CN114235164A - Thermal state monitoring system and method for empty ladle and tapping process of steel ladle - Google Patents
Thermal state monitoring system and method for empty ladle and tapping process of steel ladle Download PDFInfo
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- CN114235164A CN114235164A CN202111470718.3A CN202111470718A CN114235164A CN 114235164 A CN114235164 A CN 114235164A CN 202111470718 A CN202111470718 A CN 202111470718A CN 114235164 A CN114235164 A CN 114235164A
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Classifications
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01J—MEASUREMENT OF INTENSITY, VELOCITY, SPECTRAL CONTENT, POLARISATION, PHASE OR PULSE CHARACTERISTICS OF INFRARED, VISIBLE OR ULTRAVIOLET LIGHT; COLORIMETRY; RADIATION PYROMETRY
- G01J5/00—Radiation pyrometry, e.g. infrared or optical thermometry
- G01J5/0037—Radiation pyrometry, e.g. infrared or optical thermometry for sensing the heat emitted by liquids
- G01J5/004—Radiation pyrometry, e.g. infrared or optical thermometry for sensing the heat emitted by liquids by molten metals
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D2/00—Arrangement of indicating or measuring devices, e.g. for temperature or viscosity of the fused mass
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D2/00—Arrangement of indicating or measuring devices, e.g. for temperature or viscosity of the fused mass
- B22D2/006—Arrangement of indicating or measuring devices, e.g. for temperature or viscosity of the fused mass for the temperature of the molten metal
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D46/00—Controlling, supervising, not restricted to casting covered by a single main group, e.g. for safety reasons
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- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/02—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness
- G01B11/06—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness for measuring thickness ; e.g. of sheet material
- G01B11/0608—Height gauges
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/02—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness
- G01B11/06—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness for measuring thickness ; e.g. of sheet material
- G01B11/0616—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness for measuring thickness ; e.g. of sheet material of coating
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- G—PHYSICS
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- G01F23/00—Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm
- G01F23/22—Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm by measuring physical variables, other than linear dimensions, pressure or weight, dependent on the level to be measured, e.g. by difference of heat transfer of steam or water
- G01F23/28—Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm by measuring physical variables, other than linear dimensions, pressure or weight, dependent on the level to be measured, e.g. by difference of heat transfer of steam or water by measuring the variations of parameters of electromagnetic or acoustic waves applied directly to the liquid or fluent solid material
- G01F23/284—Electromagnetic waves
- G01F23/292—Light, e.g. infrared or ultraviolet
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01J—MEASUREMENT OF INTENSITY, VELOCITY, SPECTRAL CONTENT, POLARISATION, PHASE OR PULSE CHARACTERISTICS OF INFRARED, VISIBLE OR ULTRAVIOLET LIGHT; COLORIMETRY; RADIATION PYROMETRY
- G01J5/00—Radiation pyrometry, e.g. infrared or optical thermometry
- G01J5/02—Constructional details
- G01J5/06—Arrangements for eliminating effects of disturbing radiation; Arrangements for compensating changes in sensitivity
- G01J5/061—Arrangements for eliminating effects of disturbing radiation; Arrangements for compensating changes in sensitivity by controlling the temperature of the apparatus or parts thereof, e.g. using cooling means or thermostats
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01J—MEASUREMENT OF INTENSITY, VELOCITY, SPECTRAL CONTENT, POLARISATION, PHASE OR PULSE CHARACTERISTICS OF INFRARED, VISIBLE OR ULTRAVIOLET LIGHT; COLORIMETRY; RADIATION PYROMETRY
- G01J5/00—Radiation pyrometry, e.g. infrared or optical thermometry
- G01J5/48—Thermography; Techniques using wholly visual means
Abstract
The invention discloses a thermal state monitoring system and method for a steel ladle empty ladle and a steel tapping process, and belongs to the technical field of metallurgy. The system comprises: the thermal imaging units are used for acquiring thermal imager images and acquiring temperature data of the outer wall of the steel ladle and tapping molten steel temperature data; the imaging distance measuring unit is used for acquiring a visible light image and a thermal imager image, and acquiring the temperature of a steel ladle lining, the quality of steel slag remained in the steel ladle, the temperature of liquid slag after tapping, the height of a liquid level of the steel ladle and the thickness of the liquid slag of the steel ladle; the quality unit is used for acquiring quality data in the tapping process; and the terminal data processing and control unit is connected with the components, controls and adjusts the running state and data transmission interaction, identifies and stores the steel ladle dynamic state, the steel ladle quality, the steel ladle inner and outer wall temperature, the molten steel temperature and the slag liquid thickness, and determines the slag steel residue and the melting heat of the steel ladle lining. The invention accurately controls the empty ladle of the ladle and the thermal state of the tapping process from multiple dimensions, and analyzes the influence of the heat absorption and the heat dissipation of the ladle on the molten steel cooling in the tapping process.
