CN111947730A - Continuous casting molten pool liquid level detection system and continuous casting molten pool liquid level control method - Google Patents
Continuous casting molten pool liquid level detection system and continuous casting molten pool liquid level control method Download PDFInfo
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Abstract
The application discloses continuous casting molten bath liquid level detecting system and continuous casting molten bath liquid level control method, this system includes: the image acquisition device comprises a CCD camera and a controller, the CCD camera is connected with the controller through an anti-interference cable, the CCD camera is arranged on a rotating bracket arranged above the continuous casting molten pool, and the image acquisition device is used for acquiring image information of a junction area of molten steel and a casting roll in the continuous casting molten pool through the CCD camera under the control of the controller; the image processing device is connected with the controller and is used for processing the image information transmitted by the image acquisition device and obtaining the liquid level height of the molten steel based on the processed image information; the cooling device is a water-cooling protective cover, and the CCD camera is positioned in the water-cooling protective cover; and the purging device is arranged at the front end of the CCD camera and is used for discharging gas at the front end of the CCD camera.
Description
Technical Field
The application relates to the technical field of metallurgical continuous casting, in particular to a continuous casting molten pool liquid level detection system and a continuous casting molten pool liquid level control method.
Background
The thin strip continuous casting technology is a leading-edge technology in the technical field of metallurgical engineering, can greatly reduce the production cost, and can be beneficial to producing new materials which are difficult to roll and have special properties by the rapid solidification effect. The technology is complex, the requirements on control precision and cast strip quality are strict, and the requirements on the control precision and stability of the liquid level of a molten pool are particularly high. The real-time and accurate detection of the molten steel level of the molten pool is the premise and the basis for realizing accurate control.
The strip continuous casting process is a series of complex phase change and physicochemical processes of casting, solidification, rolling deformation and knockout which are completed in a few seconds in a narrow space of a molten pool. Research has shown that the fluctuation of molten steel level in a molten pool in the thin strip continuous casting is an important factor influencing the quality of cast strips. The liquid level of a molten pool changes in the continuous casting process of the thin strip, so that the contact time of molten steel and a crystallizer can be changed, the solidification process of the molten steel is further influenced, and the quality of the cast strip can be greatly influenced.
The requirements of various process parameters of the thin strip continuous casting are accurate, in order to ensure good strip casting quality, higher requirements are provided for various production indexes, which means that the precision of each link is improved, so that higher requirements are provided for the liquid level measurement precision and the liquid level control precision.
In continuous casting, the prior art molten pool liquid level detection methods include radiation method, laser or ultrasonic wave, electric eddy current detection and the like. The radioactive method has radioactivity, has certain harm to operators and is not beneficial to environmental protection; the laser or ultrasonic detection is easily influenced by various factors such as molten steel splashing, smoke, dust and the like, and causes interference to the detection; when the eddy current is detected, the eddy current is influenced by the detection environment and the distribution environment of the surrounding metal conductors, so that the detection stability is influenced to a certain extent.
Disclosure of Invention
In view of this, the present application provides a continuous casting molten pool liquid level detection system and a continuous casting molten pool liquid level control method, which are used to realize real-time accurate detection of a continuous casting molten pool liquid level, facilitate accurate control of the molten pool liquid level, and improve the quality of a cast strip. The problem that the detection precision is not high especially under severe environments such as high temperature, high brightness and strong interference is solved, and meanwhile, the system is small in design size, convenient to install, provided with a cooling device, high-temperature resistant and a purging device, and can be guaranteed to continuously and stably operate for a long time under the severe environments.
