CN114235164B - Thermal state monitoring system and method for empty ladle and tapping process of ladle - Google Patents

Thermal state monitoring system and method for empty ladle and tapping process of ladle Download PDF

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Publication number
CN114235164B
CN114235164B CN202111470718.3A CN202111470718A CN114235164B CN 114235164 B CN114235164 B CN 114235164B CN 202111470718 A CN202111470718 A CN 202111470718A CN 114235164 B CN114235164 B CN 114235164B
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ladle
steel
thermal
slag
temperature
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CN114235164A (en
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程树森
程晓曼
张丽英
王亮
李世旺
胡铮
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Beijing Beike Shenzhou Yili Metallurgical Materials Research Institute
University of Science and Technology Beijing USTB
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Beijing Beike Shenzhou Yili Metallurgical Materials Research Institute
University of Science and Technology Beijing USTB
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    • GPHYSICS
    • G01MEASURING; TESTING
    • G01JMEASUREMENT OF INTENSITY, VELOCITY, SPECTRAL CONTENT, POLARISATION, PHASE OR PULSE CHARACTERISTICS OF INFRARED, VISIBLE OR ULTRAVIOLET LIGHT; COLORIMETRY; RADIATION PYROMETRY
    • G01J5/00Radiation pyrometry, e.g. infrared or optical thermometry
    • G01J5/0037Radiation pyrometry, e.g. infrared or optical thermometry for sensing the heat emitted by liquids
    • G01J5/004Radiation pyrometry, e.g. infrared or optical thermometry for sensing the heat emitted by liquids by molten metals
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D2/00Arrangement of indicating or measuring devices, e.g. for temperature or viscosity of the fused mass
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D2/00Arrangement of indicating or measuring devices, e.g. for temperature or viscosity of the fused mass
    • B22D2/006Arrangement of indicating or measuring devices, e.g. for temperature or viscosity of the fused mass for the temperature of the molten metal
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D46/00Controlling, supervising, not restricted to casting covered by a single main group, e.g. for safety reasons
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01BMEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B11/00Measuring arrangements characterised by the use of optical techniques
    • G01B11/02Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness
    • G01B11/06Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness for measuring thickness ; e.g. of sheet material
    • G01B11/0608Height gauges
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01BMEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B11/00Measuring arrangements characterised by the use of optical techniques
    • G01B11/02Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness
    • G01B11/06Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness for measuring thickness ; e.g. of sheet material
    • G01B11/0616Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness for measuring thickness ; e.g. of sheet material of coating
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01FMEASURING VOLUME, VOLUME FLOW, MASS FLOW OR LIQUID LEVEL; METERING BY VOLUME
    • G01F23/00Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm
    • G01F23/22Indicating 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
    • G01F23/28Indicating 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
    • G01F23/284Electromagnetic waves
    • G01F23/292Light, e.g. infrared or ultraviolet
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01JMEASUREMENT OF INTENSITY, VELOCITY, SPECTRAL CONTENT, POLARISATION, PHASE OR PULSE CHARACTERISTICS OF INFRARED, VISIBLE OR ULTRAVIOLET LIGHT; COLORIMETRY; RADIATION PYROMETRY
    • G01J5/00Radiation pyrometry, e.g. infrared or optical thermometry
    • G01J5/02Constructional details
    • G01J5/06Arrangements for eliminating effects of disturbing radiation; Arrangements for compensating changes in sensitivity
    • G01J5/061Arrangements 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
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01JMEASUREMENT OF INTENSITY, VELOCITY, SPECTRAL CONTENT, POLARISATION, PHASE OR PULSE CHARACTERISTICS OF INFRARED, VISIBLE OR ULTRAVIOLET LIGHT; COLORIMETRY; RADIATION PYROMETRY
    • G01J5/00Radiation pyrometry, e.g. infrared or optical thermometry
    • G01J5/48Thermography; Techniques using wholly visual means
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00Technologies related to metal processing
    • Y02P10/20Recycling

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Spectroscopy & Molecular Physics (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Electromagnetism (AREA)
  • Thermal Sciences (AREA)
  • Fluid Mechanics (AREA)
  • Waste-Gas Treatment And Other Accessory Devices For Furnaces (AREA)