Description
Technical Field
The invention belongs to the technical field of metallurgy, and particularly relates to a thermal state monitoring system and method for a steel ladle empty-bag and steel tapping process, which are used for monitoring the thermal state of the steel ladle empty-bag and steel tapping process when a steel ladle moves to a converter steel tapping position in an empty-bag operation stage and the converter steel tapping.
Background
The proper molten steel temperature is the precondition for ensuring the continuous casting production and is the basis for obtaining good casting blank quality. The molten steel after smelting undergoes a plurality of temperature drop processes in the steelmaking process, wherein the temperature drop processes comprise steel tapping process temperature drop, steel ladle heat absorption temperature drop, steel ladle transportation process temperature drop, refining process temperature drop and tundish process temperature drop. The ladle is used as an important material carrier device, and the hot state of the ladle before tapping is unknown and can not be determined throughout the whole steel-making process. The attention on the monitoring of the hot state of the steel ladle has important significance for controlling the temperature of the molten steel and improving the hit rate of the end point temperature.
For a long time, steel enterprises mostly adopt manual blind selection to transfer steel ladles to a converter tapping position to wait for containing molten steel. The temperature of molten steel after tapping fluctuates greatly due to the fact that the thermal state of an empty ladle cannot be accurately controlled. For the management of the steel ladle, only the steel ladle baking and the steel ladle lining residual thickness detection are carried out or depending on experience, the fact that the temperature control data of a certain steel plant in each production procedure of high-carbon steel are analyzed through reference documents is found, the fluctuation range of the tapping temperature of the converter is large, the difference value between the highest tapping temperature and the lowest tapping temperature reaches 121 ℃, and the steel ladle condition has great influence on the whole temperature control process. CN202885936U discloses an automatic measuring device for the hot state of a steel ladle, which does not pay attention to the influence of the empty hot state of the steel ladle on the temperature drop of molten steel in the tapping process through the tracking record of a crown block, the position of a trolley and the weight of the steel ladle on the state of the steel ladle.
The above documents and patents do not propose a measuring system or method for measuring the thermal state of the ladle in multiple dimensions, which is adapted to the situation that the ladle runs to the tapping position of the converter during the empty ladle operation stage. The invention provides a thermal state monitoring system for empty ladles of ladles and a tapping process according to heat absorption and heat dissipation of molten steel due to ladles in the tapping process.
Disclosure of Invention
Aiming at the defects of the prior art, the invention discloses a system and a method for monitoring the thermal state of the empty ladle and the tapping process of a steel ladle, wherein the thermal state of the empty ladle and the tapping process of the steel ladle is accurately controlled in a multidimensional way according to the capacity of the steel ladle, the quality of the steel ladle, the temperature of the steel ladle, the lining distribution of the steel ladle, the temperature of molten steel, the thickness of slag liquid, the residue of slag liquid steel and the like, and the influence of the heat absorption and the heat dissipation of the steel ladle on the temperature reduction of the molten steel in the tapping process is analyzed.
According to a first aspect of the technical scheme of the invention, a thermal state monitoring system for a ladle empty-bag and tapping process is provided, and is characterized by comprising:
the thermal imaging units are used for acquiring thermal imager images and acquiring temperature data of the outer wall of the steel ladle and tapping molten steel temperature data;
the imaging distance measuring unit is used for acquiring a visible light image and a thermal imager image, and acquiring the temperature of a steel ladle lining, the temperature of steel ladle liquid slag, the height of a steel ladle liquid level and the thickness of the steel ladle slag liquid;
the quality unit is used for acquiring quality data in the tapping process;
and the terminal data processing and control unit is connected with the components, controls and adjusts the running state and data transmission interaction, identifies and stores the steel ladle dynamic state, the steel ladle quality, the steel ladle inner and outer wall temperature, the molten steel temperature and the slag liquid thickness, and determines the slag steel residue and the melting heat of the steel ladle lining.
Furthermore, the plurality of thermal imaging units comprise a first thermal imaging unit and a second thermal imaging unit, and the thermal imaging units and the second thermal imaging unit are both connected with the terminal data processing and control unit.
