CN109029830B - Steel leakage detection system and method - Google Patents
Steel leakage detection system and method Download PDFInfo
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- CN109029830B CN109029830B CN201811117115.3A CN201811117115A CN109029830B CN 109029830 B CN109029830 B CN 109029830B CN 201811117115 A CN201811117115 A CN 201811117115A CN 109029830 B CN109029830 B CN 109029830B
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- G—PHYSICS
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- G01K—MEASURING TEMPERATURE; MEASURING QUANTITY OF HEAT; THERMALLY-SENSITIVE ELEMENTS NOT OTHERWISE PROVIDED FOR
- G01K13/00—Thermometers specially adapted for specific purposes
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- G—PHYSICS
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
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Abstract
The invention provides a bleed-out detection system and a bleed-out detection method, which are used for timely and accurately detecting the bleed-out to give an alarm when the bleed-out occurs, and shortening the response time after the bleed-out occurs. The system comprises: the bleed-out detection assembly is arranged at the corresponding position of the crystallizer outlet and is used for detecting and obtaining at least two detection data; and the processor is connected with the breakout detection assembly and used for receiving the at least two detection data detected by the breakout detection assembly, fusing the at least two detection data to obtain a fused processing result, judging whether the crystallizer is breakout or not based on the fused processing result, and outputting alarm information if the crystallizer is determined to be breakout.
Description
Technical Field
The invention relates to the technical field of steel rolling, in particular to a bleed-out detection system and a method.
Background
In recent years, with the rapid development of a thin slab continuous casting technology and an efficient continuous casting technology, the continuous casting drawing speed is continuously improved, so that the problems of increased fluctuation of the liquid level in a crystallizer, low consumption of crystallizer casting powder, poor slagging, uneven heat transfer and the like are often caused, the solidified shell is finally thinned, and the breakout accident of the crystallizer is very easy to occur. The heat monitoring technology of the crystallizer goes through the processes of monitoring the temperature rise of the cooling water inlet and outlet of the crystallizer, measuring the friction force of the crystallizer and monitoring the temperature or heat flow of the local area of the copper plate (pipe) of the crystallizer, and goes from basic heat transfer research, bleed-out prevention and quality prediction to an expert system for decades, the research on the aspects at home and abroad is very active, and the automation and intelligence levels of the crystallizer are improved. Nevertheless, breakout accidents still frequently occur, the main variety of a sheet billet production line of a certain domestic steel mill is common low-carbon steel, the casting speed range of a continuous casting machine is 3.0-4.0 m/min, the average breakout frequency per year is about 10 according to incomplete statistics, and the average breakout frequency per month is more than 10 in the first three years of the operation of a casting machine, so that the quantity is quite remarkable.
In actual continuous casting production, the conventional breakout prediction technology has a certain degree of false report and breakout, and cannot be applied to the production rhythm of high drawing speed in the development trend of thin cast billet continuous casting and high-efficiency continuous casting technologies. Therefore, the prior art has the technical problem of inaccurate bleed-out detection.
Disclosure of Invention
The embodiment of the invention provides a bleed-out detection system and a bleed-out detection method, which are used for timely and accurately detecting the bleed-out to give an alarm when the bleed-out occurs, shortening the response time after the bleed-out occurs, and replacing a manual subjective judgment link by adopting an automatic processing mode, so that the precision of the bleed-out detection can be improved, the labor intensity of a continuous casting master control worker can be reduced, and the automation and intelligence levels of a continuous casting machine can be improved.
In a first aspect, the present invention provides a bleed-out detection system, comprising:
the bleed-out detection assembly is arranged at the corresponding position of the crystallizer outlet and is used for detecting and obtaining at least two detection data;
and the processor is connected with the breakout detection assembly and used for receiving the at least two detection data detected by the breakout detection assembly, fusing the at least two detection data to obtain a fused processing result, judging whether the crystallizer is breakout or not based on the fused processing result, and outputting alarm information if the crystallizer is determined to be breakout.
Optionally, the bleed-out detection assembly includes a bleed-out detection sensor, the bleed-out detection sensor includes an air pipe and an air pressure detection system, the air pipe is disposed at a position corresponding to the outlet of the crystallizer, the air pipe is filled with a preset gas, the air pressure detection system is configured to detect the air pressure in the air pipe, and the at least two detection data include the air pressure in the air pipe detected by the bleed-out detection sensor.
Optionally, the melting point range of the gas pipe is 400-1100 ℃.
Optionally, the bleed-out detection assembly includes a second bleed-out detection sensor, the second bleed-out detection sensor includes an image acquisition card and a plurality of color CCD cameras, wherein the plurality of color CCD cameras are circumferentially and uniformly distributed at the crystallizer outlet, the plurality of color CCD cameras continuously acquire a casting blank two-dimensional image in a steelmaking continuous casting process according to a preset time interval, the image acquisition card converts and compresses each frame of the casting blank two-dimensional image to obtain an image to be analyzed, and the at least two detection data include the image to be analyzed detected by the second bleed-out detection sensor.
Optionally, the breakout detection assembly includes a third breakout detection sensor, the third breakout detection sensor includes M temperature measurement fibers, the M temperature measurement fibers are disposed on a foot roller at the outlet of the crystallizer, the foot roller is provided with M through holes along the axial direction, the circumferential interval between two adjacent through holes in the M through holes is preset by a preset number of degrees, the M temperature measurement fibers are disposed in the M through holes in a one-to-one correspondence manner, the M temperature measurement fibers are used for collecting the temperature of the foot roller at the corresponding setting position, the at least two detection data include the current temperature detected by each temperature measurement fiber in the M temperature measurement fibers in the third breakout detection sensor, and M is an integer greater than 0.
Optionally, the distance between the center of each through hole and the surface of the foot roller ranges from 5mm to 20mm, the aperture of each through hole is smaller than 2mm, and the diameter of each temperature measuring fiber is smaller than the aperture of each through hole.
Optionally, the bleed-out detection assembly includes a production process parameter detection module, the production process parameter detection module is configured to detect a production process parameter in a steelmaking continuous casting process, and the at least two types of detection data include the production process parameter detected by the production process parameter detection module.
Optionally, the production process parameters include any one or more of a thermocouple temperature arranged on a preset surface of the crystallizer, a crystallizer heat flow density and a liquid level height of molten steel in the crystallizer.
Optionally, the processor is specifically configured to determine, for each type of detection data, a detection result corresponding to the detection data, and perform weighted fusion on the detection results corresponding to each type of detection data to obtain a fusion processing result.
In a second aspect, the present invention provides a bleed-out detection method, which is applied to the bleed-out detection system in the foregoing first aspect, and the method includes:
obtaining at least two detection data;
performing fusion processing on the at least two kinds of detection data to obtain a fusion processing result;
and judging whether the crystallizer leaks steel or not based on the fusion processing result, and outputting alarm information if the crystallizer leaks steel.
Optionally, when determining the breakout of the crystallizer, the method further comprises:
and sending a control instruction to a casting stopping system, and controlling the casting stopping equipment to perform automatic casting stopping operation.
One or more technical solutions in the embodiments of the present application have at least one or more of the following technical effects:
in the technical scheme of the embodiment of the invention, the bleed-out detection system comprises: the bleed-out detection assembly is arranged at the corresponding position of the crystallizer outlet and is used for detecting and obtaining at least two detection data; and the processor is connected with the breakout detection assembly and used for receiving at least two detection data detected by the breakout detection assembly, fusing the at least two detection data to obtain a fused processing result, judging whether the crystallizer is breakout or not based on the fused processing result, and outputting alarm information if the crystallizer is determined to be breakout. Through arranging bleed-out detection subassembly in crystallizer exit, accessible bleed-out detection subassembly detects and obtains polytype detection data, and then synthesizes polygenetic data in an intelligent way, produces more accurate, more complete, more reliable bleed-out judgement than single information source for the bleed-out detects the precision more accurate, improves the automation and the intelligent level of conticaster.