According to one aspect of the present application, there is provided a continuous casting bath level detection system, the system comprising:
the image acquisition device comprises a CCD camera and a controller, the CCD camera is connected with the controller through an anti-interference cable, the CCD camera is mounted on a rotating bracket arranged above the continuous casting molten pool, and the image acquisition device is used for acquiring image information of a junction area of molten steel and a casting roll in the continuous casting molten pool through the CCD camera under the control of the controller;
the image processing device is connected with the controller and is used for processing the image information transmitted by the image acquisition device and obtaining the liquid level height of the molten steel based on the processed image information;
the cooling device is a water-cooling protective cover, and the CCD camera is positioned in the water-cooling protective cover;
and the purging device is arranged at the front end of the CCD camera and is used for discharging gas at the front end of the CCD camera.
Specifically, the image processing apparatus is further configured to adjust an aperture and an exposure time of the camera by the controller.
Specifically, the image acquisition device comprises a plurality of cameras, and the plurality of cameras corresponding to the plurality of image acquisition devices are respectively arranged at different positions above the continuous casting molten pool.
According to another aspect of the present application, there is provided a continuous casting molten pool level control method for use in the above-mentioned continuous casting molten pool level detection system and continuous casting molten pool level control system, wherein the control system is connected with an image processing device of the detection system, the method comprising:
the image information of the continuous casting molten pool is collected by an image collecting device of the continuous casting molten pool liquid level detection system,
transmitting the image information to an image processing device;
the image processing device determines the liquid level height of the continuous casting pool based on the image information and a preset model;
and the continuous casting molten pool liquid level control system carries out liquid level control adjustment on the continuous casting molten pool based on the liquid level height.
Specifically, the establishing step of the preset model comprises:
in the cooling state of a continuous casting molten pool, a preset calibration plate is horizontally placed at a position corresponding to a casting roller, and a plurality of calibration images are acquired through an image acquisition device;
after preprocessing the calibration images, establishing coordinates according to the preprocessed calibration images;
and determining the preset model according to the coordinates, the image size of the calibration plate in the calibration image and the actual size of the calibration plate, wherein the preset model is used for determining the actual width of the liquid level in the image based on the input image.
Specifically, the determining the liquid level height of the continuous casting molten pool based on the image information and a preset model specifically comprises:
after the image information is preprocessed, determining the actual liquid level width according to the preset model and the preprocessed image information;
and calculating the liquid level height of the continuous casting molten pool according to the actual liquid level width.
In particular, the liquid level height
Wherein R is the radius of the casting rolls, W is the liquid level width, and G is the distance between the casting rolls.
Borrow by above-mentioned technical scheme, the application provides a continuous casting molten bath liquid level detection system and continuous casting molten bath liquid level control method, continuous casting molten bath liquid level detection system does not have radioactivity, need not special protection to operating personnel and can install the operation, and liquid level detection system simple to operate, do not need frequent maintenance, regular point check can, applicable in narrow and small installation volume space, lower to the installation requirement, do not receive the molten steel to splash, the influence of many-sided interference factors such as cigarette, dust, it is convenient to detect, can adapt to the service environment of high temperature, small, the long-term continuous reliable operation of guarantee production, high temperature has been satisfied comprehensively, high dust, powerful splash, work needs such as monitoring angle variation, liquid level detection method is simple and convenient, the calculated amount is little, the calculating speed is fast, can be better satisfy the real-time nature detection of liquid level.
The foregoing description is only an overview of the technical solutions of the present application, and the present application can be implemented according to the content of the description in order to make the technical means of the present application more clearly understood, and the following detailed description of the present application is given in order to make the above and other objects, features, and advantages of the present application more clearly understandable.
Drawings
The accompanying drawings, which are included to provide a further understanding of the application and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the application and together with the description serve to explain the application and not to limit the application. In the drawings:
FIG. 1 is a schematic flow chart of a continuous casting molten pool level control method provided by an embodiment of the application;
fig. 2 is a schematic flowchart illustrating a method for establishing a preset model according to an embodiment of the present disclosure;
FIG. 3 is a schematic diagram illustrating a placement of a calibration board according to an embodiment of the present disclosure;
FIG. 4 is a schematic diagram of a mathematical model for converting the liquid level width and the liquid level height of a molten pool in an image processing process according to an embodiment of the present application;
FIG. 5 is a schematic flow chart of a continuous casting molten pool liquid level detection method provided by the embodiment of the application;
FIG. 6 is a schematic structural diagram of a continuous casting molten pool level detection and control system provided by the embodiment of the application.
