CN113834558B - Ladle weighing sensor remote fault detection method - Google Patents
Ladle weighing sensor remote fault detection method Download PDFInfo
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- CN113834558B CN113834558B CN202010588469.7A CN202010588469A CN113834558B CN 113834558 B CN113834558 B CN 113834558B CN 202010588469 A CN202010588469 A CN 202010588469A CN 113834558 B CN113834558 B CN 113834558B
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- 238000005303 weighing Methods 0.000 title claims abstract description 129
- 238000001514 detection method Methods 0.000 title claims abstract description 48
- 238000004458 analytical method Methods 0.000 claims abstract description 25
- 238000004891 communication Methods 0.000 claims abstract description 14
- 238000000034 method Methods 0.000 claims abstract description 11
- 230000008054 signal transmission Effects 0.000 claims abstract description 11
- 230000000007 visual effect Effects 0.000 claims description 10
- 229910000831 Steel Inorganic materials 0.000 description 7
- 239000010959 steel Substances 0.000 description 7
- 238000005266 casting Methods 0.000 description 4
- 238000009749 continuous casting Methods 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 230000005540 biological transmission Effects 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 230000002411 adverse Effects 0.000 description 2
- 239000000428 dust Substances 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000012544 monitoring process Methods 0.000 description 2
- 230000002159 abnormal effect Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000033764 rhythmic process Effects 0.000 description 1
- 238000009628 steelmaking Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
Classifications
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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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- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Arrangements For Transmission Of Measured Signals (AREA)
Abstract
The invention discloses a ladle weighing sensor remote fault detection method, which comprises the following steps: the method comprises the steps that weighing signals of four weighing sensors (1) on a 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 output signals of the current 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; if the first ratio exceeds the first ratio range and the second ratio is within the second ratio range, determining that a faulty sensor exists in the four weighing sensors. The detection method of the invention ensures the signal transmission precision and realizes the accurate fault judgment of the symmetrical quantity sensor.
Description
Technical Field
The invention relates to a sensor detection method of steelmaking equipment, in particular to a remote fault detection method of a ladle weighing sensor.
Background
The ladle weighing device of the continuous casting machine is an important detection device in the continuous casting billet casting process, can monitor the weight change of molten steel in a ladle in the casting process in real time according to the production management and process technology requirements, coordinates the molten steel supply rhythm, ensures the stable liquid level of the molten steel in a tundish, and the like, so that the stable operation of the ladle weighing device is very important.
Referring to fig. 1, the ladle turret has two ladle seats in total, each ladle seat is provided with a set of weighing device, the set of weighing device comprises four weighing sensors 1, a weighing transmitter 3 and a weighing PLC unit 8, wherein the input end of the weighing transmitter 3 is connected with the four weighing sensors 1, the output end of the weighing transmitter 3 is connected with the weighing PLC unit 8 through a slip ring 7, the weighing transmitter 3 synthesizes and converts the output voltage signals of the four weighing sensors 1 into current signals of 4-20 mA, the output current signals are transmitted to the weighing PLC unit 8, and the output signals of the weighing transmitter 3 are converted into actual weight values after being processed by the weighing PLC unit 8 and are transmitted to an HMI terminal 9 for display.
Because weighing sensor and ladle distance are nearer, and the operational environment that is located is relatively poor, and the weight of ladle is great, weighing sensor often needs to bear the huge impact of ladle weight, therefore, under huge work load, weighing sensor is very liable to take place the trouble to influence production.
At present, no fault detection device specifically aims at a weighing sensor is provided, in the actual production process, the fault detection of the weighing sensor is mainly implemented by manually monitoring an HMI terminal picture, and when an operator monitors that the fluctuation of a ladle weighing curve is abnormal on the HMI picture, the operator must measure and check the weighing sensor signals one by one on a ladle turret. The fault detection method cannot accurately position the faulty weighing sensor, and an operator can determine the faulty weighing sensor only by testing signals one by one after removing the cables from all the weighing sensors on the ladle turret, so that the working process is complicated, the manpower consumption is high, the working efficiency is low, and the normal and stable production is not facilitated.
Disclosure of Invention
The invention aims to provide a ladle weighing sensor remote fault detection method, wherein a detection signal is transmitted in a wireless communication mode, so that signal transmission precision is ensured, and accurate judgment of faults of a weighing sensor, a signal distributor and a weighing transmitter is realized by comprehensively comparing signals output by 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: the method comprises the steps that weighing signals of four weighing sensors on a ladle seat are respectively collected through four independent signal distributors, and output signals of the signal distributors and output signals of weighing transmitters are transmitted to a signal analysis terminal through a wireless communication device;
step 2: setting an interval time, 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;
Step 3: calculating the average value of the output signals of the current 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;
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 has faults, and if the first ratio exceeds the first ratio range and the second ratio is in the second ratio range, judging that the four weighing sensors have faults;
step 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: setting a third ratio range, and judging that a weighing sensor corresponding to each signal distributor fails if the first ratio exceeds the first ratio range and the third ratio exceeds the third ratio range, and judging that the signal distributor fails if the first ratio is in the first ratio range and the third ratio exceeds the third ratio range.