Drawings
FIG. 1 is a schematic structural diagram of a breakout detection system according to a first embodiment of the present application;
fig. 2a is a schematic view illustrating a gas pipe in a first breakout detection sensor according to a first embodiment of the present disclosure, the gas pipe having a ring structure;
fig. 2b is a schematic view of a gas pipe in the first breakout detection sensor according to the first embodiment of the present disclosure;
FIG. 3 is a schematic view of foot rollers at the exit position of a crystallizer provided in a first embodiment of the present application;
FIG. 4 is a schematic view of temperature measuring fibers disposed on a foot roll according to the first embodiment of the present application;
FIG. 5 is a diagram illustrating data fusion using multi-source data according to a first embodiment of the present application;
fig. 6 is a flowchart of a breakout detection method according to a second embodiment of the present application.
Detailed Description
The embodiment of the invention provides a bleed-out detection system and a bleed-out detection method, which are used for timely and accurately detecting the bleed-out to give an alarm when the bleed-out occurs, and shortening the response time after the bleed-out occurs. The system comprises: the bleed-out detection assembly is arranged at the corresponding position of the crystallizer outlet and is used for detecting and obtaining at least two detection data; and the processor is connected with the breakout detection assembly and used for receiving the at least two detection data detected by the breakout detection assembly, fusing the at least two detection data to obtain a fused processing result, judging whether the crystallizer is breakout or not based on the fused processing result, and outputting alarm information if the crystallizer is determined to be breakout.
The technical solutions of the present invention are described in detail below with reference to the drawings and specific embodiments, and it should be understood that the specific features in the embodiments and examples of the present invention are described in detail in the technical solutions of the present application, and are not limited to the technical solutions of the present application, and the technical features in the embodiments and examples of the present application may be combined with each other without conflict.
The term "and/or" herein is merely an association describing an associated object, meaning that three relationships may exist, e.g., a and/or B, may mean: a exists alone, A and B exist simultaneously, and B exists alone. In addition, the character "/" herein generally indicates that the former and latter related objects are in an "or" relationship.
Referring to fig. 1, the breakout detection system provided by the present invention includes the following components:
the bleed-out detection assembly 10 is arranged at a position corresponding to the outlet of the crystallizer and is used for detecting and obtaining at least two detection data;
and the processor 20 is connected with the breakout detection assembly 10 and is used for receiving at least two detection data detected by the breakout detection assembly 10, fusing the at least two detection data to obtain a fused processing result, judging whether the crystallizer is breakout or not based on the fused processing result, and outputting alarm information if the crystallizer is determined to be breakout.
Specifically, in this embodiment, the multi-source detection data is adopted to perform fusion data processing, and whether steel leakage occurs is determined, so that the multi-source data fusion mode is more accurate than the steel leakage judgment mode of a single data source. In this embodiment, a plurality of data sources detect through breakout detection subassembly 10 and obtain, and is concrete, breakout detection subassembly 10 includes first breakout detection sensor, and first breakout detection sensor includes trachea and atmospheric pressure detecting system, and the trachea setting is in the corresponding position department of crystallizer export, and the trachea intussuseption is filled with preset gas, and atmospheric pressure detecting system is used for detecting the trachea in atmospheric pressure, and at least two kinds of detection data include the trachea in the trachea that first breakout detection sensor detected pressure, and tracheal melting point range is 400 ℃ -1100 ℃.
In particular, in the prior art, the foot roller is an important part of the continuous casting machine, generally arranged in the outlet area of the crystallizer, and its function is mainly represented by: (1) the dummy bar is guided to enter the crystallizer, so that a dummy head is prevented from damaging a lower opening of a copper plate (tube) when the dummy bar is penetrated, and the crystallizer copper plate (tube) is protected; (2) the weak billet shell of the primary crystallizer is supported and guided, so that the deformation or steel leakage of the casting billet is reduced, and meanwhile, the abrasion of the casting billet on the lower opening of the copper plate (tube) can be reduced. The foot roller surface is in direct contact with the casting blank surface, so the air pipe can be arranged between the upper foot roller and the lower foot roller of the outlet area of the crystallizer. Specifically, according to the structure of the crystallizer outlet, the air pipe can adopt an annular structure or a combined structure, and the shape of the air pipe is matched with that of the crystallizer outlet.
As shown in fig. 2a, in the case of an annular structure, the outlet of the mold 12 is rectangular, the air pipe may be configured as an annular rectangular structure, and the circumference of the air pipe 11 may be the same as or slightly larger than the circumference of the outlet of the mold 12. The gas pipe 11 is filled with a predetermined gas, and the gas pressure in the gas pipe 11 is an initial gas pressure. Under the condition of adopting the air pipe with the annular structure, only one air pressure detection system needs to be arranged inside the air pipe 11 and is used for detecting the air pressure inside the air pipe 11 in real time.
As shown in fig. 2b, in the case of adopting the combined structure, the outlet of the crystallizer 12 is rectangular, the air pipes may be configured as a combined rectangular structure, and include 4 air pipes, which are the air pipe 111, the air pipe 112, the air pipe 113, and the air pipe 114, respectively, the air pipe 111, the air pipe 112, the air pipe 113, and the air pipe 114 are combined to form a rectangular structure, the length of each air pipe is greater than the length of the corresponding side of the outlet of the crystallizer 12, and the total length of the 4 air pipes added up is the same as the perimeter of the outlet of the crystallizer 12 or slightly greater than the perimeter of the outlet. Each trachea is filled with preset gas, and the gas pressure in each trachea is initial gas pressure. Under the trachea condition that adopts integrated configuration, every trachea is inside all to need to set up an atmospheric pressure detecting system for the inside atmospheric pressure of this root trachea of real-time detection.
Further, in this embodiment, the preset gas filled in the air tube may be compressed air or industrial nitrogen, and of course, may also be other inert gases, which is not limited in this application. The filling air pressure is an initial air pressure, which can be set according to actual conditions, and the application is not limited herein.
Further, in the present embodiment, the melting point of the gas pipe is less than the temperature of the molten steel in the mold 12, and the melting point ranges from 400 ℃ to 1100 ℃, so that in the case of a steel leakage in the mold 12, the leaked molten steel can melt the gas pipe, which leads to gas output in the gas pipe and gas pressure reduction. Further, considering the influence on the normal work of the continuous casting machine to be reduced as much as possible, the pipe diameter range of the air pipe is 8mm-30mm, and the wall thickness range is 0.2mm-0.5 mm. In consideration of the cost of the material, the material of the gas tube is preferably copper or aluminum, if the novel non-metal material or the polymer material can have a melting point in the above range and is easy to machine, it is also conceivable that the specific material of the gas tube can be set according to the actual situation in the specific implementation process, and the application is not limited herein.
Further, only one exhaust pipe is arranged in fig. 2a and fig. 2b, in an actual application scenario, multiple exhaust pipes may be arranged in the withdrawal direction of the outlet of the crystallizer 12, the number of rows of the exhaust pipes is 2 rows in the withdrawal direction of the outlet of the crystallizer 12 in principle, and the exhaust pipes are symmetrical to the continuous casting slab and distributed on two sides of the inner arc and the outer arc of the casting machine in the horizontal direction. And the multiple exhaust pipes are respectively provided with corresponding air pressure detection systems.