Abstract

The invention discloses a thermal state monitoring system and a method for empty ladle and tapping processes of a ladle, and belongs to the technical field of metallurgy. The system comprises: the thermal imaging units are used for collecting images of the thermal imaging system and collecting steel ladle outer wall temperature data and tapping molten steel temperature data; the imaging ranging unit is used for acquiring visible light images and thermal imager images, and acquiring ladle lining temperature, ladle residual slag steel quality, liquid slag temperature after tapping, ladle liquid level height and ladle slag liquid thickness; the quality unit is used for collecting quality data in the tapping process; and the terminal data processing and controlling unit is connected with the components, controls and adjusts the running state and data transmission interaction, and identifies and stores ladle dynamics, ladle quality, ladle inner and outer wall temperature, molten steel temperature and slag liquid thickness, and determines slag steel residue in the lining of the ladle and melts the heat. According to the invention, the thermal state of the empty ladle and the tapping process of the ladle is accurately controlled from multiple dimensions, and the influence of heat absorption and heat dissipation of the ladle on the cooling of molten steel in the tapping process is analyzed.

Description

Thermal state monitoring system and method for empty ladle and tapping process of ladle
Technical Field
The invention belongs to the technical field of metallurgy, and particularly relates to a thermal state monitoring system and a thermal state monitoring method for a steel ladle blank and tapping process, wherein the thermal state of the steel ladle blank and tapping process is monitored when the steel ladle is conveyed to a converter tapping position and tapped from the converter in the blank operation stage.
Background
The proper temperature of molten steel is a precondition for ensuring continuous casting production and is also a basis for obtaining good casting blank quality. The molten steel after smelting is subjected to a plurality of temperature reduction processes in the steel making process, wherein the temperature reduction processes comprise steel tapping process temperature reduction, ladle heat absorption temperature reduction, ladle transportation temperature reduction, refining process temperature reduction and tundish process temperature reduction. The ladle is used as important material carrier equipment, and the thermal state of the ladle before tapping is unknown and cannot be determined throughout the whole steelmaking process. The attention to ladle thermal state monitoring has important significance for controlling the temperature of molten steel and improving the hit rate of the terminal temperature.
For a long time, most of iron and steel enterprises adopt manual blind selection to call steel ladles to a converter tapping position to wait for containing molten steel. The thermal state of the empty ladle cannot be accurately controlled, so that the temperature of molten steel after tapping fluctuates greatly. For the steel ladle management, the steel ladle is only stopped at the baking of the steel ladle, the residual thickness detection of the lining of the steel ladle or the experience is relied on, and the reference literature is consulted to find that the temperature control data of a certain steel factory in each production process of high carbon steel is analyzed, the fluctuation range of the tapping temperature of a converter is larger, the difference 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 ladle thermal state, tracking record of ladle state by crane, trolley position and ladle weight, and does not pay attention to the influence of ladle blank thermal state on molten steel temperature drop in tapping process.
The above documents and patents do not propose a measuring system or method adapted to measuring the thermal state of the ladle in a multi-dimensional manner when the ladle blank operation stage is going to the tapping position of the converter. According to the heat absorption and heat dissipation of molten steel in the tapping process, the heat state monitoring system for empty ladle and the tapping process is provided.
Disclosure of Invention
Aiming at the defects of the prior art, the invention discloses a thermal state monitoring system and a thermal state monitoring method for empty ladle and tapping process of a ladle, which accurately control the thermal state of the empty ladle and tapping process of the ladle according to the multidimensional degree of ladle capacity, ladle quality, ladle temperature, ladle lining distribution, molten steel temperature, slag liquid thickness, slag liquid residue and the like, and analyze the influence of heat absorption and heat dissipation of the ladle on molten steel cooling in the tapping process.