Detailed Description
The present application will be described in detail below with reference to the accompanying drawings in conjunction with embodiments. It should be noted that the embodiments and features of the embodiments in the present application may be combined with each other without conflict.
In this embodiment, a continuous casting bath level detection system is provided, the system comprising: the image acquisition device comprises a CCD camera and a controller, the CCD camera is connected with the controller through an anti-interference cable, the CCD camera is mounted on a rotating bracket arranged above the continuous casting molten pool, and the image acquisition device is used for acquiring image information of a junction area of molten steel and a casting roll in the continuous casting molten pool through the CCD camera under the control of the controller; the image processing device is connected with the controller and is used for processing the image information transmitted by the image acquisition device and obtaining the liquid level height of the molten steel based on the processed image information; the cooling device is a water-cooling protective cover, and the CCD camera is positioned in the water-cooling protective cover; and the purging device is arranged at the front end of the CCD camera and is used for discharging gas at the front end of the CCD camera.
In the above embodiment, the continuous casting molten pool liquid level detection system includes an image acquisition device, an image processing device, a cooling device and a purging device, wherein the image acquisition device further includes a CCD camera and a controller. In this embodiment, image acquisition device adopts the high resolution CCD camera of separation, and the CCD camera of separation is connected with video controller (being the controller) through long distance high anti-interference cable, and video controller is connected with the industrial computer (the image processing unit is placed in the industrial computer in), and the CCD camera is used for acquireing molten bath molten steel and casting roller boundary region image to in passing through controller real-time transmission to the industrial computer, the CCD camera is installed on runing rest, the angular adjustment of being convenient for, runing rest is fixed in the continuous casting molten bath top. The image processing device is used for processing the image acquired by the image acquisition device and calculating the liquid level height according to the processed image and a preset mathematical model.
In addition, in order to ensure the operation stability of the CCD camera, the system also comprises a cooling device and a purging device. The cooling device can be specifically a water-cooling protective cover, and the CCD camera is located in the multifunctional water-cooling protective cover and used for cooling the camera, and an efficient vortex refrigeration technology and a water-cooling technology are used, so that the camera can continuously and stably operate in a high-temperature extremely severe environment. Be provided with gaseous device that sweeps at camera lens the place ahead tip, can blow to the camera lens front end through the device, can take away partial heat promptly, guarantee that camera and cable move in lower environment, also can form a high pressure environment at the camera lens front end, reduce that on-the-spot molten steel splashes, the dust is stained with the phenomenon emergence on the lens, reduces the plant maintenance, guarantees to obtain the image of high definition, provides the basis for molten bath liquid level detection.
As mentioned above, the separated high-resolution CCD lens has low requirement on the use temperature and small volume, and is matched with the cooling device and the blowing device to be arranged at the corresponding position above the casting and rolling crystallization roller, so that the stable operation of the CCD camera is ensured; the controller is connected with the CCD camera through a cable, so that the controller can be installed and kept away from a high-temperature environment, the requirement of running under the high-temperature environment and narrow and small field installation volume can be met, the equipment can run stably for a long time, the detection work of the liquid level of the molten pool under the conditions of high temperature detection of the liquid level of the molten pool and severe environment is solved, and a foundation is laid for the subsequent liquid level control of the molten pool.
In the embodiment of the present application, specifically, the image processing apparatus is further configured to adjust an aperture and an exposure time of the camera by the controller.
In this embodiment, the image processing apparatus may automatically adjust the aperture and the exposure time of the CCD camera through the controller, thereby acquiring an image. Meanwhile, each region is compensated according to the difference of the light intensity of each region in the molten pool, and images with relatively good quality of each part and good overall quality are obtained, so that the subsequent accurate calculation of the liquid level height based on the images is facilitated, and accurate liquid level control is realized.