Furthermore, after the air pipe and the air pressure detection system in the first breakout detection sensor are set, the air pressure detection system is connected with the processor 20, the processor 20 is used for receiving the current air pressure of the air pipe detected by the air pressure detection system, judging whether the crystallizer 12 is breakout or not based on the current air pressure, and outputting alarm information if the breakout of the crystallizer 12 is determined.
Specifically, in the present embodiment, the air pipes are arranged in different manners, so that the processor 20 determines whether the crystallizer leaks steel in different manners, and the specific implementation of determining whether the crystallizer leaks steel by the processor 20 will be described in detail in the following two cases.
In the first case, the air tube is arranged in a ring structure, and the air pressure detection system detects the current air pressure in the air tube. Because the gas pipe is filled with the preset gas with the initial gas pressure, when the processor 20 obtains that the difference value between the current gas pressure of the gas pipe detected by the gas pressure detection system and the initial gas pressure is greater than the preset threshold value, it is determined that the gas pipe is burnt out by the leaked molten steel, and the condition of steel leakage of the crystallizer occurs. Further, if a plurality of rows of air pipes with annular structures are arranged, the current air pressure of each row of air pipes with annular structures detected by each air pressure detection system can be respectively obtained, and if the current air pressure with the difference value between the initial air pressure and the current air pressure being greater than a preset threshold value exists, the condition that the steel leakage occurs in the crystallizer can be determined. Furthermore, every blast pipe sets up the serial number that corresponds, and is corresponding, the current atmospheric pressure that every blast pipe corresponds has the serial number that this trachea corresponds, detects the current atmospheric pressure that is greater than the preset threshold value with the difference of initial atmospheric pressure, then the trachea that is burnt out by the molten steel is located to the serial number of this current atmospheric pressure, and then fixes a position to the crystallizer position that the steel leakage appears fast, and the staff of being convenient for salvagees in time and maintains. In a specific implementation process, the preset threshold may be set according to an actual situation, and the application is not limited herein.
Similarly, in this embodiment, in the case that the air tube is arranged in a ring structure, the air pressure detection system detects the current air pressure in the air tube. And under the condition that the processor 20 obtains the air pressure detected by the air pressure detection system that the current air pressure of the air pipe is less than a first preset air pressure, determining that the condition of steel leakage of the crystallizer occurs. Further, if a plurality of rows of air pipes with annular structures are arranged, the current air pressure of each row of air pipes with annular structures detected by the air pressure detection system can be respectively obtained, and if the current air pressure which is smaller than the first preset air pressure exists, the condition that the steel leakage occurs in the crystallizer can be determined. Furthermore, every blast pipe sets up the serial number that corresponds, and is corresponding, the current atmospheric pressure that every blast pipe corresponds has the serial number that this trachea corresponds, is detecting the current atmospheric pressure that is less than first preset atmospheric pressure, and then the trachea burnt out by the molten steel is located to the serial number of this current atmospheric pressure to the accessible, and then fixes a position the crystallizer position that the breakout appears fast, and the staff of being convenient for promptly salvagees the maintenance. In a specific implementation process, the first preset air pressure may be set according to an actual situation, and the application is not limited herein.
Further, in this embodiment, in the case where the air tube is provided in a ring structure, the air pressure detection system detects the current air pressure in the air tube. Under the condition that the processor 20 obtains that the air pressure detection system detects that the current air pressure of the air pipe is smaller than a second preset air pressure, if the current air pressure of the air pipe is detected to be smaller than the second preset air pressure within a preset time range (for example, 3 seconds, 5 seconds and the like), determining that the condition of steel leakage of the crystallizer occurs. Further, if a plurality of rows of air pipes with annular structures are arranged, the current air pressure of each row of air pipes with annular structures detected by the air pressure detection system can be respectively obtained, and if the air pipes with the current air pressure smaller than a second preset air pressure exist and the current air pressures of the air pipes in a preset time range (for example, 3 seconds, 5 seconds and the like) are all smaller than the second preset air pressure, the condition that the steel leakage occurs in the crystallizer can be determined. Furthermore, every blast pipe sets up the serial number that corresponds, and is corresponding, the current atmospheric pressure that every blast pipe corresponds has the serial number that this trachea corresponds, is all being less than the second and predetermines atmospheric pressure detecting the current atmospheric pressure in predetermineeing the time horizon, and then the trachea that is burnt out by the molten steel is located to the serial number of this current atmospheric pressure to the accessible, and then fixes a position the crystallizer position that the steel leakage appears fast, and the staff of being convenient for promptly repairs the maintenance. In a specific implementation process, the second preset air pressure may be set according to an actual situation, and the application is not limited herein. In order to ensure that the breakout detection system successfully sends out a breakout alarm within 5s, the set value of the preset time range is controlled within 4 s.
In the second case, in which the air tubes are arranged in a combined structure, each air pressure detection system detects the current air pressure in each air tube. Because each air pipe is filled with the preset gas with the initial air pressure, after the processor 20 obtains the current air pressure of each air pipe detected by each air pressure detection system, if the air pipe with the difference value between the initial air pressure and the current air pressure being greater than the preset threshold value exists, the air pipe is determined to be burnt out by the leaked molten steel, and the condition that the steel leakage occurs in the crystallizer is determined. Furthermore, every trachea is provided with corresponding serial number, can fix a position the trachea that the difference of current atmospheric pressure and this initial atmospheric pressure is greater than the predetermined threshold value through this serial number, fixes a position the crystallizer position that the bleed-out appears through the trachea of fixing a position fast, and the staff of being convenient for promptly salvages and maintains. In a specific implementation process, the preset threshold may be set according to an actual situation, and the application is not limited herein. Of course, a plurality of rows of air tubes with a combined structure may be provided, the manner of providing the air tubes with the combined structure is described in detail in the foregoing embodiment, and the manner of positioning the air tubes burnt by molten steel is also described in detail in the foregoing embodiment, which is not described in detail herein.
Similarly, in the present embodiment, in the case where the air tubes are arranged in a combined structure, each air pressure detecting system detects the current air pressure in the air tube. And obtaining the current air pressure of each air pipe detected by each air pressure detection system through the processor 20, and determining that the leaked molten steel of the air pipe is burnt out and determining that the crystallizer has the steel leakage condition under the condition that the current air pressure is smaller than a first preset air pressure. Furthermore, every trachea is provided with corresponding serial number, can fix a position the trachea that current atmospheric pressure is less than first preset atmospheric pressure through this serial number, fixes a position the crystallizer position that the bleed-out appears through the trachea of fixing a position fast, and the staff of being convenient for promptly salvages and maintains. In a specific implementation process, the first preset air pressure may be set according to an actual situation, and the application is not limited herein. Of course, a plurality of rows of air tubes with a combined structure may be provided, the manner of providing the air tubes with the combined structure is described in detail in the foregoing embodiment, and the manner of positioning the air tubes burnt by molten steel is also described in detail in the foregoing embodiment, which is not described in detail herein.