Further, the first thermal imaging unit and the second thermal imaging unit are identical in structure and comprise:
the first/second thermal infrared imagers are used for acquiring thermal imager images and acquiring temperature data of the outer wall of the steel ladle and tapping molten steel temperature data;
the first/second cloud deck is provided with a first/second thermal infrared imager;
the first/second sliding table is arranged at the lower part of the first/second tripod head.
Further, the imaging range unit includes:
the high-definition industrial camera is used for collecting visible light images and determining the arrival/departure condition of the steel ladle;
the third thermal infrared imager is used for acquiring thermal imager images and acquiring the temperature of the lining of the steel ladle and the temperature of liquid slag of the steel ladle;
the laser ranging scanner is used for collecting the height of the liquid level of the steel ladle and the thickness of the slag liquid of the steel ladle;
the third cloud deck is provided with the high-definition industrial camera, a third thermal infrared imager and a laser ranging scanner;
and the third sliding table is arranged at the lower part of the third cloud platform.
Further, the mass unit includes:
the weighing device is used for measuring the empty ladle mass of the ladle and the total ladle mass after tapping;
and the collecting device is used for collecting the alloy adding amount, the recarburizing agent quality and the slagging agent quality in the tapping process.
Further, the identifying the ladle by the terminal data processing and control unit includes: determining ladle arrival/departure conditions and identifying ladle numbers.
Further, the method for identifying the ladle number by the terminal data processing and control unit is as follows:
acquiring a first visible light image and a first thermal imager image through an imaging ranging unit, and fusing the first visible light image and the first thermal imager image to form a first fused image;
cutting a steel ladle number region from the first fusion image;
and identifying the serial number of the steel packet through the trained deep learning neural network model.
Further, the method for determining the residual quantity of the molten steel in the steel ladle lining slag by the terminal data processing and control unit comprises the following steps:
acquiring a second visible light image and a second thermal imager image through an imaging ranging unit, preprocessing the images, and then respectively carrying out image segmentation based on morphology to respectively obtain a visible light residual steel region and a thermal imager residual steel region;
carrying out image feature registration on the visible-light residual slag steel area and the thermal imager residual slag steel area to form a second fusion image, and determining a plurality of suspected areas and three-dimensional coordinates of suspected slag steel residues by combining image coordinates and real three-dimensional coordinates of the second fusion image so as to obtain the areas of the suspected areas;
sequentially measuring and collecting the total thickness (the average thickness of the residual slag steel area and the original thickness of the lining of the steel ladle) of each of the plurality of suspected areas by an imaging distance measuring unit;
and determining the average thickness of each suspected area according to the original thickness of the ladle lining, thereby determining the total mass of the ladle lining slag steel residue and determining the heat required by the melting of the ladle lining slag steel residue.
Further, the terminal data processing and control unit determines the arrival/departure condition of the steel ladle through a third visible light image acquired by the imaging distance measuring unit.
Furthermore, the plurality of thermal imaging units and the imaging distance measuring units are all provided with cooling protection devices.
Further, the cooling protection device comprises cooling water cooling protection, compressed air lens purging and a lens protection window.
Furthermore, after the terminal data processing and control unit identifies that the steel ladle arrives, a compressed air lens purging window and a lens protection window are opened, so that bright and clear imaging is ensured; and when the terminal data processing and control unit identifies that the steel ladle is away, the compressed air lens purging and lens protection window is closed to prevent the equipment lens from being polluted by dust.
Further, after the terminal data processing and control unit identifies that the steel ladle arrives, all the components are started; and when the terminal data processing and control unit identifies that the ladle leaves, all the components are closed.
Furthermore, the motion device is connected with the control unit, images of the equipment are observed through the industrial personal computer, the mobile thermal imager and the laser range finder are controlled, and the temperature and the thickness of the steel ladle at different positions are monitored.
Furthermore, thermal infrared imagers arranged on the outer wall of the steel ladle observe the temperature distribution of the outer wall of the steel ladle, area-by-area key monitoring is carried out on the easily damaged area of the steel ladle, and the number of the thermal imagers is 1 or 2, and the number of the thermal imagers is generally 1 or 2, according to data measured by an actual site, the thermal infrared imagers arranged on the inner lining of the steel ladle and the laser ranging scanner.
Further, the imaging distance measuring unit comprises two working states:
and the measurement is carried out independently, the steel ladle lining temperature is measured by a steel ladle lining thermal infrared imager, and the steel ladle lining thickness is measured by a lining laser ranging scanner.
And (4) linkage measurement, analyzing the area and the position of the residual area of the molten slag steel through a visible light image and a thermal image by an image algorithm, controlling a laser ranging scanner to sequentially measure the area, acquiring the thickness of the area, and calculating the residual thickness of the molten slag steel according to the thickness information of the previous steel ladle lining, so that the residual quality of the molten slag steel and the residual heat required for melting the molten slag steel are obtained.