In the embodiment of the application, specifically, the image acquisition device comprises a plurality of cameras, and the plurality of cameras corresponding to the plurality of image acquisition devices are respectively arranged at different positions above the continuous casting molten pool.
In the embodiment, a plurality of sets of image acquisition devices can be arranged on one continuous casting pool to carry out multi-point measurement, image information of a plurality of positions is obtained simultaneously, and optimization processing is carried out on the image information of each area, so that the measurement result is more comprehensive and reliable. In the continuous production operation process, when the single-point image acquisition device breaks down, production does not need to be interrupted, the continuity of the system is improved, and the continuity of production is ensured.
Further, the present application also provides a continuous casting molten pool liquid level control method, as shown in fig. 1, which is used in the above continuous casting molten pool liquid level detection system and continuous casting molten pool liquid level control system, wherein the control system is connected with an image processing device of the detection system, and the method includes:
102, determining the liquid level height of a continuous casting molten pool by an image processing device based on image information and a preset model;
and 103, carrying out liquid level control and adjustment on the continuous casting molten pool by the continuous casting molten pool liquid level control system based on the liquid level height.
In the above embodiment, the CCD camera pre-installed in the continuous casting pool is used to collect the image information of the junction between the molten steel in the continuous casting pool and the casting roll, so that after the image information is processed, the liquid level height of the continuous casting pool corresponding to the image information is analyzed according to the preset model matched with the CCD camera, and after the liquid level height is obtained, the liquid level height data can be transmitted to the continuous casting pool liquid level control system, which may specifically be a PLC control device, so as to control and adjust the liquid level of the continuous casting pool, thereby ensuring the stability of the liquid level of the pool.
The method solves the difficult problem of molten pool liquid level height detection in special environments such as high temperature, high brightness, strong interference, sealing, limited space and the like in the continuous casting process; the device can be suitable for installation under various severe conditions, and is convenient to install; slag inclusion is not needed, and the components of the molten steel are not influenced; no radiation pollution, safety, reliability and good equipment maintenance; special protection is not needed, and the device can adapt to the field high-temperature environment; the method is not influenced by the environment during casting, and the accurate liquid level value can be accurately obtained. The liquid level control system of the continuous casting molten pool can be well controlled, and the control system controls the casting roller, so that the stability of the casting process and the quality of a cast strip product can be ensured.
In the embodiment of the present application, specifically, as shown in fig. 2, the step of establishing the preset model includes:
and 203, determining a preset model according to the coordinates, the image size of the calibration plate in the calibration image and the actual size of the calibration plate, wherein the preset model is used for determining the actual width of the liquid level in the image based on the input image.
In the embodiment, in the cooling state of the continuous casting molten pool, as shown in FIG. 3, a calibration plate is horizontally placed on the measured target position, the molten pool liquid level is simulated by the calibration plate, a plurality of calibration images containing the calibration plate are collected by an image collecting device after the calibration plate is placed, then processing the collected image including the boundary image of the calibration plate and the casting roller, counting the image coordinate data, and the image acquisition and coordinate data statistics steps are repeated to obtain a plurality of groups of calibration plate and image corresponding data, and further, since the actual size of the calibration plate is known, the image size of the calibration plate in the image can be obtained by calibrating the image, so that the preset mathematical model is established according to the actual size of the calibration plate and the image size, the mathematical model can realize the calibration of the image based on the input image information and calculate the actual liquid level width.
In this embodiment, step 102 may specifically include:
step 102-1, after image information is preprocessed, determining the actual liquid level width according to a preset model and the preprocessed image information;
and 102-1, calculating the liquid level height of the continuous casting molten pool according to the actual liquid level width.