According to a first aspect of the present invention, there is provided a thermal state monitoring system for empty ladle and tapping process of a ladle, characterized in that the system comprises:
The thermal imaging units are used for collecting images of the thermal imaging system and collecting steel ladle outer wall temperature data and tapping molten steel temperature data;
The imaging ranging unit is used for acquiring visible light images and thermal imager images, and acquiring ladle lining temperature, ladle liquid slag temperature, ladle liquid level height and ladle slag liquid thickness;
The quality unit is used for collecting quality data in the tapping process;
And the terminal data processing and controlling unit is connected with the components, controls and adjusts the running state and data transmission interaction, and identifies and stores ladle dynamics, ladle quality, ladle inner and outer wall temperature, molten steel temperature and slag liquid thickness, and determines slag steel residue in the lining of the ladle and melts the heat.
Further, the plurality of thermal imaging units comprise a first thermal imaging unit and a second thermal imaging unit, and the thermal imaging unit 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 include:
the first infrared thermal imager is used for acquiring images of the thermal imager and acquiring steel ladle outer wall temperature data and tapping molten steel temperature data;
the first/second cradle head is provided with a first/second thermal infrared imager;
the first sliding table and the second sliding table are arranged at the lower part of the first cloud deck and the second cloud deck.
Further, the imaging ranging unit includes:
The high-definition industrial camera is used for collecting visible light images and determining the arrival/departure condition of the ladle;
The third thermal infrared imager is used for collecting images of the thermal infrared imager and collecting the temperature of the ladle lining and the temperature of ladle liquid slag;
the laser ranging scanner is used for collecting the liquid level height of the steel ladle and the thickness of slag liquid of the steel ladle;
The third cradle head is provided with the high-definition industrial camera, the third thermal infrared imager and the laser ranging scanner;
The third sliding table is arranged at the lower part of the third cradle head.
Further, 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;
The collecting device is used for collecting the alloy addition amount, the carburant mass and the slag former mass in the tapping process.
Further, the terminal data processing and controlling unit identifies the ladle includes: determining the arrival/departure condition of the ladle and identifying the number of the ladle.
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 ladle numbering region from the first fused image;
And identifying the ladle number through the trained deep learning neural network model.
Further, the method for determining the steel ladle lining slag liquid steel residual quantity by the terminal data processing and controlling unit comprises the following steps:
acquiring a second visible light image and a second thermal imager image through an imaging ranging unit, preprocessing, and then respectively performing morphological-based image segmentation to respectively obtain a visible light slag steel residual area and a thermal imager slag steel residual area;
Carrying out image feature registration on the visible light slag steel residual region and the thermal imager slag steel residual region to form a second fusion image, and determining a plurality of suspected regions 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 respective areas of the plurality of suspected regions;
Sequentially measuring and collecting the total thickness (average thickness of slag steel residual area+original thickness of ladle lining) of each of the plurality of suspected areas through an imaging ranging unit;
and determining the average thickness of each suspected area according to the original thickness of the ladle lining, thereby determining the total residual mass of the ladle lining slag steel and determining the heat required by melting the ladle lining slag steel.
Further, the terminal data processing and control unit determines the arrival/departure condition of the ladle through a third visible light image acquired by the imaging ranging unit.
Further, the plurality of thermal imaging units and the imaging distance measuring unit are both provided with cooling protection devices.
Further, the cooling protection device comprises a cooling water cooling protection, a compressed air lens blowing and a lens protection window.
Further, after the terminal data processing and control unit recognizes that the ladle arrives, a compressed air lens blowing and lens protecting window is opened, so that bright and clear imaging is ensured; and when the terminal data processing and control unit recognizes that the ladle leaves, closing the compressed air lens blowing and lens protecting window to prevent the equipment lens from being polluted by dust.
