wherein, industry spot control unit (IFCU) is the front-end control member of system, be used to realize graphical user interface at the scene long-range demonstration, control onsite alarming device and the execute-in-place switch is provided; Industry spot auxiliary unit (IFAU) is used for accepting the steering order from system control unit (IMCU) 4, and realizes the wave and the view data transmission of far infrared data acquisition module (IVS); System control unit (IMCU) comprises an indoor housing of piecing assembly, its inner integrated following function device: technical grade liquid crystal display device (ILCD), technical grade Personal Computer (IPC), industry spot processing and control element (PCE) (IPCU), PMU (IPMU) and electric control unit (IECU);
Wherein, industry spot processing and control element (PCE) (IPCU) is used to accept the realtime graphic signal that industry spot auxiliary unit (IFAU) is uploaded, and realize Signal Pretreatment, output wave and with technical grade Personal Computer (IPC) communication; PMU (IPMU) is used to that each module provides power supply in the system; Electric control unit (IECU), the electrical control and the cable that are used for system connect;
Said industry spot processing and control element (PCE) (IPCU) is connected to the following function device respectively: be connected to industry spot control unit (IFCU) through cable, realize the transmission of switching value signal and vision signal; Connect industry spot auxiliary unit (IFAU), far infrared data acquisition module (IVS) 1 and far infrared thermal imager successively through cable, realize the transmission of view data and wave; Be connected to technical grade Personal Computer (IPC) through cable, realize the transmission of switching value and simulating signal, wave;
Said electric control unit (IECU) is connected to PMU (IPMU) through cable, and PMU (IPMU) is connected to industry spot processing and control element (PCE) (IPCU), industry spot control unit (IFCU), far infrared data acquisition module (IVS) and Personal Computer (IPC) through cable respectively; Far infrared data acquisition module (IVS) is realized power supply by industry spot auxiliary unit (IFAU).
Among the present invention, the cabinet of said system control unit (IMCU) 4 housings is through the surface treatment cold drawing, and its bottom is provided with ground terminal, and the top is furnished with fan disk; The bottom is provided with the line hole, so that being connected of supply lead, SW and wire to be provided.
Among the present invention, said electric control unit (IECU) comprises air switch, power safety, panel control and circuit connector.
Among the present invention, the inside of said far infrared data acquisition module (IVS) is also integrated TP, coil heats device, gas quench system and cleaning apparatus.
Among the present invention, said industry spot control unit (IFCU) is connected to the onsite alarming device, and said onsite alarming device is warning light and alarming horn.
Compared with prior art, beneficial effect of the present invention mainly shows:
1, adopts componentization modular design method, infrared slag detection system is down carried out the modularization encapsulation, gather in the increase system, reduce the coupling between the module, make it carry out reconstruct according to different continuous casting working conditions and process requirements.
2, adopt the figure signal treatment process of software filtering and wavelet transformation, can realize the multiresolution analysis and the identification in time-frequency two territories, improved Dynamic Recognition efficient, thereby success ratio is reliably guaranteed the molten steel radiant ratio.
3, convenient for installation and maintenance, do not transform existing equipment, do not influence STEELMAKING PRODUCTION;
4, adopt import uncooled ir thermal imaging system, resolving power is high, and is quick on the draw at 8-14 μ m far infrared band;
5, non-contact detection, transmitter installation site be apart from tap hole 10-30m, and internal temperature is regulated automatically, dedusting automatically, metal housing seal protection, long service life;
6, clear demonstration live view, tapping process, steel stream and slag;
7, adopt advanced image boundary and steel stream feature intelligent extractive technique, and descend slag to differentiate algorithm accurately and effectively;
8, hommization software design, objective interface is friendly, and system parameter is online adjustable;
9, observation interface is on-the-spot shows synchronously, reports to the police promptly and accurately.
Description of drawings
Fig. 1 is a system function framework synoptic diagram;
Fig. 2 is the system module composition and is electrically connected synoptic diagram.
Reference numeral among Fig. 1: 1 far infrared data acquisition module (IVS) 1; 2 industry spot auxiliary units (IFAU); 3 industry spot control units (IFCU); 4 system control units (IMCU); 5 cables.
