CN113834558A - Remote fault detection method for steel ladle weighing sensor - Google Patents
Remote fault detection method for steel ladle weighing sensor Download PDFInfo
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- CN113834558A CN113834558A CN202010588469.7A CN202010588469A CN113834558A CN 113834558 A CN113834558 A CN 113834558A CN 202010588469 A CN202010588469 A CN 202010588469A CN 113834558 A CN113834558 A CN 113834558A
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- 238000005303 weighing Methods 0.000 title claims abstract description 123
- 238000001514 detection method Methods 0.000 title claims abstract description 46
- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 16
- 239000010959 steel Substances 0.000 title claims abstract description 16
- 238000004891 communication Methods 0.000 claims abstract description 14
- 230000008054 signal transmission Effects 0.000 claims abstract description 7
- 230000000007 visual effect Effects 0.000 claims description 7
- 238000000034 method Methods 0.000 claims description 6
- 238000009749 continuous casting Methods 0.000 description 6
- 230000005540 biological transmission Effects 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 4
- 238000005266 casting Methods 0.000 description 3
- 230000008859 change Effects 0.000 description 3
- 230000008569 process Effects 0.000 description 3
- 230000002411 adverse Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 239000000428 dust Substances 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 241001391944 Commicarpus scandens Species 0.000 description 1
- 241000196324 Embryophyta Species 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012544 monitoring process Methods 0.000 description 1
- 230000033764 rhythmic process Effects 0.000 description 1
- 238000009628 steelmaking Methods 0.000 description 1
- 238000003786 synthesis reaction Methods 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01G—WEIGHING
- G01G23/00—Auxiliary devices for weighing apparatus
- G01G23/01—Testing or calibrating of weighing apparatus
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Abstract
The invention discloses a remote fault detection method for a ladle weighing sensor, which comprises the following steps: weighing signals of four weighing sensors (1) on a steel ladle seat are respectively collected through four independent signal distributors (2), and output signals of the signal distributors and output signals of weighing transmitters (3) are transmitted to a signal analysis terminal (5) through a wireless communication device; calculating the ratio between the current output signal of the weighing transmitter and the output signal before the interval time, and setting the ratio as a first ratio; calculating the average value of the current output signals of the four signal distributors, calculating the ratio between the average value and the current output signal of the weighing transmitter, and setting the ratio as a second ratio; and if the first ratio exceeds the first ratio range and the second ratio is within the second ratio range, judging that a faulty sensor exists in the four weighing sensors. The detection method ensures the signal transmission precision and realizes the accurate fault judgment of the weighing sensor.
Description
Technical Field
The invention relates to a detection method of a steel-making equipment sensor, in particular to a remote fault detection method of a steel ladle weighing sensor.
Background
The ladle weighing device of the continuous casting machine is important detection equipment in the casting process of continuous casting billets, and can monitor the weight change of molten steel in the ladle in the casting process in real time according to production management and process technical requirements, coordinate molten steel supply rhythm, ensure that the molten steel level of a tundish is stable, and the like, so that the ladle weighing device is very important to ensure stable operation.
Referring to fig. 1, the ladle turret has two ladle seats altogether, every ladle seat disposes one set of weighing device, include four weighing sensor 1 in one set of weighing device, weigh changer 3 and weigh PLC unit 8, wherein weigh changer 3's input and four weighing sensor 1 and be connected, weigh changer 3's output and pass through the sliding ring 7 and be connected with weighing PLC unit 8, weigh changer 3 and convert the output voltage signal synthesis of four weighing sensor 1 into 4-20 mA's current signal, and with this output current signal conveying to weighing PLC unit 8, weigh changer 3's output signal and convert actual weight numerical value and convey to and show in HMI terminal 9 after weighing PLC unit 8 handles.
Because the weighing sensor is close to the ladle, the working environment is poor, the weight of the ladle is large, and the weighing sensor always bears the huge impact of the weight of the ladle, so that the weighing sensor is easy to break down under huge working load, thereby influencing production.