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:
Step 7: the signal analysis terminal displays the fault determination result on a display.
Further, the detection method further comprises:
step 8: and the signal analysis terminal sends out audible and visual alarm according to the fault judgment result.
Further, the wireless communication device adopts a frequency of 2.4GHz or 5GHz for signal transmission.
Compared with the prior art, the detection method has the beneficial effects 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 slip ring is not passed in the signal transmission process, and the adverse effects of signal loss, discontinuous signal transmission and the like caused by dust or poor contact of a slip ring contact are avoided, so that the detection result is accurate and reliable; the detection method of the invention can realize the accurate judgment of the faults of the weighing sensor, the signal distributor and the weighing transmitter by comprehensively comparing the ratio between the output signals of the signal distributor and the weighing transmitter.
Drawings
FIG. 1 is an electrical schematic diagram of a prior art ladle turret weighing apparatus;
FIG. 2 is an electrical schematic diagram of a ladle weighing sensor detection apparatus employed in the present invention;
FIG. 3 is an electrical schematic diagram of a signal analysis terminal;
FIG. 4 is a flow chart of the ladle weighing sensor remote fault detection method of the present invention.
In the figure: 1-weighing sensor, 2-signal distributor, 3-weighing transmitter, 4-wireless signal transmitter, 5-signal analysis terminal, 51-fault detection PLC unit, 52-fault judgement display, 53-audible and visual alarm, 6-wireless signal receiver, 7-sliding ring, 8-weighing PLC unit, 9-HMI terminal.
Detailed Description
The invention is further described with reference to the drawings and the specific embodiments below:
referring to fig. 2, the present embodiment provides a method for detecting a remote fault of a ladle weighing sensor, which aims at a weighing sensor 1 on a revolving platform of a continuous casting ladle, and aims at continuously monitoring the signal condition of the weighing sensor 1, and timely finding and judging the fault condition of the weighing sensor 1.
Referring to fig. 4, the detection method includes:
Step 1: the method comprises the steps that weighing signals of four weighing sensors 1 on a ladle seat are respectively collected through four independent signal distributors 2, and output signals of the signal distributors 2 and output signals of 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;
Step 3: calculating the average value of the output signals of the current 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;
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 faults, and if the first ratio exceeds the first ratio range and the second ratio is in the second ratio range, judging that the four weighing sensors 1 have faults;
Step 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 judging that the weighing sensor 1 corresponding to each signal distributor 2 fails if the first ratio exceeds the first ratio range and the third ratio exceeds the third ratio range, and judging that the signal distributor 2 fails if the first ratio is within the first ratio range and the third ratio exceeds the third ratio range;
Step 7: the signal analysis terminal 5 displays the failure determination result on a display;
step 8: the signal analysis terminal 5 gives an audible and visual alarm according to the failure determination result.
Examples:
Referring to fig. 2 and 3, the implementation background of the embodiment is a continuous casting operation area of a steel plant, a set of ladle weighing sensor detection device is arranged for a weighing sensor of a ladle turret, 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 the four weighing sensors 1 on the ladle turret, the 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 4-20 mA current signal, and the output ends of the signal distributors 2 are connected with the wireless signal transmitter 4, so that a sensor signal acquisition circuit is formed; the signal analysis terminal 5 is connected with the wireless signal receiver 6, the signal distributor 2 can realize wireless communication with the signal analysis terminal 5 through the wireless signal transmitter 4 and the wireless signal receiver 6, the wireless communication adopts the frequency of 2.4GHz or 5GHz for signal transmission, the output signal of each signal distributor 2 can be transmitted into the signal analysis terminal 5 through the 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 into the signal analysis terminal 5 through the wireless communication mode, and the signal analysis terminal 5 carries out 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, where 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 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 output signals of the signal distributor 2 and the weighing transducer 3, performs fault analysis determination on the output signals, and transmits a 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 an audible and visual alarm 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 when a ladle filled with molten steel is seated on a ladle turret weighing arm, the detection method of the present embodiment starts to detect a weighing sensor 1 on a ladle seat, and includes:
Step 1: the method comprises the steps that weighing signals of four weighing sensors 1 on a ladle seat are respectively collected through four independent signal distributors 2, and output signals of the signal distributors 2 and output signals of weighing transmitters 3 are transmitted to a signal analysis terminal 5 through a wireless communication device; the weighing sensor 1 is pressed to send out weighing signals, the weighing signals of the weighing sensor 1 are simultaneously transmitted to the fault detection PLC unit 51 through the signal distributor 2 and the weighing transmitter 3 respectively, and the fault detection PLC unit 51 starts to continuously analyze the change condition of the signals of the signal distributor 2 and 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 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; in the present embodiment, the set interval time is 1 second.