Embodiment
In conjunction with accompanying drawing, be elaborated in the face of the present invention down.
1. system function framework and module are formed
Overall technological scheme of the present invention is: the steel stream thermal image signal when utilizing far infrared thermal imager to gather converter tapping; According to comprising molten steel, the thermal emissivity rate difference of slag in specific far infrared wave segment limit in the steel stream; In conjunction with wavelet transform (Discrete Wavelet Transfer, DWT) algorithm carries out ONLINE RECOGNITION to the steel stream mode; And then send relevant steering order; Drive on-the-spot executive device, accomplish the real-time monitoring of converter tapping and control automatically, finally reach the slag content that can reduce in the ladle, again can improve the molten steel yield, reduce the purpose of labor strength.
The function framework of system is by system control unit (Industrial Monitoring Control Unit; IMCU), industry spot control unit (Industrial Field Control Unit; IFCU), industry spot auxiliary unit (Industrial Field Associated Unit; IFAU), (Infrared Video Sampling System IVS) waits composition to the far infrared data acquisition module.
The inside of far infrared data acquisition module (IVS) 1 is integrated TP, coil heats device, gas quench system and cleaning apparatus; Above-mentioned configuration can effectively keep the relative stability of infrared video camera envrionment temperature, reduces the interference of on-the-spot dust to picture quality.Far infrared data acquisition module (IVS) 1 gathers metallurgical industry on-the-spot steel stream picture signal, temperature signal, converter dip angle signal, oxygen rifle altitude signal and the body of heater signal that rocks back and forth through far infrared thermal imager; Through the cable 5 of migrating with above-mentioned signal conveys to industry spot processing and control element (PCE); And carry out OPERA, and obtain current steel stream mode through exporting the technical grade Personal Computer to after the numerary signal pretreatment operation.System control unit (IMCU) 4 is system's steering order with the steel stream mode conversion of signals that obtains, and exports industry spot control unit (IFCU) 3 to through SW, drives alarming horn and warning light work, and automatically the console stove with close the tap hole slide plate.
Industry spot control unit (IFCU) the 3rd, the front-end control member of system is according to the instruction that system control unit (IMCU) 4 sends, driving execution device.The following function of main completion: graphical user interface long-range demonstration at the scene; Control onsite alarming device comprises slag alarming horn under warning light control of the Lamb-5 five colors and the MS-24; Supply the site operation personnel manually to drop into and detect and close detection (system default is for automatic); Supply the site operation personnel to carry out manually or close slide plate automatically.Industry spot control unit (IFCU) 3 modules link to each other with other modules at scene as the core component of field control.From the signal at scene, like far infrared data acquisition module (IVS) 1 temperature, vision signal, converter inclination angle, oxygen rifle height, alarm level, close etc. and to do the industry spot processing and control element (PCE) (IPCU) of delivering to system control unit (IMCU) 4 after prime is handled automatically by industry spot control unit (IFCU) 3 modules.
The major function of industry spot auxiliary unit (IFAU) 2 is to be far infrared data acquisition module (IVS) 1 service; For it provides power supply and cooling and heating source of the gas, cooling, heating and the dust removal operation of startup, initialize, IMAQ and the far infrared data acquisition module (IVS) 1 of receiving system control unit (IMCU) 4 control commands control far infrared data acquisition modules (IVS) 1 simultaneously; The working order of far infrared data acquisition module (IVS) 1 uploads to (comprising envrionment temperature, operating mode, working parameter etc.) system control unit (IMCU) 4 of converter watch-keeping cubicle housing via industry spot auxiliary unit (IFAU) 2.
System control unit (IMCU) 4 is the indoor housing of piecing assembly, and metallic substance adopts the cold rolled quality steel sheet after the surface treatment, thereby the protective value that guarantees frame is good, erosion resistance is strong; Housing is provided with ground terminal in the bottom, and the ground wire in the machine room can directly connect on the ground terminal of housing bottom; The housing top is furnished with fan disk, successfully discharges to guarantee the warm air in the housing; The housing bottom is provided with the line hole, and being connected of supply lead, SW and wire can be provided.