At present, a fault detection device special for a weighing sensor is not provided, in the actual production process, the fault of the weighing sensor is mainly checked through manually monitoring an HMI terminal picture, and when an operator monitors that a ladle weighing curve fluctuates abnormally on the HMI picture, the operator must go to a ladle turret to measure and check signals of the weighing sensor one by one. The method for detecting the faults cannot accurately position the faulty weighing sensors, and operators can determine the faulty weighing sensors only by testing signals one by one after cables are detached from all the weighing sensors on the ladle turret, so that the working process is complicated, the labor consumption is high, the working efficiency is low, and the normal stability of production is not facilitated.
Disclosure of Invention
The invention aims to provide a remote fault detection method for a steel ladle weighing sensor, which adopts a wireless communication mode to transmit detection signals so as to ensure the signal transmission precision, and realizes the accurate judgment of equipment faults of the weighing sensor, the signal distributor and the weighing transmitter by comprehensively comparing output signals of the signal distributor and the weighing transmitter.
In order to achieve the technical purpose, the invention adopts the following technical scheme:
a ladle weighing sensor remote fault detection method comprises the following steps:
step 1: weighing signals of four weighing sensors on a steel ladle seat are respectively collected through four independent signal distributors, and output signals of the signal distributors and output signals of the weighing transmitters are transmitted to a signal analysis terminal through a wireless communication device;
step 2: setting an interval time, calculating the ratio of the current output signal of the weighing transmitter to the output signal before the interval time, and setting the ratio as a first ratio;
and step 3: calculating the average value of the current output signals of the four signal distributors, calculating the ratio of the average value to the current output signal of the weighing transmitter, and setting the ratio as a second ratio;
and 4, step 4: setting a first ratio range and a second ratio range, if the first ratio exceeds the first ratio range and the second ratio exceeds the second ratio range, judging that the weighing transmitters have faults, and if the first ratio exceeds the first ratio range and the second ratio is in the second ratio range, judging that a faulty sensor exists in the four weighing sensors;
and 5: for each signal distributor, calculating the ratio between the output signal of the signal distributor and the average value of the output signals of the other three signal distributors, and setting the ratio as a third ratio;
step 6: and setting a third ratio range, and for each signal distributor, if the first ratio exceeds the first ratio range and the third ratio exceeds the third ratio range, judging that the weighing sensor corresponding to the signal distributor fails, and if the first ratio is in the first ratio range and the third ratio exceeds the third ratio range, judging that the signal distributor fails.
Further, the interval time is set to 1 second, and the first ratio range is set to 0.99 to 1.01.
Further, the second ratio range is set to 0.995 to 1.005.
Further, the third ratio range is set to 0.97 to 1.03.
Further, the detection method further comprises:
and 7: and the signal analysis terminal displays the fault judgment result on a display.
Further, the detection method further comprises:
and 8: and the signal analysis terminal sends out audible and visual alarm according to the fault judgment result.
Further, the wireless communication device adopts the frequency of 2.4GHz or 5GHz for signal transmission.
Compared with the prior art, the detection method has the advantages that the detection signal is transmitted in a wireless communication mode, so that the signal loss of a signal cable in the transmission process can be avoided, the electromagnetic interference of high-power equipment around the weighing sensor is reduced to the greatest extent, the signal transmission precision is ensured, meanwhile, the signal does not pass through a slip ring in the transmission process, so that the adverse effects of signal loss, signal propagation discontinuity and the like caused by dust or poor contact of a slip ring contact are avoided, and the detection result is accurate and reliable; the detection method of the invention can realize the accurate judgment of the equipment faults of the weighing sensor, the signal distributor and the weighing transmitter by comprehensively comparing the ratio of the output signals of the signal distributor and the weighing transmitter.
Drawings
FIG. 1 is an electrical schematic diagram of a ladle turret weighing apparatus of the prior art;
FIG. 2 is an electrical schematic diagram of a ladle weighing sensor detection device employed in the present invention;
FIG. 3 is an electrical schematic of the signal analysis terminal;
fig. 4 is a flow chart of the ladle weighing sensor remote fault detection method of the invention.