Further, in the present embodiment, in the case where the air tubes are arranged in a combined structure, each air pressure detecting system detects the current air pressure in the corresponding air tube. If the processor 20 determines that the current air pressure detected by the air pressure detection system is smaller than the second preset air pressure, if the current air pressure of the air pipe is detected to be smaller than the second preset air pressure within a preset time range (for example, 3 seconds, 4 seconds and the like), it is determined that the air pipe is burned out by the leaked molten steel, and it is determined that the steel leakage of the crystallizer occurs. Furthermore, every trachea is provided with corresponding serial number, can fix a position the trachea that all is less than the second and predetermines atmospheric pressure at the current atmospheric pressure of predetermineeing the time horizon through this serial number, fixes a position the position that the bleed-out appears in the crystallizer fast through the trachea of fixing a position, and the staff of being convenient for promptly salvagees and maintains. In a specific implementation process, the second preset air pressure may be set according to an actual situation, and the application is not limited herein. In order to ensure that the breakout detection system successfully sends out a breakout alarm within 5s, the set value of the preset time range is controlled within 4 s. Of course, a plurality of rows of air tubes with a combined structure may be provided, the manner of providing the air tubes with the combined structure is described in detail in the foregoing embodiment, and the manner of positioning the air tubes burnt by molten steel is also described in detail in the foregoing embodiment, which is not described in detail herein.
Further, in this embodiment, the breakout detection assembly 10 includes a second breakout detection sensor, the second breakout detection sensor includes an image acquisition card and a plurality of color CCD cameras, wherein the plurality of color CCD cameras are circumferentially and uniformly distributed at the exit of the mold, the plurality of color CCD cameras continuously acquire two-dimensional images of the casting blank in the steelmaking continuous casting process according to a preset time interval, the image acquisition card converts and compresses each frame of two-dimensional image of the casting blank to obtain an image to be analyzed, and the at least two types of detection data include the image to be analyzed detected by the second breakout detection sensor.
Specifically, in this embodiment, can include a plurality of colored CCD cameras among the second bleed-out detection sensor, can set up 2 ~ 10 colored CCD cameras and install 0.5-2m department apart from the casting blank, then these 2 ~ 10 colored CCD cameras circumference evenly distributed are in conticaster crystallizer exit. For example, fixing frames are welded on the inner arc side, the outer arc side, the left side and the right side of the crystallizer outlet of the casting blank continuous casting machine, 4 color CCD cameras are correspondingly arranged on the fixing frames on the inner arc side, the outer arc side, the left side and the right side, the 4 color CCD cameras adopt wide-angle lenses, each color CCD camera is vertically aligned to the surface of the casting blank as much as possible, and the deviation angle is less than or equal to 30 degrees.
The color CCD camera has a wide light sensing range, the CCD is made of a high-light-sensitivity semiconductor material, a plurality of photodiodes which are arranged in order are arranged on the CCD and can sense light and convert light signals into electric signals, so that 2-10 color CCD cameras collect casting blank two-dimensional images of a continuous casting blank at the outlet of a crystallizer of a continuous casting machine in real time from different angles according to a preset time interval, and continuously convert and compress the collected casting blank two-dimensional images in real time through an image collecting card and transmit the images to a processor 20. The two-dimensional image of the casting slab is continuously received by the processor 20. In a specific implementation process, the preset time interval may be set according to an actual situation, for example, in order to obtain more accurate detection, the preset time interval is reduced as much as possible, and it is preferable to acquire a two-dimensional image of the casting blank in real time.
The lens of the color CCD camera is subjected to water mist and dust interference prevention treatment; the casting machine in the actual steelmaking continuous casting process is in a high-temperature high-humidity state, a protective cover is arranged outside each color CCD camera, cooling modes such as water cooling and air cooling are arranged to reduce the environmental temperature of a camera element, and meanwhile, inert gas is blown into the protective cover to carry out air sealing, so that the pollution to the lens of the color CCD camera is reduced, and the color CCD camera can continuously work for a long time in a severe environment.
The processor 20 receives the two-dimensional image of the casting blank of the frame, performs simple image preprocessing, and then determines the area change of the foreign matter on the surface of the casting blank body. Firstly, extracting the contour of a casting blank body from the two-dimensional image of the casting blank of the frame through image segmentation, and identifying whether a foreign matter region exists on the surface of the casting blank body in the two-dimensional image of the casting blank of the frame to obtain a first identification result.
Specifically, because the casting blank body and the foreign matter on the surface of the casting blank body have different gray values, the casting blank body in the two-dimensional image of the casting blank of the frame is extracted by image segmentation, the foreign matter such as casting powder or iron scale possibly existing on the surface of the casting blank body is defined, and the casting blank body and the foreign matter region can be distinguished, so that whether the foreign matter region exists on the surface of the casting blank body in the two-dimensional image of the casting blank of the frame is identified.
Specifically, the boundary point of the foreign matter region is immediately marked when the foreign matter is found on the two-dimensional image of the casting blank of the frame, and in the specific implementation process, the two-dimensional image of the casting blank in which the foreign matter region is found may be any frame acquired by steelmaking continuous casting.
When the first recognition result is yes, whether the foreign object area is increased from the casting blank two-dimensional image of the frame to the casting blank two-dimensional image of the next frame is judged, and a first judgment result is obtained.
Specifically, when the first identification result indicates that a foreign object is found on the two-dimensional image of the casting blank of the frame, the number m of pixel points of the foreign object region in the two-dimensional image of the casting blank of the frame is recorded so as to represent the area occupied by the foreign object region on the two-dimensional image of the casting blank of the frame. And then waiting for receiving a next frame of casting blank two-dimensional image, and recording the number n of pixel points of the same foreign matter region in the next frame of casting blank two-dimensional image when the next frame of casting blank two-dimensional image is received so as to represent the area occupied by the foreign matter region on the next frame of casting blank two-dimensional image. Therefore, the respective area sizes of the same foreign matter in two-dimensional images of two adjacent frames of casting blanks are recorded. If the number n of the pixel points is larger than the number m of the pixel points, the area of the foreign matter area is increased; if the number n of the pixel points is equal to the number m of the pixel points, the area of the foreign matter area is unchanged; if the number n of the pixel points is smaller than the number m of the pixel points, the area of the foreign matter area is reduced.
For example, if a foreign object is found on the 10 th casting blank two-dimensional image, the number m of pixel points of the foreign object region in the 10 th casting blank two-dimensional image is recorded, then, the reception of the 11 th casting blank two-dimensional image is waited, and when the 11 th casting blank two-dimensional image is received, the number n of pixel points of the foreign object region in the 11 th casting blank two-dimensional image is recorded. Calculating (n-m), and judging whether (n-m) is larger than zero. If (n-m) is larger than zero, the number of the pixel points in the foreign matter region is increased, which indicates that the area of the foreign matter region is increased; if (n-m) is equal to 0, the number of the pixel points in the foreign matter region is not changed, which indicates that the area of the foreign matter region is not changed, and if (n-m) is less than 0, the number of the pixel points in the foreign matter region is reduced, which indicates that the area of the foreign matter region is reduced. Of course, in the specific implementation process, the size of the number m of pixels and the size of the number n of pixels may be directly compared to determine whether the foreign object region is increased or decreased or not.
In a further technical scheme, if the first judgment result represents that the foreign matter area is increased, foreign matter early warning information is sent out. After the foreign matter early warning information is sent out, whether a foreign matter area exists on the surface of the casting blank body in each frame of casting blank two-dimensional image received again is sequentially judged, and a second identification result is obtained; and if the second identification result is negative, indicating that the foreign matter area disappears on the surface of the casting blank body, and removing the foreign matter early warning information.
After the processor 20 receives the two-dimensional image of the casting blank of the frame, the processor 20 performs simple image preprocessing and then determines the temperature change of the foreign matter on the surface of the casting blank body. Determining whether the average surface temperature of the foreign object region rises within a preset time period, and determining whether the average surface temperature is higher than a preselected temperature value.