System control unit (IMCU) the 4th, the leitungskern member of system, its installation site is the metallurgical plant main control room, accomplishes the online judgement of converter tapping process and control automatically; Based on above-mentioned requirements; The inside of system control unit (IMCU) 4 is integrated following functional device: technical grade liquid crystal display device (Industrial Liquid Crystal Device; ILCD), technical grade Personal Computer (Industrial Personal Computer; IPC), industry spot processing and control element (PCE) (Industrial Processing Control Unit; IPCU), PMU (Industrial Power Management Unit, IPMU) and electric control unit (Industrial Electric Control Unit, IECU).
Industry spot processing and control element (PCE) (IPCU) is accepted the real-time graph picture signal that industry spot auxiliary unit (IFAU) 2 is uploaded, accomplish to input signal carry out pre-treatment, output wave and with three main tasks such as technical grade Personal Computer (IPC) communication.Wherein, The Signal Pretreatment process is that the signal that industry spot control unit (IFCU) 3, industry spot auxiliary unit (IFAU) 2 are uploaded is carried out pre-treatment; As the discrete data of the online judgement of steel stream mode source, wherein the signal from industry spot control unit (IFCU) 3 comprises: shake before converter dip angle signal, the body of heater/after shake signal, oxygen rifle altitude signal, alarm level signal, on-the-spot button signal; Signal from industry spot auxiliary unit (IFAU) 2 comprises temperature signal, the vision signal that far infrared data acquisition module (IVS) 1 collects.The output wave is accomplished the automated operation to the converter tapping process for exporting to the steering order of industry spot control unit (IFCU) 3, industry spot auxiliary unit (IFAU) 2 respectively.The wave that wherein exports industry spot control unit (IFCU) 3 to comprises: steel stream vision signal, detected state signal, warning light signal, audible warning, reservation wave; The wave that exports industry spot auxiliary unit (IFAU) 2 to comprises: video camera initiating signal, dedusting signal, cooling signal, heating signal.Be meant that with the communication process of technical grade Personal Computer (IPC) industry spot processing and control element (PCE) (IPCU) is uploaded to the steel stream mode monitor data of technical grade Personal Computer (IPC), mainly comprises: steel stream video data, pretreated inclination data, pretreated temperature data, pretreated oxygen rifle altitude information, pretreated alarm level data, pretreated switching value control information.
PMU (IPMU) is that system control unit (IMCU) 4, industry spot control unit (IFCU) 3 provide power supply, its specified input AC 220V, and 50～60HZ, specified received current＜5A, and have power work/abnormal indication function.
Electric control unit (IECU) is used for system electrical control and cable 5 connects, and comprises air switch, power safety, panel control and circuit connector.
The module dependence be electrically connected
The module dependence of system be electrically connected shown in accompanying drawing 2.Industry spot control unit (IFCU) 3 links to each other with other modules at scene as the core component of field control.From the signal at scene, like far infrared data acquisition module (IVS) 1 temperature, vision signal, converter inclination angle, oxygen rifle height, alarm level, close etc. and to do the industry spot processing and control element (PCE) (IPCU) of delivering to system control unit (IMCU) after prime is handled automatically by industry spot control unit (IFCU) 3.
Industry spot processing and control element (PCE) (IPCU) is passing the data collecting card that is uploaded to technical grade Personal Computer (IPC) after the signal of coming carries out second-stage treatment to the scene; Utilize the wavelet transform image analysis algorithm that the data that collect are carried out after the analysis-by-synthesis computing result being fed back to industry spot processing and control element (PCE) (IPCU); Industry spot processing and control element (PCE) (IPCU) reinforms industry spot control unit (IFCU) 3, by industry spot control unit (IFCU) 3 control Lamb-5, MS-24 and lift stove or close behavior such as slide plate.
Employed each functional module or functional device are prior art among the present invention, can open purchasing from market, so parameters such as its concrete structure, performance are repeated no more.