Step 3: calculating the average value of the output signals of the current 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;
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 faults, and if the first ratio exceeds the first ratio range and the second ratio is in the second ratio range, judging that the four weighing sensors 1 have faults; 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;
Step 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 judging that the weighing sensor 1 corresponding to each signal distributor 2 fails if the first ratio exceeds the first ratio range and the third ratio exceeds the third ratio range, and judging that the signal distributor 2 fails if the first ratio is within the first ratio range and the third ratio exceeds the third ratio range; in the present embodiment, the third ratio range is set to 0.97 to 1.03;
Step 7: the signal analysis terminal 5 displays the failure determination result on a display;
step 8: the signal analysis terminal 5 gives an audible and visual alarm according to the failure determination result.
In the above-described step, the output signal of the signal distributor 2 is analyzed and judged, but the signal distributor 2 collects the weighing signal of the weighing sensor 1 and then outputs the weighing signal, that is, the weighing signal of the weighing sensor 1 is actually analyzed, so that the fault condition of the weighing sensor 1 is judged.
In the detection method of the embodiment, the detection signal is transmitted in a wireless communication mode, and the wireless data transmission frequency is higher, so that signal loss of a signal cable in the transmission process can be avoided, electromagnetic interference of high-power equipment around the weighing sensor 1 is reduced to the greatest extent, signal transmission precision is guaranteed, meanwhile, a slip ring is not passed in the signal transmission process, and adverse effects such as signal loss, signal transmission discontinuity and the like caused by dust or poor contact of a slip ring contact are avoided, so that the detection result is accurate and reliable; when the fault is judged, the signal analysis terminal 5 can display fault information and carry out audible and visual alarm, so that equipment operators 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, in normal stable casting, the molten steel in the ladle is steadily reduced along with the 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 normal working states, the output signals and the time are in a certain linear relation, in theory, the trend of the change of the output current signals of the signal distributor 2 and the weighing transmitter 3 along with the time is not great, if the difference is too great, the output signals are problematic, and if the difference exceeds the judgment range, the difference of the output signals of the signal distributor 2 and the weighing transmitter 3 is too great, so that one of the two is considered to be faulty, and then through accurate comparison, the accurate judgment of the faults of the equipment of the weighing sensor 1, the signal distributor 2 and the weighing transmitter 3 can be finally realized.
The above embodiments are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention, therefore, any modifications, equivalent substitutions, improvements, etc. made within the spirit and principle of the present invention should be included in the scope of the present invention.
Claims (7)
1. A ladle weighing sensor remote fault detection method is characterized in that: comprising the following steps:
step 1: the method comprises the steps that weighing signals of four weighing sensors (1) on a ladle seat are respectively collected through four independent signal distributors (2), and output signals of the signal distributors (2) and output signals of 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;
Step 3: calculating the average value of the output signals of the current four signal distributors (2), calculating the ratio between the average value and the current output signal of the weighing transmitter (3), and setting the ratio as a second ratio;
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 faults, and if the first ratio exceeds the first ratio range and the second ratio is in the second ratio range, judging that the four weighing sensors (1) have faults;
step 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 judging that the weighing sensor (1) corresponding to each signal distributor (2) fails if the first ratio exceeds the first ratio range and the third ratio exceeds the third ratio range, and judging that the signal distributor (2) fails if the first ratio is in the first ratio range and the third ratio exceeds the third ratio range.
2. The ladle weighing sensor remote fault detection method according to claim 1, wherein: 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, wherein: 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, wherein: 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, wherein: the detection method further comprises the following steps:
Step 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, wherein: the detection method further comprises the following steps:
step 8: and the signal analysis terminal (5) sends out an audible and visual alarm according to the fault judgment result.
7. The ladle weighing sensor remote fault detection method according to claim 1, wherein: the wireless communication device employs a frequency of 2.4GHz or 5GHz for signal transmission.
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| CN202010588469.7A CN113834558B (en) | 2020-06-24 | 2020-06-24 | Ladle weighing sensor remote fault detection method |
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