Specifically, the step of determining whether the average value of the surface temperature in the foreign matter area rises within a preset time period comprises the following steps one to two:
the method comprises the following steps: obtaining the color value of each pixel point in the foreign matter area, and converting the color value and the brightness intensity information of each pixel point in the foreign matter area into a temperature value corresponding to each pixel point in the foreign matter area; and then carrying out mean value calculation on the temperature values of all pixel points in the foreign object region to obtain the surface temperature average value of the foreign object region.
Step two: and judging whether the average value of the surface temperature of the foreign matter area rises within a preset time period, wherein the preset time period can be any time period value of 0.01-1 s in the specific implementation process. For example, it may be determined whether the average value of the inner surface temperature of the foreign matter region rises within 1s, or it may be determined whether the average value of the inner surface temperature of the foreign matter region rises within 0.5s, or the like.
Specifically, there are at least two embodiments for determining whether the average value of the surface temperature in the foreign matter region is higher than a preselected temperature value:
one embodiment is: and judging whether the average value of the surface temperature is higher than the temperature value of the adjacent pixel point outside the foreign body area, and if the average value of the surface temperature in the foreign body area is lower than the temperature value of the adjacent pixel point outside the foreign body area, determining that the foreign body area is the covering slag or the iron scale. The adjacent pixel points outside the foreign matter area specifically refer to the pixel points outside the foreign matter area adjacent to the boundary pixel points of the foreign matter area.
The other implementation mode is as follows: and judging whether the average value of the surface temperature in the foreign matter area is higher than the average temperature value of the image. Specifically, the image average temperature value is obtained through the following steps: obtaining the color value of each pixel point in the casting blank two-dimensional image of the frame, converting the color value and the brightness intensity information of each pixel point in the casting blank two-dimensional image of the frame into the temperature value of each pixel point in the casting blank two-dimensional image of the frame, and then carrying out mean value calculation on the temperature values of all pixel points in the casting blank two-dimensional image of the frame to obtain the image average temperature value of the casting blank two-dimensional image of the frame. And if the surface temperature average value in the foreign matter area is lower than the image average temperature value, determining the foreign matter area as the mold flux or the iron scale. The image mean temperature values are also used to approximately judge the cooling effect in the mold and the balance of the solidified shell growth.
And when the first judgment result is yes, the surface temperature average value rises within the preset time and is higher than the preselected temperature value, a corresponding detection result is obtained, and the steel leakage is judged.
Specifically, if the first determination result is yes, and the surface temperature average value rises above a preselected temperature value within a preset time period, the occurrence of bleed-out is determined. And if the foreign matter area is determined to be the protective slag or the iron scale, determining that no steel leakage exists.
The following examples illustrate: firstly, judging whether the average value of the inner surface temperature of the foreign matter area is higher than a preselected temperature value, if so, continuously judging whether the average value of the inner surface temperature of the foreign matter area rises within a preset time; otherwise, determining the foreign matter area as the protective slag or the iron scale. And then, if the judgment shows that the average value of the temperature of the inner surface of the foreign body area rises within a preset time period, judging that the steel leakage occurs.
In the specific implementation process, the acquired two-dimensional image of the casting blank is also displayed on a window interface of an engineering computer in real time, so that the abnormal shape of the casting blank body (such as the bulging condition of the casting blank) can be directly observed by manpower as auxiliary monitoring.
Furthermore, all the obtained analysis results, foreign matter early warning information and main process parameters can be displayed on a window interface of an engineering computer in real time and stored periodically, so that historical inquiry and playback in the pouring process are facilitated.
Because a plurality of colored CCD cameras are circumferentially and uniformly distributed at the outlet of the crystallizer of the continuous casting machine to continuously acquire the two-dimensional images of the casting blank, the blank of monitoring at the outlet area of the crystallizer of the continuous casting machine is filled, the labor intensity and the danger degree of field workers are greatly reduced, and the on-line detection level of continuous casting machine equipment is improved.
Further, in this embodiment, breakout detection subassembly 10 still includes third breakout detection sensor, third breakout detection sensor includes M temperature measurement fibre, M temperature measurement fibre sets up on the foot roller of crystallizer exit, the foot roller is provided with M through-hole along axial direction, two adjacent through-hole hoop interval preset number of degrees in M through-hole, M temperature measurement fibre sets up in M through-hole one-to-one, M temperature measurement fibre is used for gathering the temperature that corresponds the foot roller of position department that sets up, at least two kinds of detection data include the current temperature that every temperature measurement fibre detected among M temperature measurement fibre in the third breakout detection sensor, M is for being greater than 0 integer. The distance between the center of each through hole and the surface of the foot roller ranges from 5mm to 20mm, the aperture of each through hole is smaller than 2mm, and the diameter of each temperature measuring fiber is smaller than the aperture of each through hole.
Specifically, in the present embodiment, since the surface of the foot roll is in direct contact with the surface of the cast slab, the temperature measuring fiber in the third drop-out detection sensor may be disposed on the upper foot roll and/or the lower foot roll in the outlet region of the mold. Of course, the temperature measuring fibers can also be arranged on a plurality of rows of foot rollers close to the outlet area of the crystallizer, the number of the arranged rows can be 1-3, the specific number of the arranged rows can be set according to actual needs, and the application is not limited herein. For example, as shown in fig. 3, 1 row of wide foot rollers 31 is disposed at positions corresponding to the long sides at the outlet of the mold 12, and 4 rows of narrow foot rollers 32 are disposed side by side at positions corresponding to the wide sides at the outlet of the mold. The temperature measuring fibers can be arranged on the wide-mouth foot roll 31, and the temperature measuring fibers can also be arranged on the 2 rows of narrow-mouth foot rolls 32 closest to the crystallizer.
Further, on every sufficient roller, set up M through-hole along axial direction, M through-hole is followed sufficient roller hoop interval and is preset the number of degrees, and is specific, predetermines the number of degrees 360/M degree. Each temperature measuring fiber is arranged in each through hole. M temperature measuring fibers are correspondingly arranged in M through holes, and one temperature measuring fiber is arranged in each through hole. The length of each temperature measuring fiber is consistent with the length of the foot roller or slightly larger than the length of the foot roller. The purpose of the modification of the foot roll with the through hole is to install temperature measuring fibers for monitoring the change of the surface temperature thereof. As shown in fig. 4, 4 through holes are arranged on the foot roller along the length direction, and the circumferential interval between two adjacent through holes is 90 degrees. Thus, 4 temperature measuring fibers are arranged in each through hole after the temperature measuring fibers are arranged in each through hole. In a specific implementation process, the number of the included temperature measuring fibers can be set according to actual needs, and the application is not limited herein. Such as: when the temperature measurement fibers are set to be 4, the annular interval between two adjacent temperature measurement fibers is 90 degrees, and when the temperature measurement fibers are set to be 3, the annular interval between two adjacent temperature measurement fibers is 120 degrees. Because the rotating speed of the foot roller is not high, the refreshing period of the temperature detection of the foot roller can be effectively reduced through a plurality of temperature measuring fibers.