Further, the terminal data processing and controlling unit includes:
the control unit comprises a PLC module and auxiliary electrical elements thereof, is arranged in the field control box and is used for controlling the cooling protection device, the first/second/third cradle head, the first/second/third sliding table and data information receiving;
and the industrial personal computer is connected with the control unit through the communication transmission unit, controls and adjusts the running state and data transmission interaction, identifies and stores the ladle dynamics, the ladle quality, the ladle inner and outer wall temperature, the molten steel temperature and the slag liquid thickness, and determines the slag steel residue and the melting heat of the ladle lining.
Furthermore, the thermal state monitoring system also comprises a communication transmission unit which is used for transmitting equipment data, control instructions and power supply and comprises equipment data interfaces, cables and related communication equipment.
According to a second aspect of the present invention, there is provided a thermal state monitoring method for a ladle empty and tapping process, the thermal state monitoring method operating based on the thermal state monitoring system according to any one of the above aspects, the thermal state monitoring method comprising:
determining that a steel ladle arrives, and starting a thermal state monitoring system;
acquiring a first visible light image and a first thermal imager image, and determining the number of the steel ladle;
acquiring temperature data of an outer wall of a steel ladle, temperature data of a lining of the steel ladle, temperature data of tapping molten steel and temperature of liquid slag of the steel ladle;
collecting the height of the liquid level of the steel ladle and the thickness of the slag liquid of the steel ladle;
measuring the empty ladle quality of the steel ladle and the total weight of the steel ladle after tapping, and collecting the alloy adding amount, the recarburizing agent quality and the slagging agent quality in the tapping process;
acquiring a second visible light image and a second thermal imager image, determining a suspected slag steel residual region, measuring the total thickness of the suspected slag steel residual region, determining the average thickness of the suspected slag steel residual region according to the original thickness of the ladle lining, determining the residual quality of the ladle lining slag steel and determining the heat required by melting the ladle lining slag steel;
and transmitting the data to an industrial personal computer database for classified storage according to the ladle numbers, recording each ladle, comparing the data with the previous data after new data is acquired, and tracking the use condition of the ladle.
Furthermore, the industrial personal computer calls the measured data information from the database, extracts various data information according to the time sequence or the ladle number, and draws a corresponding change curve graph.
The steel ladle empty ladle thermal state monitoring system has the beneficial effects that the steel ladle empty ladle thermal state monitoring system adopts a plurality of measuring instruments such as an infrared thermal imager, a laser range finder, a weighing device and the like to comprehensively acquire the inner and outer wall temperatures of the steel ladle and the state of the lining material before tapping. The slag molten steel residue is obtained by adopting a linked measurement mode of the thermal infrared imager and the laser range finder, so that the influence of the heat absorption of the steel ladle on the molten steel cooling is clearly known, the temperature control of the molten steel is further facilitated, and the product quality is stabilized.
Drawings
Fig. 1 is a schematic structural diagram of a thermal state monitoring system for empty ladles of ladles according to an embodiment of the invention.
Fig. 2 shows a multi-dimensional ladle thermal state establishment diagram according to an embodiment of the invention.
Fig. 3 shows a flow chart of image fusion of visible light and infrared according to an embodiment of the invention.
Fig. 4 shows a flow chart of a steel number identification method for an outer wall of a ladle according to an embodiment of the invention.
FIG. 5 shows a flow chart of a method for measuring the residual slag-steel liquid according to an embodiment of the invention.
Detailed description of the invention
The invention is further illustrated with reference to the following figures and examples.
The invention provides a thermal state monitoring system for a steel ladle empty ladle and a steel tapping process.
The imaging ranging unit comprises a high-definition industrial camera, a steel ladle lining thermal infrared imager and a laser ranging scanner and is used for monitoring the surrounding environment condition, automatically starting other acquisition equipment after identifying that a steel ladle reaches a specified place, and automatically closing other acquisition equipment after identifying that the steel ladle leaves, so as to prevent the equipment lens from being infected with dust. And acquiring high-definition industrial camera images and thermal imager images, and identifying the number of the steel ladle through image processing. The laser ranging scanner and the high-definition industrial camera can be used for measuring the total height and the thickness of the slag liquid in the steel ladle after tapping is finished. The high-definition industrial camera, the steel ladle lining thermal infrared imager and the laser ranging scanner can also be used for monitoring the thickness of the steel ladle lining and the residue of molten steel slag.