In the figure: the system comprises a weighing sensor 1, a signal distributor 2, a weighing transmitter 3, a wireless signal transmitter 4, a signal analysis terminal 5, a fault detection PLC unit 51, a fault judgment display 52, an audible and visual alarm 53, a wireless signal receiver 6, a slip ring 7, a weighing PLC unit 8 and an HMI terminal 9.
Detailed Description
The invention will be further described with reference to the following figures and specific examples:
referring to fig. 2, the present embodiment provides a ladle weighing sensor remote fault detection method, which is directed to a weighing sensor 1 on a continuous casting ladle turret, and aims to continuously monitor the signal condition of the weighing sensor 1 and timely find and judge the fault condition of the weighing sensor 1.
Referring to fig. 4, the detection method includes:
step 1: weighing signals of four weighing sensors 1 on a steel ladle seat are respectively collected through four independent signal distributors 2, and output signals of the signal distributors 2 and output signals of the weighing transmitters 3 are transmitted to a signal analysis terminal 5 through a wireless communication device;
step 2: setting an interval time, calculating the ratio of the current output signal of the weighing transmitter 3 to the output signal before the interval time, and setting the ratio as a first ratio;
and step 3: calculating the average value of the current output signals of the four signal distributors 2, calculating the ratio of the average value to the current output signal of the weighing transmitter 3, and setting the ratio as a second ratio;
and 4, step 4: setting a first ratio range and a second ratio range, if the first ratio exceeds the first ratio range and the second ratio exceeds the second ratio range, judging that the weighing transmitter 3 has a fault, and if the first ratio exceeds the first ratio range and the second ratio is in the second ratio range, judging that a faulty sensor exists in the four weighing sensors 1;
and 5: for each signal distributor 2, calculating the ratio between the output signal of the signal distributor 2 and the average value of the output signals of the other three signal distributors 2, and setting the ratio as a third ratio;
step 6: setting a third ratio range, and for each signal distributor 2, if the first ratio exceeds the first ratio range and the third ratio exceeds the third ratio range, determining that the weighing sensor 1 corresponding to the signal distributor 2 is in fault, and if the first ratio is in the first ratio range and the third ratio exceeds the third ratio range, determining that the signal distributor 2 is in fault;
and 7: the signal analysis terminal 5 displays the failure determination result on a display;
and 8: and the signal analysis terminal 5 gives out sound and light alarm according to the fault judgment result.
Example (b):
referring to fig. 2 and fig. 3, the background of the embodiment is a continuous casting operation area of a certain steel plant, a set of ladle weighing sensor detection device is provided for a weighing sensor of a ladle turret, wherein the ladle weighing sensor detection device comprises four signal distributors 2, a wireless signal transmitter 4, a wireless signal receiver 6 and a signal analysis terminal 5, the four signal distributors 2 respectively correspond to four weighing sensors 1 on the ladle turret, signal input ends of the signal distributors 2 are connected with the weighing sensors 1, each signal distributor 2 can convert a voltage signal corresponding to the weighing sensor 1 into a current signal of 4-20 mA, and output ends of the signal distributors 2 are connected with the wireless signal transmitter 4, so that a sensor signal acquisition line is formed; the signal analysis terminal 5 is connected with the wireless signal receiver 6, the signal distributor 2 can be in wireless communication with the signal analysis terminal 5 through the wireless signal transmitter 4 and the wireless signal receiver 6, the wireless communication adopts 2.4GHz or 5GHz frequency for signal transmission, the output signal of each signal distributor 2 can be transmitted to the signal analysis terminal 5 through a wireless communication mode, in addition, the output end of the weighing transmitter 3 is also connected with the wireless signal transmitter 4, the output signal of the weighing transmitter 3 is also transmitted to the signal analysis terminal 5 through a wireless communication mode, and the signal analysis terminal 5 performs fault analysis on the output signals of the signal distributor 2 and the weighing transmitter 3; more specifically, the signal analysis terminal 5 includes a fault detection PLC unit 51, a fault determination display 52 and an audible and visual alarm 53, wherein the fault detection PLC unit 51 is connected to the wireless signal receiver 6, that is, the fault detection PLC unit 51 is responsible for receiving the output signals of the signal distributor 2 and the weighing transducer 3, the fault detection PLC unit 51 is connected to the fault determination display 52, the fault determination display 52 is further connected to the audible and visual alarm 53, the fault detection PLC unit 51 receives the output signals of the signal distributor 2 and the weighing transducer 3 and then performs fault analysis determination on the output signals and transmits the fault determination result to the fault determination display 52, and the fault determination display 52 displays the fault determination result and controls the audible and visual alarm 53 to emit audible and visual alarms according to the fault determination result.