Further, after the terminal data processing and control unit recognizes that the ladle arrives, all the components are started; and when the terminal data processing and control unit recognizes that the ladle leaves, all the components are closed.
Further, the motion device is connected with the control unit, and the imaging picture of the equipment is observed through the industrial personal computer, so that the mobile thermal imager and the laser range finder are controlled, and the temperature and the thickness of different positions of the ladle are monitored.
Further, the infrared thermal imaging device arranged on the outer wall of the steel ladle observes the temperature distribution of the outer wall of the steel ladle, the regional key monitoring is carried out aiming at the fragile region of the steel ladle, the number of the thermal imaging devices is 1 or 2 according to the actual site, the data measured by the infrared thermal imaging device with the steel ladle lining and the laser ranging scanner, and a heat transfer mathematical model is built.
Further, the imaging ranging unit includes two operating states:
Independently measuring, measuring the temperature of the ladle lining by using a ladle lining infrared thermal imager, and measuring the thickness of the ladle lining by using a lining laser ranging scanner.
And (3) linkage measurement, namely analyzing the area and the position of the residual slag and molten steel area through an image algorithm by using a visible light image and a thermal image, controlling a laser ranging scanner to sequentially measure the area, obtaining the thickness of the area, and calculating the residual thickness of the slag and molten steel according to the thickness information of the lining of the steel ladle in the past, so that the residual quality of the slag and molten steel and the heat required for melting the residual slag and molten steel are known.
Further, the terminal data processing and controlling unit includes:
The control unit comprises a PLC module and auxiliary electric 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 the data information receiving;
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, and identifies and stores the ladle dynamics, the ladle quality, the temperature of the inner wall and the outer wall of the ladle, the molten steel temperature and the slag liquid thickness, and determines the residue of slag steel in the lining of the ladle and melts the heat.
Further, the thermal state monitoring system further comprises a communication transmission unit for transmitting equipment data, control instructions and power supply, and the communication transmission unit comprises equipment data interfaces, cables and related communication equipment.
According to a second aspect of the technical solution of the present invention, there is provided a thermal state monitoring method for a ladle blank 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 the arrival of a ladle, and starting a hot state monitoring system;
Acquiring a first visible light image and a first thermal imager image, thereby determining a ladle number;
collecting steel ladle outer wall temperature data, steel ladle lining temperature data, tapping molten steel temperature data and steel ladle liquid slag temperature;
Collecting the liquid level height of the steel ladle and the thickness of slag liquid of the steel ladle;
measuring the empty ladle quality of the ladle and the total ladle quality after tapping, and collecting the alloy addition amount, the carburant quality and the slag former quality in the tapping process;
Acquiring a second visible light image and a second thermal imager image, thereby determining a suspected slag steel residual area, measuring the total thickness of the suspected slag steel residual area, determining the average thickness of the suspected slag steel residual area according to the original thickness of the ladle lining, thereby determining the residual quality of the ladle lining slag steel, and determining the heat required for melting the ladle lining slag steel residual;
And transmitting the data to an industrial personal computer database, classifying and storing according to ladle numbers, recording each ladle, comparing the new data with the previous data after acquiring the new data, and tracking the use condition of the ladle.
Further, the industrial personal computer retrieves the measured data information from the database, extracts various data information according to time sequence or ladle number, and draws a corresponding change curve graph.
The invention has the beneficial effects that the thermal state monitoring system of the empty ladle adopts various measuring instruments such as an infrared thermal imager, a laser range finder, a weighing device and the like to comprehensively acquire the temperature of the inner wall and the outer wall of the ladle before tapping and the state of lining materials. And the residue of the molten slag is obtained by adopting a linkage measurement mode of the thermal infrared imager and the laser range finder, so that the influence of heat absorption of the steel ladle on cooling of the molten steel is clearly known, the temperature control of the molten steel is further facilitated, and the product quality is stabilized.