The thermal imaging unit comprises a steel ladle outer wall infrared thermal imager and a steel ladle lining infrared thermal imager and is used for collecting temperature information of the inner wall and the outer wall of a steel ladle empty ladle, and the cradle head and the sliding table are adjusted in the tapping process, so that the steel ladle thermal imager can clearly measure the temperature of molten steel and the temperature of the outer wall of the steel ladle.
The quality unit comprises a weighing device and an acquisition module, the weighing device is used for measuring the empty ladle quality of the steel ladle and the total ladle quality after tapping is finished, and the acquisition module is used for acquiring data so as to acquire the alloy adding amount, the recarburizing agent quality, the slagging agent quality and the like in the tapping process.
The terminal data processing and controlling unit comprises a controlling unit and a terminal industrial personal computer, wherein the controlling unit comprises a PLC module and auxiliary electric elements thereof, is placed in the field control box and is used for controlling a protective cooling device, a cradle head, a sliding table and data information receiving of each device; the communication transmission unit comprises data interfaces of various devices, cables and related communication devices; the terminal data processing and controlling unit comprises a terminal industrial personal computer, analyzes and displays data through specific software, and controls and adjusts the running state of each device. And the influence of the heat absorption and the heat dissipation of the steel ladle on the molten steel cooling in the tapping process is analyzed according to the multi-dimensional accurate control of the empty ladle of the steel ladle and the thermal state of the tapping process, such as the capacity of the steel ladle, the quality of the steel ladle, the temperature of the steel ladle, the lining distribution of the steel ladle, the temperature of molten steel, the thickness of slag liquid, the residue of slag liquid in the steel ladle and the like.
Preferably, the ladle outer wall thermal infrared imager, the ladle lining thermal infrared imager and the laser range finder all comprise cooling protection devices. The cooling protection device comprises cooling water cooling protection, compressed air lens blowing and a lens protection window. And when the steel ladle is identified to leave, closing the compressed air lens purging and the lens protection window to prevent the equipment lens from being polluted by dust. And when the ladle is identified to arrive, the compressed air lens purging and the lens protection window are started to ensure bright and clear imaging.
Preferably, the steel ladle outer wall thermal infrared imager, the steel ladle lining thermal infrared imager and the laser range finder are provided with a cloud deck, the moving devices such as the sliding table and the like are connected with the control unit, the industrial personal computer is used for observing an imaging picture of equipment, the cloud deck is controlled to move the thermal infrared imager and the laser range finder, and different positions of the steel ladle are monitored.
Preferably, the steel ladle outer wall infrared thermal imagers observe the temperature distribution of the steel ladle outer wall, the area-by-area key monitoring is carried out on the easily damaged area of the steel ladle, the number of the thermal imagers is 1 or 2, and a heat transfer mathematical model is established according to data measured by an actual field, the steel ladle lining infrared thermal imagers and the laser ranging scanners.
Preferably, the steel ladle lining thermal infrared imager and the lining laser range finder have two working states, wherein one working state is independent measurement, and the other working state is linkage measurement. When the temperature measuring device is used for measuring the temperature of the steel ladle lining independently, the steel ladle lining thermal infrared imager measures the temperature of the steel ladle lining, and the lining laser range finder measures the thickness of the steel ladle lining. During linkage measurement, due to the fact that the emissivity of the lining and the residual slag steel liquid is different, the temperature distribution presented by the thermal image is different, the area and the position of the residual slag steel liquid area are analyzed through an image algorithm, then the laser range finder is controlled to measure the position area in sequence, the thickness of the area is obtained, the residual thickness of the slag steel liquid is calculated according to the thickness information of the previous steel ladle lining, and therefore the residual quality of the slag steel liquid, namely the lining slag iron residual monitoring unit, is obtained.
Preferably, the weighing device weighs the empty ladle mass of the ladle, compares the empty ladle mass with the ladle mass after measurement and calculation, and needs manual inspection and repair if the difference is too large. And when tapping is finished, the steel passes through the thermal state monitoring system again, the weighing device measures the mass after tapping, and the high-definition industrial camera and the laser range finder measure the total height and the thickness of the slag liquid in the steel ladle.
Preferably, the measuring device and the motion device are connected with the control unit and then perform data transmission interaction with the industrial personal computer through the communication unit. The industrial personal computer at the terminal acquires data information and operating states of the measuring equipment, the moving device and the cooling device, analyzes and displays the data through specific software, and performs control adjustment and data transmission interaction on the operating states of the equipment. The temperature data, the image data, the position thickness data and the quality data are transmitted to an industrial personal computer database and are stored in a classified mode according to the ladle numbers, and various data information can be extracted from the database according to time sequence or the ladle numbers.