Referring to fig. 4, the detection method of the present embodiment is based on the above-described detection apparatus, and starts to detect the weighing sensor 1 on the ladle seat when the ladle filled with molten steel is seated on the ladle turret weighing arm, and includes:
step 1: weighing signals of four weighing sensors 1 on a steel ladle seat are respectively collected through four independent signal distributors 2, and output signals of the signal distributors 2 and output signals of the weighing transmitters 3 are transmitted to a signal analysis terminal 5 through a wireless communication device; the weighing sensor 1 is pressed to send a weighing signal, the weighing signal of the weighing sensor 1 is simultaneously transmitted to the fault detection PLC unit 51 through the signal distributor 2 and the weighing transmitter 3, and the fault detection PLC unit 51 starts to continuously analyze the change conditions of the signal distributor 2 and the signal of the weighing transmitter 3 after receiving the output signals of the signal distributor 2 and the weighing transmitter 3;
step 2: setting an interval time, calculating the ratio of the current output signal of the weighing transmitter 3 to the output signal before the interval time, and setting the ratio as a first ratio; in the present embodiment, the interval time is set to 1 second.
And step 3: calculating the average value of the current output signals of the four signal distributors 2, calculating the ratio of the average value to the current output signal of the weighing transmitter 3, and setting the ratio as a second ratio;
and 4, step 4: setting a first ratio range and a second ratio range, if the first ratio exceeds the first ratio range and the second ratio exceeds the second ratio range, judging that the weighing transmitter 3 has a fault, and if the first ratio exceeds the first ratio range and the second ratio is in the second ratio range, judging that a faulty sensor exists in the four weighing sensors 1; in the present embodiment, the first ratio range is set to 0.99 to 1.01, and the second ratio range is set to 0.995 to 1.005;
and 5: for each signal distributor 2, calculating the ratio between the output signal of the signal distributor 2 and the average value of the output signals of the other three signal distributors 2, and setting the ratio as a third ratio;
step 6: setting a third ratio range, and for each signal distributor 2, if the first ratio exceeds the first ratio range and the third ratio exceeds the third ratio range, determining that the weighing sensor 1 corresponding to the signal distributor 2 is in fault, and if the first ratio is in the first ratio range and the third ratio exceeds the third ratio range, determining that the signal distributor 2 is in fault; in the present embodiment, the third ratio range is set to 0.97 to 1.03;
and 7: the signal analysis terminal 5 displays the failure determination result on a display;
and 8: and the signal analysis terminal 5 gives out sound and light alarm according to the fault judgment result.
Although the output signal of the signal distributor 2 is analyzed and determined in the above step process, the signal distributor 2 collects the weighing signal of the weighing sensor 1 and outputs the signal, that is, actually, the weighing signal of the weighing sensor 1 is analyzed, so as to determine the fault condition of the weighing sensor 1.
In the detection method of the embodiment, the detection signal is transmitted in a wireless communication mode, and the wireless data transmission frequency is high, so that the signal loss of a signal cable in the transmission process can be avoided, meanwhile, the electromagnetic interference of high-power equipment around the weighing sensor 1 is reduced to the greatest extent, the signal transmission precision is ensured, and meanwhile, the signal does not pass through a slip ring in the transmission process, so that the adverse effects of signal loss, signal propagation discontinuity and the like caused by dust or poor contact of a slip ring contact are avoided, and the detection result is accurate and reliable; when a fault is judged, the signal analysis terminal 5 can display fault information and carry out sound-light alarm, so that equipment operation and maintenance personnel can timely and conveniently acquire the fault information.