Further, in the present embodiment, the distance between the center of each through hole formed in the foot roller and the surface of the foot roller is in the range of 5mm to 20mm, and the hole diameter is generally set within 2mm, so that the influence of the formation of the through hole on the strength and the service performance of the foot roller can be minimized. The diameter of each temperature measuring fiber is smaller than the aperture of each through hole. The diameter of the temperature measuring fiber is micron-sized, so that the temperature measuring fiber can be easily installed even if the through hole on the foot roller is small. In addition, this temperature measurement fibre still has the characteristic of many temperature measurement points, and every last correspondence of temperature measurement fibre has N temperature measurement points, and the current temperature that this root temperature measurement fibre detected includes the current temperature that N temperature measurement points detected, and every temperature measurement fibre correspondence has N current temperature, and at concrete implementation in-process, N's numerical value can be set for according to actual need, here, and this application does not do the restriction.
After obtaining the N current temperatures corresponding to each temperature measuring fiber of the M temperature measuring fibers, the processor 20 may determine whether the crystallizer leaks steel in the following manners.
The first mode is as follows: the processor 20 can determine the current temperature distribution corresponding to each temperature measuring fiber by means of interpolation fitting according to the N current temperatures corresponding to each temperature measuring fiber, and determine whether the crystallizer leaks steel based on the current temperature distribution corresponding to each temperature measuring fiber. Specifically, the temperature distribution corresponding to each temperature measuring fiber is obtained, so that the highest temperature in the temperature distribution can be obtained, and whether the crystallizer leaks steel or not can be determined according to the highest temperature.
Specifically, the processor 20 is configured to determine that the crystallizer bleeds steel when it is determined that the first temperature measurement fiber, of the M temperature measurement fibers, exists, where a difference between the highest temperature and the initial temperature is greater than a preset threshold value.
Because each temperature measuring fiber can detect an initial temperature when the crystallizer normally runs, after the processor 20 obtains the highest temperature corresponding to each temperature measuring fiber, the total number of M highest temperatures can be obtained, if the processor 20 determines that the M highest temperatures have the highest temperature of which the difference value with the initial temperature is larger than the preset threshold value, the highest temperature corresponds to the first temperature measuring fiber, and thus, the condition that the crystallizer has steel leakage can be determined. Furthermore, every temperature measurement fibre sets up the serial number that corresponds, and is corresponding, the highest temperature that every temperature measurement fibre corresponds also is provided with the serial number of this temperature measurement fibre, is greater than the highest temperature of presetting the threshold value detecting the difference of the highest temperature and initial atmospheric pressure, then the serial number of this highest temperature of accessible is fixed a position to the concrete temperature measurement fibre unanimous with this serial number, and then fixes a position to the sufficient roller of this temperature measurement fibre installation to fix a position the position that the bleed-out appears in the crystallizer fast, the staff of being convenient for promptly repairs the maintenance. In a specific implementation process, the preset threshold may be set according to an actual situation, and the application is not limited herein.
Further, the processor 20 is configured to determine that the crystallizer bleeds steel when it is determined that a second temperature measurement fiber exists in the M temperature measurement fibers, where maximum temperatures of the second temperature measurement fiber within a preset time range are all greater than the first preset temperature.
Specifically, in this embodiment, after the processor 20 obtains the maximum temperature corresponding to each temperature measuring fiber, M maximum temperatures may be obtained in total, if the processor 20 determines that there is a maximum temperature greater than the first preset temperature in the M maximum temperatures, the maximum temperature corresponds to the second temperature measuring fiber, and if the maximum temperature of the second temperature measuring fiber is greater than the first preset temperature within a preset time range (e.g., 3 seconds, 5 seconds, or the like), it is determined that steel leakage occurs in the mold. Furthermore, every temperature measurement fibre sets up the serial number that corresponds, it is corresponding, the highest temperature that every temperature measurement fibre corresponds also is provided with the fibrous serial number of this temperature measurement, all be greater than the first highest temperature of predetermineeing the temperature in detecting the time span of predetermineeing, then the serial number of this highest temperature of accessible is fixed a position to the concrete second temperature measurement fibre unanimous with this serial number, and then fix a position the position of the sufficient roller of this second temperature measurement fibre installation, thereby fix a position the crystallizer position that the bleed-out appears fast, the staff of being convenient for promptly repairs and maintains. In a specific implementation process, the first preset temperature may be set according to an actual situation, and the application is not limited herein. In order to ensure that the breakout detection device successfully sends out a breakout alarm within 5s, the set value of the preset time range is controlled within 4 s.
The second mode is as follows: the processor 20 is configured to determine that the crystallizer leaks steel when it is determined that third temperature measurement fibers exist in the M temperature measurement fibers, where current temperatures corresponding to P temperature measurement points exist in the N temperature measurement points corresponding to the third temperature measurement fibers are all greater than a second preset temperature, and P is an integer greater than 0 and less than or equal to N.
Specifically, processor 20 is after obtaining the N current temperature that every temperature measurement fibre corresponds in M temperature measurement fibre, if there is the third temperature measurement fibre, and there is the current temperature that P temperature measurement point corresponds in the N temperature measurement point that this third temperature measurement fibre corresponds all to be greater than the second and predetermine the temperature, and the numerical value of P can set up to numerical values such as 1, 2, 3, and at concrete implementation in-process, the numerical value of P can set for according to actual need, here, this application does not do the restriction. Furthermore, every temperature measurement fibre sets up the serial number that corresponds, it is corresponding, the current temperature of the N temperature measurement point that every temperature measurement fibre corresponds also is provided with the fibrous serial number of this temperature measurement, detect that there are P current temperature that temperature measurement point corresponds all to be greater than the second and predetermine the temperature, confirm the serial number of the corresponding current temperature of this P temperature measurement point, fix a position to the concrete third temperature measurement fibre unanimous with this serial number, and then fix a position to the sufficient roller of this third temperature measurement fibre installation, thereby fix a position the position that the bleed-out appears in the crystallizer fast, the staff of being convenient for promptly repairs the maintenance. In a specific implementation process, the preset threshold may be set according to an actual situation, and the application is not limited herein.
Further, in the present embodiment, the breakout detection assembly 10 includes a production process parameter detection module, the production process parameter detection module is configured to detect a production process parameter in the steelmaking continuous casting process, and the at least two types of detection data include the production process parameter detected by the production process parameter detection module. The production process parameters comprise any one or more of the combination of thermocouple temperature arranged on a copper plate (or copper pipe) of the crystallizer, average heat flow density of the crystallizer or liquid level height of molten steel in the crystallizer.
Specifically, the production process parameter detection module comprises two rows, three rows or even multiple rows of thermocouples for detecting the temperature distribution of the crystallizer copper plate. Specifically, typical temperature signals in the upper and lower rows of thermocouple crystallizers in the copper plate are divided into 4 modes of normal, surface defect, bonded bleed-out and corner bleed-out.
In the normal mode, the temperature values detected by the upper and lower 2 heat discharge couples embedded in the crystallizer copper plate should be relatively straight 2 curves with only slight fluctuation in the normal production process.
Among them, in the surface defect mode, this mode is generated because the surface quality of the cast slab is affected due to poor melting of the mold flux or winding of the slag bar into the meniscus. In addition, this mode also occurs if longitudinal cracks occur in the solidified shell. The temperature curve characteristic of the mode is that the temperature wave forms of the 2-row heat discharge couples all have a wave trough, and the occurrence of the wave trough can be related to an air gap formed between the crystallizer and the solidified blank shell. In addition, the slag block which is not melted well descends along with the billet shell and slides to the position where the thermocouple is embedded, and a trough can be formed. When this occurs, some surface quality problems often result. The propagation rate of surface longitudinal cracks is greatly higher than the blank drawing speed, the upper thermocouple and the lower thermocouple almost simultaneously detect temperature changes, and the occurrence of the mode often does not cause steel leakage, but only has one surface defect and can be incorporated into quality problems so as to process a casting blank product by subsequent processes if necessary.