In the technical scheme of the invention, all parts cooperate with each other and influence each other, thereby realizing corresponding technical effects. In particular, the ladle transports molten steel to each smelting station, which is an important smelting vessel in the metallurgical production process. Therefore, the contact type temperature measurement mode is not suitable for the ladle moving in a long distance. As long as steel leakage occurs at any position of the steel ladle, serious safety accidents can be caused, so that a thermal infrared imager needs to be selected to realize non-contact temperature imaging and carry out omnibearing temperature detection on the steel ladle. Whether the ladle refractory material is damaged by erosion or the outer wall of the ladle is deformed and cracked, the temperature is suddenly changed, and the temperature is displayed in an infrared thermal image. So far, in order to omnidirectional detection and save equipment cost as far as possible, add cloud platform and slip table device. Because the steel ladle is cylindrical, two groups of thermal imaging combinations are arranged on two sides of the steel ladle to realize the monitoring of the outer wall of the steel ladle; and a group of thermal imaging combination is arranged above the steel ladle to realize the monitoring of the inner wall of the steel ladle.
During tapping, high-temperature molten steel is filled into a ladle, and low-temperature ladle and slag steel residue in the ladle lead to the reduction of the temperature of the molten steel. In order to clarify the cooling process of molten steel, the ladle temperature and the residual quantity of slag steel before tapping need to be clarified. According to the temperature measurement principle of a thermal imager, different materials have different emissivities, and thermal imaging pictures are displayed differently. The ladle lining is a non-metal object, the slag steel residue is a mixture of metal and non-metal, a suspected area can be extracted through a thermal imaging picture and a visible light image, and the area of the suspected area is measured. The laser ranging scanner measures the distance from laser to an object by using the time flight principle, and is not influenced by a high-temperature and high-dust environment of a metallurgical site. The residual thickness of the slag steel in the suspected area can be measured by comparing the thickness of the original ladle lining, and the residual quality of the slag steel is calculated. The measurement combination unit comprises a thermal imager, an industrial camera, a laser ranging scanner, a cradle head and a sliding table. And placing the measurement combination above the ladle to realize the slag steel residue monitoring of the ladle lining.
Examples
As can be seen from fig. 1: the thermal state monitoring system for the steel ladle empty ladle and the steel tapping process comprises a high-temperature thermal infrared imager 1, a high-temperature thermal infrared imager 2, a high-temperature thermal infrared imager 3, a laser ranging scanner 4, a high-definition industrial camera 5, a holder device 6, an electric sliding table 7, a weighing device 8, a cooling device 9, a field control box 10 and an industrial personal computer 11; the electric sliding table 7 has the limiting and locking functions, the holder device 6 can be controlled to rotate by 300 degrees, the electric sliding table 7 is fixedly connected with the holder device 6, the holder device 6 is fixedly connected with the laser ranging scanner 4, the high-temperature thermal infrared imager 3 and the high-definition industrial camera 5 are fixedly connected with the high-temperature laser ranging scanner 4, and the high-temperature thermal infrared imager 3 and the high-temperature laser ranging scanner 4 are connected with the field control box 10 through data lines. The high-definition industrial camera 5 is connected with the high-temperature laser ranging device 4 through a data line and a power line so as to transmit, control and provide power for data; the high-temperature thermal infrared imager 1 and the high-temperature thermal infrared imager 2 are both provided with a holder device 6 and an electric sliding table 7; the high-temperature thermal infrared imager 1, the high-temperature thermal infrared imager 2, the holder device 6, the electric sliding table 7 and the cooling device 9 are connected with the field control box 10 through data lines and power lines so as to transmit and control data and provide power. The field control box 10 is connected with the industrial personal computer 11 for data transmission interaction. And acquiring data information and running states of the measuring equipment, the moving device and the cooling device at the industrial personal computer of the terminal, and analyzing and displaying the data through specific software. The temperature data, the image data, the position thickness data and the quality data are transmitted to an industrial personal computer database and are stored in a classified mode according to the ladle numbers, and various data information can be extracted from the database according to time sequence or the ladle numbers.
The invention is implemented as follows: the whole system device is arranged near a waiting position of a steel tapping ladle of the converter, and starts to detect after an empty ladle is in place in the later stage of steel making of the converter, and data information of the empty ladle, the steel tapping process and the finished steel tapping is collected, as shown in figure 2.