In the embodiment, in the actual use process of the continuous casting molten pool, after the image information is collected by the CCD camera and is preprocessed, the liquid level width data in the image can be obtained by analyzing the preprocessed image information, the liquid level width data of the image is converted into the actual width data of the liquid level by using the preset model, and therefore the liquid level height can be calculated according to the actual liquid level width and the setting of the casting roller.
It should be noted that the image preprocessing in the embodiment of the present application may include filtering processing, contrast stretching, and the like, and further, may further include performing binarization processing on the processed image, converting the image into a binary image, extracting the binary image, and extracting a molten pool liquid level edge image, so that the edge image is used as a preprocessed image to perform subsequent liquid level width calculation.
In the embodiment of the present application, specifically, as shown in FIG. 4, R is the radius of the casting rolls, W is the actual width of molten steel in the molten bath, G is the roll gap width between the casting rolls, and based on the Pythagorean theorem,
i.e. height of liquid level
Can find out through above embodiment and process, this application is nonradioactive, need not special protection to operating personnel and can install the operation, and liquid level detection system simple to operate, do not need frequent maintenance, regular point examine can, applicable in narrow and small installation volume space, it is lower to the installation requirement, do not receive the molten steel to splash, cigarette, the influence of many-sided interference factors such as dust, it is convenient to detect, can adapt to high temperature's service environment, small, the long-term reliable operation in succession of guarantee production, high temperature has been satisfied comprehensively, high dust, brute force splashes, work needs such as monitoring angle change, the liquid level detection method is simple and convenient, the calculated amount is little, the computational rate is fast, can be better satisfy the real-time detection of liquid level.
Fig. 5 shows a method for detecting a liquid level of a continuous casting molten pool provided by an embodiment of the present application, as shown in fig. 5, before steel is poured in a molten pool, it is determined whether calibration is completed or not, that is, whether a calibration plate is placed and a preset model is established based on a calibration image or not, steel pouring is started after the completion of calibration is confirmed, simultaneously, an image is acquired by a CCD camera, filtering processing and edge detection are performed on the image, then, a continuous casting molten pool liquid level width is calculated by the processed image, a liquid level height is calculated by combining with the preset model obtained by calibration, in addition, liquid level height data can be sent to a PLC, so that the PLC controls working parameters of a casting roll based on the liquid level height to realize liquid level control, and the liquid level stability is ensured. As shown in fig. 6, in the liquid level detection and control system provided in the embodiment of the present application, after the casting machine starts to work, the CCD camera collects images, the image processing device performs image processing based on the images collected by the CCD camera and calculates the liquid level height of the continuous casting molten pool, and the PLC controls the operating parameters of the casting machine according to the liquid level height of the molten pool to ensure the stable liquid level of the continuous casting molten pool.
Based on the above-mentioned method shown in fig. 1 to 6, correspondingly, the present application further provides a storage medium, on which a computer program is stored, and the computer program is executed by a processor to implement the above-mentioned continuous casting molten bath level control method shown in fig. 1 to 6.
Based on such understanding, the technical solution of the present application may be embodied in the form of a software product, which may be stored in a non-volatile storage medium (which may be a CD-ROM, a usb disk, a removable hard disk, etc.), and includes several instructions for enabling a computer device (which may be a personal computer, a server, or a network device, etc.) to execute the method according to the implementation scenarios of the present application.
Based on the above-mentioned methods as shown in fig. 1 to fig. 6, in order to achieve the above-mentioned object, an embodiment of the present application further provides a computer device, which may specifically be a personal computer, a server, a network device, and the like, where the computer device includes a storage medium and a processor; a storage medium for storing a computer program; a processor for executing a computer program to implement the above-described continuous casting bath level control method as shown in fig. 1 to 6.
Optionally, the computer device may also include a user interface, a network interface, a camera, Radio Frequency (RF) circuitry, sensors, audio circuitry, a WI-FI module, and so forth. The user interface may include a Display screen (Display), an input unit such as a keypad (Keyboard), etc., and the optional user interface may also include a USB interface, a card reader interface, etc. The network interface may optionally include a standard wired interface, a wireless interface (e.g., a bluetooth interface, WI-FI interface), etc.