Wherein in the breakout mode of bonding, this temperature mode typically occurs when the tear point passes the location where the thermocouple is located when bonding occurs. When bonding occurs, a casting blank tearing point is not only longitudinally propagated, but the bonding breakout is most obviously characterized in that the falling speed of a bonding hot point is lower than the blank drawing speed, a blank shell is broken, the temperature measured by a thermocouple is greatly increased after molten steel seeps out, the temperature measured by the thermocouple is obviously fallen back along with the falling of the bonding hot point (damaged point), and the phenomenon that the lower-row temperature exceeds the upper-row temperature occurs when the hot point passes through the lower-row thermocouple.
The reason why the corner breakout mode is formed in the corner breakout mode is that the cooling is too strong at the corner of the crystallizer, the solidified blank shell shrinks to form a gap between the blank shell and the crystallizer, and the subsequent molten steel overflows a meniscus formed in the previous period, enters the gap and solidifies, so that the blank drawing resistance is increased, the blank shell descends unsmoothly, and the pull crack is possibly formed at the position. This mode of temperature signature often occurs when a strain-break point passes through a thermocouple embedded in a corner of the mold. The accident is mostly caused by the conditions that the tundish is replaced, the liquid level of the crystallizer is low and the pulling speed is low, the copper plate of the crystallizer is well cooled, a gap is formed at the corner of a solidified casting blank, the liquid level of the crystallizer fluctuates due to the change of the pulling speed or other reasons, and the subsequent molten steel overflows over a meniscus and enters the gap. In addition, when the width of the mold is adjusted on-line, the mold flux enters the corner portion, and such a gap is also formed. The angle breakout is mainly suspended breakout, and the typical suspended breakout is characterized in that the upper row of thermocouples are close to the damaged billet shell, so that the temperature is obviously increased due to the seepage of molten steel or the great thinning of the primary billet shell, and the lower row of thermocouples are obviously increased due to the thinning of the billet shell, but the temperature of the lower row of thermocouples does not exceed the temperature measurement value of the upper row of thermocouples due to the fact that the molten steel does not seep. The main difference between longitudinal crack and bonded breakout is the propagation speed, the propagation speed of the longitudinal crack is greatly higher than the blank drawing speed, the propagation speed of slag inclusion is consistent with the blank drawing speed, and the bonding propagation speed is usually 50% -80% of the normal drawing speed, which is a typical difference beneficial for judging the generation of slag inclusion, longitudinal crack and bonded breakout.
Therefore, in the method of the present embodiment, the processor 20 may determine whether steel is leaking according to the temperature profile of the thermocouple disposed on the copper plate, and obtain a prediction result.
Furthermore, the production process parameter detection module also comprises the average heat flux density of the crystallizer, and the average heat flux density is obtained by detecting the water flow of cooling water of the crystallizer and the temperature difference of the inlet and the outlet of the cooling water according to a calculation formula of the heat flux density. Under the condition of stable casting at a casting speed, the average heat flow density value of the crystallizer is in stable fluctuation, and when breakout occurs, the heat flow density value of the crystallizer is reduced, so that whether breakout occurs can be determined according to the detection of the average heat flow density of the crystallizer, and a breakout detection result is obtained.
Furthermore, the production process parameter detection module also comprises a liquid level detection sensor, and the liquid level detection sensor is arranged in the crystallizer and used for detecting the liquid level height of the molten steel in the crystallizer. Under normal conditions, the liquid level of molten steel in the crystallizer needs to be maintained at 75% -90% of the height of the crystallizer, and when steel leakage occurs, the liquid level is rapidly reduced, so that whether steel leakage occurs or not can be determined according to the liquid level, and a steel leakage detection result is obtained.
In the specific implementation process, the production process parameters are not limited to the thermocouple temperature, the average heat flow density value and the liquid level height, and other process parameters such as the crystallizer friction force can be included, the lubrication condition between the crystallizer and the casting blank is evaluated through the periodic variation condition of the friction force and the vibration speed, the fluctuation of the crystallizer friction force is severe and the variation is irregular before steel leakage, and therefore, a steel leakage judgment sub-result can also be obtained. The application is not limited thereto.
The source data for determining whether steel leakage occurs in this embodiment is only an example, and details of the air pressure in the air pipe detected by the first steel leakage detection sensor, the two-dimensional image of the casting blank detected by the first steel leakage detection sensor, the temperature of the foot roll detected by the third steel leakage detection sensor, and the thermocouple temperature and the liquid level height of the production process parameter detection module are described, and in a specific implementation process, other parameters may be included, which is not limited in this application.
Further, the processor 20 is specifically configured to determine a detection result corresponding to each type of detection data, and perform weighted fusion on the detection results corresponding to each type of detection data to obtain a fusion processing result.
Data fusion is the intelligent synthesis of multi-source data, resulting in more accurate, more complete, and more reliable estimation and judgment than a single information source. The processor 20 performs bleed-out determination on each detection parameter according to the corresponding rule to obtain the corresponding detection result, and performs weighted fusion on the detection results corresponding to each type of detection data to obtain the fusion processing result when performing data fusion. Following the above example, as shown in fig. 5, the data obtained by the system includes the air pressure in the air pipe detected by the first breakout detection sensor, the two-dimensional image of the cast slab detected by the first breakout detection sensor, the temperature of the foot roll detected by the third breakout detection sensor, and the thermocouple temperature and the liquid level of the production process parameter detection module. Based on the current air pressure in the air pipe, the processor 20 may determine whether the crystallizer is missing in the corresponding determination manner as described above, and obtain a first detection result S1. Based on the two-dimensional image of the casting blank, the processor 20 may determine whether the mold has a steel leakage in the corresponding determination manner, and obtain a second detection result S2. Based on the temperature of the foot roll, the processor 20 may determine whether the mold is missing in the corresponding determination manner as described above, and obtain a third detection result S3. Based on the thermocouple temperature, the processor 20 may determine whether the mold is tapped in the corresponding determination manner as described above, and obtain a fourth detection result S4. Based on the liquid level, the processor 20 may determine whether the mold is tapped in the corresponding determination manner as described above, and obtain a fifth detection result S5. The values of S1-S5 are two, and the value is 1 when bleed-out is determined, and the value is-1 when no bleed-out is determined.
The detection result of each kind of data corresponds to a respective weight value, the weight value may be preset based on the accuracy of the detection result of the data, and the accuracy of the detection result corresponding to each kind of data may be dynamically checked and determined through an experiment. Such as: the accuracy rates are in the order of from high to low, namely the accuracy rate of a first detection result determined based on the current air pressure, a second detection result determined based on a two-dimensional image of the casting blank, a third detection result determined based on the temperature of the foot roller, a fourth detection result determined based on the temperature of the thermocouple, and finally a fifth detection result determined based on the liquid level height. The weight value of the first detection result is K1, the weight value of the second detection result is K2, the weight value of the third detection result is K3, the weight value of the fourth detection result is K4, the weight value of the fifth detection result is K5, K1> K2> K3> K4> K5, and K1+ K2+ K3+ K4+ K5 is 1, so that the obtained fusion processing result is SUM 1S 1+ K2S 2+ K3S 3+ K4S 4+ K5S 5, when SUM is greater than 0, it is determined that steel leakage occurs, and when SUM is less than 0, it is determined that steel leakage does not occur.