Monitoring and image processing analysis are carried out through a high-definition industrial camera 5, and as shown in fig. 3 and 4, the ladle number is identified; after the detection steel ladle is in place, all measuring equipment measuring windows are opened through the field control box PLC, the measuring equipment starts to collect data, and data information of the thermal imager, the laser range finder and the weighing device is displayed on a screen of the industrial personal computer through the data collecting unit and the communication unit.
And adjusting probes of the high-temperature thermal infrared imager 3 and the laser ranging scanner 4 to enable the probes to be opposite to the upper edge of the axis of the ladle opening, starting data acquisition, and detecting the temperature of the lining of the ladle and the residue of molten steel slag. As shown in fig. 3 and 5, the detection steps are as follows: firstly, starting a high-temperature thermal infrared imager 3 and a high-definition industrial camera 5 to image a steel ladle lining, collecting temperature distribution, thermal imaging images and visible light images of the steel ladle lining, and carrying out image fusion according to the method of the figure 3; secondly, because different substances have different emissivities, areas where molten slag steel remains are obtained through image processing of visible light images and thermal images, and the three-dimensional positions of the areas are found out by combining image coordinates and real three-dimensional coordinates. And thirdly, according to the three-dimensional coordinates of the suspected area position, the laser range finder and the high-definition industrial camera are moved through the cradle head and the sliding table, and the thickness change and the area of the lining in the area are collected. And fourthly, comparing the original thickness of the lining of the steel ladle, and calculating the residual mass of the slag molten steel and the residual heat quantity of the slag molten steel.
The empty ladle mass of the ladle is weighed by the weighing device 8, the empty ladle mass is compared with the ladle mass after measurement and calculation, and if the difference is too large, manual inspection and repair are needed.
And in the tapping process, adjusting the high-temperature thermal infrared imager 1 or the high-temperature thermal infrared imager 2 to enable the high-temperature thermal infrared imager to be opposite to the vicinity of the tapped steel flow, and detecting the temperature of the molten steel and the temperature change of the outer wall of the steel ladle.
And when tapping is finished, the steel passes through the thermal state monitoring system again, the weighing device measures the mass after tapping, and the high-definition industrial camera and the laser range finder measure the total height and the thickness of the slag liquid in the steel ladle.
And transmitting the temperature data, the image data, the position thickness data and the quality data to an industrial personal computer database for classified storage according to the ladle numbers, recording each ladle, comparing the data with the previous data after acquiring new data, and tracking the use condition of the ladle.
The industrial personal computer is mainly divided into 4 parts, namely, a high-temperature thermal infrared imager 1, a high-temperature thermal infrared imager 2 and a high-definition industrial camera 5; secondly, displaying data of the laser range finder and the weighing device; thirdly, displaying the residual molten steel of the high-temperature thermal infrared imager 3 and the laser ranging scanner 4; and fourthly, controlling the cradle head and the sliding table.
The main control computer can call the measured data information from the database, extract various data information according to time sequence or ladle coding, and draw corresponding change curve graphs by using the main control computer.
Finally, it should be noted that: although the present invention has been described in detail with reference to the foregoing embodiments, it will be apparent to those skilled in the art that changes may be made in the embodiments and/or equivalents thereof without departing from the spirit and scope of the invention. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (10)
1. A thermal condition monitoring system for use in a ladle emptying and tapping process, the system comprising:
the thermal imaging units are used for acquiring thermal imager images and acquiring temperature data of the outer wall of the steel ladle and tapping molten steel temperature data;
the imaging distance measuring unit is used for acquiring a visible light image and a thermal imager image, and acquiring the temperature of a steel ladle lining, the quality of steel slag remained in the steel ladle, the temperature of liquid slag after tapping, the height of a liquid level of the steel ladle and the thickness of the liquid slag of the steel ladle;
the quality unit is used for acquiring quality data in the tapping process;
and the terminal data processing and control unit is connected with the components, controls and adjusts the running state and data transmission interaction, identifies and stores the steel ladle dynamic state, the steel ladle quality, the steel ladle inner and outer wall temperature, the molten steel temperature and the slag liquid thickness, and determines the slag steel residue and the melting heat of the steel ladle lining.
2. The thermal condition monitoring system of claim 1, wherein the plurality of thermal imaging units includes first and second thermal imaging units of identical construction configured to:
the first/second thermal infrared imagers are used for acquiring thermal imager images and acquiring temperature data of the outer wall of the steel ladle and tapping molten steel temperature data;
the first/second cloud deck is provided with a first/second thermal infrared imager;
the first/second sliding table is arranged at the lower part of the first/second tripod head.