The method of the embodiment not only can accurately judge the fault condition of the weighing sensor 1, but also can realize the self-detection of the equipment states of the signal distributor 2 and the weighing transmitter 3. Specifically, when the continuous casting machine is in normal and stable casting, the molten steel in the ladle is steadily reduced along with the continuous casting time, that is, the weight of the molten steel in the ladle is linearly reduced along with the time, so that when the weighing sensor 1, the signal distributor 2 and the weighing transmitter 3 are in a normal working state, the output signals and the time are in a certain linear relation, theoretically, the output current signals of the signal distributor 2 and the weighing transmitter 3 have little difference along with the time change trend, if the difference is too large, the output signals have problems, and by comprehensively comparing the ratio between the output signals of the signal distributor 2 and the weighing transmitter 3 and setting a judgment range for the ratio, if the ratio exceeds the judgment range, the output signals of the two parties are compared to be too large, so that one of the two parties is considered to have a fault, and finally, the equipment faults of the weighing sensor 1, the signal distributor 2 and the weighing transmitter 3 can be accurately judged through accurate comparison.
The present invention is not limited to the above embodiments, and any modifications, equivalent replacements, improvements, etc. within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (7)
1. A ladle weighing sensor remote fault detection method is characterized in that: the method comprises the following steps:
step 1: weighing signals of four weighing sensors (1) on a steel ladle seat are respectively collected through four independent signal distributors (2), and output signals of the signal distributors (2) and output signals of the weighing transmitters (3) are transmitted to a signal analysis terminal (5) through a wireless communication device;
step 2: setting an interval time, calculating the ratio between the current output signal of the weighing transmitter (3) and the output signal before the interval time, and setting the ratio as a first ratio;
and step 3: calculating the average value of the current output signals of the four signal distributors (2), calculating the ratio of the average value to the current output signal of the weighing transmitter (3), and setting the ratio as a second ratio;
and 4, step 4: setting a first ratio range and a second ratio range, if the first ratio exceeds the first ratio range and the second ratio exceeds the second ratio range, judging that the weighing transmitter (3) has a fault, and if the first ratio exceeds the first ratio range and the second ratio is in the second ratio range, judging that a faulty sensor exists in the four weighing sensors (1);
and 5: for each signal distributor (2), calculating the ratio between the output signal of the signal distributor (2) and the average value of the output signals of the other three signal distributors (2), and setting the ratio as a third ratio;
step 6: and setting a third ratio range, and if the first ratio exceeds the first ratio range and the third ratio exceeds the third ratio range, judging that the weighing sensor (1) corresponding to the signal distributor (2) fails, and if the first ratio is in the first ratio range and the third ratio exceeds the third ratio range, judging that the signal distributor (2) fails.
2. The ladle weighing sensor remote fault detection method according to claim 1, characterized in that: the interval time is set to 1 second, and the first ratio range is set to 0.99 to 1.01.
3. The ladle weighing sensor remote fault detection method according to claim 1, characterized in that: the second ratio range is set to 0.995 to 1.005.
4. The ladle weighing sensor remote fault detection method according to claim 1, characterized in that: the third ratio range is set to 0.97 to 1.03.
5. The ladle weighing sensor remote fault detection method according to claim 1, characterized in that: the detection method further comprises the following steps:
and 7: the signal analysis terminal (5) displays the failure determination result on a display.
6. The ladle weighing sensor remote fault detection method according to claim 5, characterized in that: the detection method further comprises the following steps:
and 8: and the signal analysis terminal (5) sends out audible and visual alarm according to the fault judgment result.
7. The ladle weighing sensor remote fault detection method according to claim 1, characterized in that: the wireless communication device adopts the frequency of 2.4GHz or 5GHz for signal transmission.
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