The weight values of the detection results corresponding to various data can be adjusted according to actual situations, for example: when a CCD camera in the second breakout detection sensor fails, the weight value of the second detection result corresponding thereto may be adjusted to 0, i.e., the input source data is not considered.
Of course, the weighted fusion data processing mode is only shown as an example, and in the specific implementation process, relevant multi-source data can be fused through methods such as principal component analysis and D-S evidence reasoning, so that the robustness of steel leakage detection is ensured.
Further, the processor 20 outputs alarm information when the crystallizer bleed-out is determined by fusing the processing results. Specifically, the breakout detection system further comprises an alarm system, or the alarm system can be independent of the breakout detection system and is connected with the processor 20 in a wired or wireless manner, and the processor 20 sends a control instruction to the alarm system when determining breakout of the crystallizer, and controls the alarm system to output alarm information. The specific alarm system can be a loudspeaker, a voice output system, an acousto-optic output system, a system with a display screen and a voice output module, and the like, and correspondingly, the alarm information can be alarm bell, alarm voice, alarm music, acousto-optic information and the like. If the alarm system comprises a display screen, alarm information, the number of the problematic trachea and the like can be displayed on the display screen. In a specific implementation process, the alarm system and the alarm information can be set according to actual needs, and the application is not limited herein.
Further, the processor 20 further comprises a set of automatic casting stopping module program, and when the processor 20 determines that the crystallizer has steel leakage, the automatic casting stopping program is automatically executed, the pouring outlet channel of the tundish is closed, and the pulling speed of the continuous casting machine is directly reduced to zero, so that the steel leakage of molten steel is reduced, and the damage to various parts such as the fan-shaped section of the continuous casting machine is caused.
Referring to fig. 6, a second embodiment of the present invention provides a bleed-out detection method, which is applied to the bleed-out detection system in the first embodiment, and the method includes the following steps:
s601: obtaining at least two detection data;
s602: performing fusion processing on the at least two kinds of detection data to obtain a fusion processing result;
s603: and judging whether the crystallizer leaks steel or not based on the fusion processing result, and outputting alarm information if the crystallizer leaks steel.
Further, in this embodiment, when determining the breakout of the crystallizer, the method further includes:
and sending an instruction to an automatic casting stop control module, performing automatic casting stop operation, closing a pouring outlet channel of the tundish, and simultaneously directly reducing the casting speed of the continuous casting machine to zero.
The bleed-out detection method in this embodiment is mainly applied to the bleed-out detection system in the foregoing first embodiment, and the method for the system to perform the bleed-out detection has been described in detail in the foregoing first embodiment, and herein, the embodiment in this market is not described again.
One or more technical solutions in the embodiments of the present application have at least one or more of the following technical effects:
in the technical scheme of the embodiment of the invention, the bleed-out detection system comprises: the bleed-out detection assembly is arranged at the corresponding position of the crystallizer outlet and is used for detecting and obtaining at least two detection data; and the processor is connected with the breakout detection assembly and used for receiving at least two detection data detected by the breakout detection assembly, fusing the at least two detection data to obtain a fused processing result, judging whether the crystallizer is breakout or not based on the fused processing result, and outputting alarm information if the crystallizer is determined to be breakout. Through arranging bleed-out detection subassembly in crystallizer exit, accessible bleed-out detection subassembly detects and obtains polytype detection data, and then synthesizes polygenetic data in an intelligent way, produces more accurate, more complete, more reliable bleed-out judgement than single information source for the bleed-out detects the precision more accurate, improves the automation and the intelligent level of conticaster.
While preferred embodiments of the present invention have been described, additional variations and modifications in those embodiments may occur to those skilled in the art once they learn of the basic inventive concepts. Therefore, it is intended that the appended claims be interpreted as including preferred embodiments and all such alterations and modifications as fall within the scope of the invention.
It will be apparent to those skilled in the art that various changes and modifications may be made in the present invention without departing from the spirit and scope of the invention. Thus, if such modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include such modifications and variations.
Claims (7)
1. A bleed-out detection system, comprising:
the breakout detection assembly is arranged at a position corresponding to an outlet of the crystallizer and used for detecting and obtaining at least two detection data, wherein the breakout detection assembly comprises a third breakout detection sensor, the third breakout detection sensor comprises M temperature measurement fibers, the M temperature measurement fibers are arranged on a foot roller at the outlet of the crystallizer, the foot roller is provided with M through holes along the axial direction, two adjacent through holes in the M through holes are circumferentially spaced by a preset number of degrees, the M temperature measurement fibers are correspondingly arranged in the M through holes one by one, the M temperature measurement fibers are used for collecting the temperature of the foot roller at the corresponding position, the at least two detection data comprise the current temperature detected by each temperature measurement fiber in the M temperature measurement fibers in the third breakout detection sensor, M is an integer larger than 0, and the distance range between the center of each through hole and the surface of the foot roller is 5-20 mm, the aperture of each through hole is smaller than 2mm, and the diameter of each temperature measuring fiber is smaller than the aperture of each through hole; the bleed-out detection assembly comprises a first bleed-out detection sensor, the first bleed-out detection sensor comprises an air pipe and an air pressure detection system, the air pipe is arranged at a position corresponding to an outlet of the crystallizer, preset gas is filled in the air pipe, the air pressure detection system is used for detecting air pressure in the air pipe, and the at least two detection data comprise the air pressure in the air pipe detected by the first bleed-out detection sensor;
and the processor is connected with the breakout detection assembly and used for receiving the at least two detection data detected by the breakout detection assembly, fusing the at least two detection data to obtain a fused processing result, judging whether the crystallizer is breakout or not based on the fused processing result, and outputting alarm information if the crystallizer is determined to be breakout.
2. The system of claim 1, wherein the trachea has a melting point in the range of 400 ℃ to 1100 ℃.
3. The system of claim 1, wherein the breakout detection assembly comprises a second breakout detection sensor, and the second breakout detection sensor comprises an image acquisition card and a plurality of color CCD cameras, wherein the plurality of color CCD cameras are uniformly distributed at the exit of the mold in the circumferential direction, the plurality of color CCD cameras continuously acquire two-dimensional images of the casting blank during the continuous steel casting process at preset time intervals, the image acquisition card converts and compresses each two-dimensional image of the casting blank to obtain an image to be analyzed, and the at least two types of detection data comprise the image to be analyzed detected by the second breakout detection sensor.
4. The system of claim 1, wherein the breakout detection assembly comprises a production process parameter detection module for detecting a production process parameter during the steelmaking continuous casting process, and the at least two types of detection data include the production process parameter detected by the production process parameter detection module.
5. The system of claim 4, wherein the production process parameters include any one or more of a thermocouple temperature disposed on a predetermined face of the mold, a mold heat flux density, and a level of molten steel in the mold.
6. The system of claim 1, wherein the processor is specifically configured to determine, for each type of detection data, a detection result corresponding to the detection data, and perform weighted fusion on the detection results corresponding to each type of detection data to obtain a fusion processing result.
7. A bleed-out detection method, applied to the bleed-out detection system of any one of claims 1 to 6, the method comprising:
obtaining at least two detection data;
performing fusion processing on the at least two kinds of detection data to obtain a fusion processing result;
and judging whether the crystallizer leaks steel or not based on the fusion processing result, and outputting alarm information if the crystallizer leaks steel.
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| CN115582550A (en) * | 2022-10-17 | 2023-01-10 | 深圳市深汕特别合作区万泽精密科技有限公司 | Tundish, bleed-out protection system of tundish and gas atomization powder making device |
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