At last, it is also to be noted that what more than enumerate only is a specific embodiment of the present invention.Obviously, the invention is not restricted to above embodiment, many distortion can also be arranged.All distortion that those of ordinary skill in the art can directly derive or associate from content disclosed by the invention all should be thought protection scope of the present invention.
Claims (5)
1. a converter tapping monitor control system of handling based on heat picture comprises the far infrared data acquisition module that is connected to far infrared thermal imager, it is characterized in that, also comprises industry spot control unit, industry spot auxiliary unit and system control unit; Wherein,
The industry spot control unit is the front-end control member of system, be used to realize graphical user interface at the scene long-range demonstration, control onsite alarming device and the execute-in-place switch is provided;
The industry spot auxiliary unit is used to accept the steering order from system control unit, and realizes the wave and the view data transmission of far infrared data acquisition module;
System control unit comprises an indoor housing of piecing assembly, its inner integrated following function device: technical grade liquid crystal display device, technical grade Personal Computer, industry spot processing and control element (PCE), PMU and electric control unit; Wherein,
The industry spot processing and control element (PCE) is used to accept the realtime graphic signal that the industry spot auxiliary unit is uploaded, and realize Signal Pretreatment, output wave and with the communication of technical grade Personal Computer;
PMU is used to that each module provides power supply in the system;
Electric control unit, the electrical control and the cable that are used for system connect;
Said industry spot processing and control element (PCE) is connected to the following function device respectively: be connected to the industry spot control unit through cable, realize the transmission of switching value signal and vision signal; Connect industry spot auxiliary unit, far infrared data acquisition module and far infrared thermal imager successively through cable, realize the transmission of view data and wave; Be connected to the technical grade Personal Computer through cable, realize the transmission of switching value and simulating signal, wave;
Said electric control unit is connected to PMU through cable, and PMU is connected to industry spot processing and control element (PCE), industry spot control unit, far infrared data acquisition module and Personal Computer through cable respectively; The far infrared data acquisition module is realized power supply by the industry spot auxiliary unit.
2. monitor control system according to claim 1 is characterized in that, the cabinet of said system control unit housing is surface treated cold drawing, and its bottom is provided with ground terminal, and the top is furnished with fan disk; The bottom is provided with the line hole, so that being connected of supply lead, SW and wire to be provided.
3. monitor control system according to claim 1 is characterized in that, said electric control unit comprises air switch, power safety, panel control and circuit connector.
4. monitor control system according to claim 1 is characterized in that, the inside of said far infrared data acquisition module is also integrated TP, coil heats device, gas quench system and cleaning apparatus.
5. monitor control system according to claim 1 is characterized in that, said industry spot control unit is connected to the onsite alarming device, and said onsite alarming device is warning light and alarming horn.
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| CN2012100545201A CN102534097A (en) | 2012-03-04 | 2012-03-04 | Converter tapping monitoring control system based on thermal image processing |
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| CN102899442A (en) * | 2012-08-15 | 2013-01-30 | 天津市三特电子有限公司 | Converter tapping process detecting and controlling device |
| CN102921915A (en) * | 2012-10-23 | 2013-02-13 | 杭州谱诚泰迪实业有限公司 | Slag carry-over detection method and device based on image recognition of vortex on surface of molten steel |
| CN104180780A (en) * | 2014-09-05 | 2014-12-03 | 哈尔滨工业大学 | High-temperature liquid container wall thickness monitoring system and method based on infrared thermal images |
| CN104232837A (en) * | 2014-09-24 | 2014-12-24 | 杭州谱诚泰迪实业有限公司 | Monitoring device for tapping of converter/electric furnace and control method |
| CN109880964A (en) * | 2019-04-16 | 2019-06-14 | 山东钢铁股份有限公司 | State testing method and equipment in a kind of Converter |
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| CN104232837A (en) * | 2014-09-24 | 2014-12-24 | 杭州谱诚泰迪实业有限公司 | Monitoring device for tapping of converter/electric furnace and control method |
| CN109880964A (en) * | 2019-04-16 | 2019-06-14 | 山东钢铁股份有限公司 | State testing method and equipment in a kind of Converter |
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Application publication date: 20120704 |