3. The thermal condition monitoring system of claim 1, wherein the imaging ranging unit comprises:
the high-definition industrial camera is used for collecting visible light images and determining the arrival/departure condition of the steel ladle;
the third thermal infrared imager is used for acquiring images of the thermal imager, acquiring the temperature of the lining of the steel ladle and the temperature of liquid slag after tapping;
the laser ranging scanner is used for the height of the liquid level of the steel ladle and the thickness of the slag liquid of the steel ladle;
the third cloud deck is provided with the high-definition industrial camera, a third thermal infrared imager and a laser ranging scanner;
and the third sliding table is arranged at the lower part of the third cloud platform.
4. The thermal condition monitoring system of claim 1, wherein the terminal data processing and control unit identifying the ladle comprises: determining ladle arrival/departure conditions and identifying ladle numbers.
5. The thermal condition monitoring system according to claim 4, wherein the method for the terminal data processing and control unit to identify the ladle number is as follows:
acquiring a first visible light image and a first thermal imager image through an imaging ranging unit, and fusing the first visible light image and the first thermal imager image to form a first fused image;
cutting a steel ladle number region from the first fusion image;
and identifying the serial number of the steel packet through the trained deep learning neural network model.
6. The thermal condition monitoring system of claim 4, wherein the method for determining the residual amount of molten steel in the steel ladle lining slag by the terminal data processing and control unit is as follows:
acquiring a second visible light image and a second thermal imager image through an imaging ranging unit, preprocessing the images, and then respectively carrying out image segmentation based on morphology to respectively obtain a visible light residual steel region and a thermal imager residual steel region;
carrying out image feature registration on the visible-light residual slag steel area and the thermal imager residual slag steel area to form a second fusion image, and determining a plurality of suspected areas and three-dimensional coordinates of suspected slag steel residues by combining image coordinates and real three-dimensional coordinates of the second fusion image so as to obtain the areas of the suspected areas;
sequentially measuring and collecting the thicknesses of the plurality of suspected areas through an imaging distance measuring unit;
and determining the average thickness of each suspected area according to the original thickness of the ladle lining, thereby determining the total mass of the ladle lining slag steel residue and determining the heat required by the melting of the ladle lining slag steel residue.
7. The thermal condition monitoring system of claim 1, wherein the mass unit comprises:
the weighing device is used for measuring the empty ladle mass of the ladle and the total ladle mass after tapping;
and the collecting device is used for collecting the alloy adding amount, the recarburizing agent quality and the slagging agent quality in the tapping process.
8. The thermal condition monitoring system of claim 1, wherein the plurality of thermal imaging units and imaging ranging units are each provided with a cooling protection device.
9. The thermal condition monitoring system of claim 1, wherein the terminal data processing and control unit comprises:
the control unit comprises a PLC module and auxiliary electrical elements thereof, is arranged in the field control box and is used for controlling the cooling protection device, the first/second/third cradle head, the first/second/third sliding table and data information receiving;
and the industrial personal computer is connected with the control unit through the communication transmission unit, controls and adjusts the running state and data transmission interaction, identifies and stores the ladle dynamics, the ladle quality, the ladle inner and outer wall temperature, the molten steel temperature and the slag liquid thickness, and determines the slag steel residue and the melting heat of the ladle lining.
10. A thermal condition monitoring method for a ladle emptying and tapping process, characterized in that it operates on the basis of a thermal condition monitoring system according to any one of claims 1 to 9, comprising:
determining that a steel ladle arrives, and starting a thermal state monitoring system;
acquiring a first visible light image and a first thermal imager image, and determining the number of the steel ladle;
acquiring temperature data of an outer wall of a steel ladle, temperature data of a lining of the steel ladle, temperature data of tapping molten steel and temperature of liquid slag after tapping;
collecting the height of the liquid level of the steel ladle and the thickness of the slag liquid of the steel ladle;
measuring the empty ladle quality of the steel ladle and the total weight of the steel ladle after tapping, and collecting the alloy adding amount, the recarburizing agent quality and the slagging agent quality in the tapping process;
acquiring a second visible light image and a second thermal imager image, determining a plurality of areas of suspected slag steel residues, sequentially measuring the thicknesses of the suspected slag steel residue areas, determining the average thickness of each suspected slag steel residue area according to the original thickness of the steel ladle lining, determining the total mass of the steel ladle lining slag steel residues, and determining the heat required by melting the steel ladle lining slag steel residues;
and transmitting the data to an industrial personal computer database for classified storage according to the ladle numbers, recording each ladle, comparing the data with the previous data after new data is acquired, and tracking the use condition of the ladle.
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| CN202111470718.3A CN114235164B (en) | 2021-12-03 | Thermal state monitoring system and method for empty ladle and tapping process of ladle |
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