Drawings
Fig. 1 shows a schematic structural diagram of a thermal state monitoring system for empty ladle according to an embodiment of the present invention.
Fig. 2 shows a multi-dimensional ladle thermal state establishment schematic according to an embodiment of the invention.
Fig. 3 shows a flow chart of visible and infrared image fusion according to an embodiment of the invention.
Fig. 4 shows a flowchart of a method for identifying steel numbers of an outer wall of a ladle according to an embodiment of the invention.
Fig. 5 shows a flow chart of a molten slag steel residue measuring method according to an embodiment of the present invention.
Detailed description of the preferred embodiments
The invention will be further described with reference to the drawings and examples.
The invention provides a thermal state monitoring system for empty ladle and tapping processes of a ladle, which comprises a plurality of thermal imaging units, an imaging ranging unit, a quality unit, a communication transmission unit and a terminal data processing and control unit.
The imaging range unit comprises a high-definition industrial camera, a ladle lining thermal infrared imager and a laser range scanner and is used for monitoring the surrounding environment condition, when the ladle is identified to reach a designated place, other acquisition equipment is automatically started, when the ladle is identified to leave, the other acquisition equipment is automatically closed, and dust is prevented from being polluted by equipment lenses. And acquiring a high-definition industrial camera image and a thermal imager image, and identifying the ladle number through image processing. The laser ranging scanner and the high-definition industrial camera can be used for measuring the total height and thickness of the steel slag liquid in the steel ladle after tapping. The high-definition industrial camera, the ladle lining infrared thermal imager and the laser ranging scanner can also be used for monitoring the thickness of the ladle lining and the residue of slag and molten steel.
The thermal imaging unit comprises a ladle outer wall infrared thermal imager and a ladle lining infrared thermal imager and is used for collecting temperature information of the inner wall and the outer wall of the empty ladle, and the cradle head and the sliding table are adjusted in the tapping process, so that the ladle thermal imager can clearly measure the temperature of molten steel and the temperature of the ladle outer wall.
The mass unit comprises a weighing device and an acquisition module, wherein the weighing device is used for measuring the empty ladle mass of the ladle and the total ladle mass after tapping, and the acquisition module is used for carrying out data acquisition, so that the alloy addition, the carburant mass, the slag former mass and the like in the tapping process are acquired.
The terminal data processing and controlling unit comprises a control unit and a terminal industrial personal computer, wherein the control unit comprises a PLC module and auxiliary electric elements thereof, and is arranged in a field control box and used for controlling a protection cooling device, a cradle head, a sliding table and data information receiving of each device; the communication transmission unit comprises a data interface of each device, a cable 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 according to the multi-dimensional degrees such as ladle capacity, ladle quality, ladle temperature, ladle lining distribution, molten steel temperature, slag-liquid thickness, ladle slag-liquid steel residue and the like, accurately controlling the thermal state of the empty ladle and the tapping process of the ladle, and analyzing the influence of heat absorption and heat dissipation of the ladle on molten steel cooling in the tapping process.
Preferably, the ladle outer wall infrared thermal imager, the ladle lining infrared thermal imager and the laser range finder all comprise cooling protection devices. The cooling protection device comprises a cooling water cooling protection device, a compressed air lens sweeping device and a lens protection window. And when the steel ladle is identified to leave, closing the compressed air lens blowing and lens protecting window to prevent the equipment lens from being stained with dust. And when the ladle is identified to arrive, opening a compressed air lens blowing and lens protecting window to ensure bright and clear imaging.
Preferably, the ladle outer wall infrared thermal imager, the ladle lining infrared thermal imager and the laser range finder are provided with a cradle head, the moving devices such as a sliding table are connected with the control unit, the imaging picture of equipment is observed through the industrial personal computer, the cradle head is controlled to move the thermal imager and the laser range finder, and different positions of the ladle are monitored.