It will be appreciated by those skilled in the art that the present embodiment provides a computer device architecture that is not limiting of the computer device, and that may include more or fewer components, or some components in combination, or a different arrangement of components.
The storage medium may further include an operating system and a network communication module. An operating system is a program that manages and maintains the hardware and software resources of a computer device, supporting the operation of information handling programs, as well as other software and/or programs. The network communication module is used for realizing communication among components in the storage medium and other hardware and software in the entity device.
Those skilled in the art will appreciate that the figures are merely schematic representations of one preferred implementation scenario and that the blocks or flow diagrams in the figures are not necessarily required to practice the present application. Those skilled in the art will appreciate that the modules in the devices in the implementation scenario may be distributed in the devices in the implementation scenario according to the description of the implementation scenario, or may be located in one or more devices different from the present implementation scenario with corresponding changes. The modules of the implementation scenario may be combined into one module, or may be further split into a plurality of sub-modules.
The above application serial numbers are for description purposes only and do not represent the superiority or inferiority of the implementation scenarios. The above disclosure is only a few specific implementation scenarios of the present application, but the present application is not limited thereto, and any variations that can be made by those skilled in the art are intended to fall within the scope of the present application.
Claims (7)
1. A continuous casting bath level detection system, the system comprising:
the image acquisition device comprises a CCD camera and a controller, the CCD camera is connected with the controller through an anti-interference cable, the CCD camera is mounted on a rotating bracket arranged above the continuous casting molten pool, and the image acquisition device is used for acquiring image information of a junction area of molten steel and a casting roll in the continuous casting molten pool through the CCD camera under the control of the controller;
the image processing device is connected with the controller and is used for processing the image information transmitted by the image acquisition device and obtaining the liquid level height of the molten steel based on the processed image information;
the cooling device is a water-cooling protective cover, and the CCD camera is positioned in the water-cooling protective cover;
and the purging device is arranged at the front end of the CCD camera and is used for discharging gas at the front end of the CCD camera.
2. The system of claim 1, wherein the image processing device is further configured to adjust an aperture and an exposure time of the camera via the controller.
3. The system according to claim 1 or 2, wherein the image acquisition device comprises a plurality of cameras, and the plurality of cameras corresponding to the plurality of image acquisition devices are respectively arranged at different positions above the continuous casting molten pool.
4. A continuous casting molten pool level control method used in the continuous casting molten pool level detection system and the continuous casting molten pool level control system according to any one of claims 1 to 3, wherein the control system is connected with an image processing device of the detection system, the method comprising:
acquiring image information of a continuous casting pool through an image acquisition device of a continuous casting pool liquid level detection system, and transmitting the image information to an image processing device;
the image processing device determines the liquid level height of the continuous casting pool based on the image information and a preset model;
and the continuous casting molten pool liquid level control system carries out liquid level control adjustment on the continuous casting molten pool based on the liquid level height.
5. The method of claim 4, wherein the step of building the predetermined model comprises:
in the cooling state of a continuous casting molten pool, a preset calibration plate is horizontally placed at a position corresponding to a casting roller, and a plurality of calibration images are acquired through an image acquisition device;
after preprocessing the calibration images, establishing coordinates according to the preprocessed calibration images;
and determining the preset model according to the coordinates, the image size of the calibration plate in the calibration image and the actual size of the calibration plate, wherein the preset model is used for determining the actual width of the liquid level in the image based on the input image.
6. The method according to claim 5, wherein the determining the level of the continuous casting pool based on the image information and a preset model comprises:
after the image information is preprocessed, determining the actual liquid level width according to the preset model and the preprocessed image information;
and calculating the liquid level height of the continuous casting molten pool according to the actual liquid level width.
7. The method of claim 6,
the height of the liquid level
Wherein R is the radius of the casting rolls, W is the liquid level width, and G is the distance between the casting rolls.
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