Preferably, the ladle outer wall infrared thermal imager observes the ladle outer wall temperature distribution, carries out regional key monitoring aiming at the ladle fragile region, establishes a heat transfer mathematical model according to the actual site, ladle lining infrared thermal imager and the data measured by the laser ranging scanner by the number of the thermal imagers, and configures 1 or 2.
Preferably, the ladle lining thermal infrared imager and the lining laser range finder have two working states, wherein one is respectively and independently measured, and the other is in linkage measurement. When independently measured, the ladle lining infrared thermal imager measures the temperature of the ladle lining, and the lining laser range finder measures the thickness of the ladle lining. When in linkage measurement, the temperature distribution presented by the thermal image is also different due to the different emissivity of the lining and the slag molten steel, the area and the position of the slag molten steel residual area are analyzed through an image algorithm, then a laser range finder is controlled to sequentially measure the position area, the thickness of the area is obtained, the thickness of the slag molten steel residual is calculated according to the previous steel ladle lining thickness information, and therefore the quality of the slag molten steel residual, namely a lining slag iron residual monitoring unit is known.
Preferably, the weighing device weighs the empty ladle mass of the ladle, and compared with the measured and calculated ladle mass, if the difference is too large, the ladle mass is required to be manually inspected and repaired. When tapping is finished, the steel ladle passes through the thermal state monitoring system again, the weighing device measures the quality after tapping, and the high-definition industrial camera and the laser range finder measure the total height and thickness of steel slag liquid in the steel ladle.
Preferably, the measuring device and the moving device are connected with the control unit, and then the data transmission interaction is carried out with the industrial personal computer through the communication unit. And acquiring data information and running states of the measuring equipment, the moving device and the cooling device by the terminal industrial personal computer, analyzing and displaying the data by specific software, and controlling, adjusting and interacting the running states of the equipment and data transmission. The temperature data, the image data, the position thickness data and the quality data are transmitted to an industrial personal computer database and stored according to the steel ladle number classification, and various data information can be extracted from the database according to time sequence or steel ladle number.
In the technical scheme of the invention, all the components cooperate with each other and are mutually influenced, so that corresponding technical effects are realized. Specifically, the steel ladle transports molten steel to each smelting station, and is an important smelting container in the metallurgical production process. Therefore, the contact type temperature measurement mode is not suitable for ladles moving in long distance. As long as steel leakage occurs at any position of the steel ladle, serious safety accidents can be caused, therefore, a thermal infrared imager is needed to be selected, non-contact temperature imaging is realized, and the steel ladle is subjected to omnibearing temperature detection. Both erosion damage of the ladle refractory material and deformation and cracking of the outer wall of the ladle can cause abrupt change of temperature, so that the temperature is displayed in an infrared thermal image. To achieve the purpose of omnibearing detection and saving equipment cost as much as possible, a cradle head and a sliding table device are added. Because the ladle is cylindrical, two groups of thermal imaging combinations are arranged on two sides of the ladle to realize monitoring of the outer wall of the ladle; and a group of thermal imaging combinations are arranged above the ladle to realize the monitoring of the inner wall of the ladle.
In the tapping process, high-temperature molten steel is filled into a ladle, and the temperature of the molten steel is reduced due to residue of slag steel in the ladle and the ladle at a low temperature. In order to clarify the cooling process of molten steel, the ladle temperature and slag steel residue before tapping are clarified. According to the temperature measurement principle of the thermal imager, the emissivity of different materials is different, and the display of thermal imaging pictures is also different. The ladle lining is a nonmetallic substance, slag steel remains as a mixture of metal and nonmetal, suspected areas can be extracted through thermal imaging pictures and visible light images, and the areas of the suspected areas are measured. The laser ranging scanner measures the distance from the laser to the object by utilizing the time flight principle, and can not be influenced by the high-temperature and high-dust environment of the metallurgical site. And (5) comparing the thickness of the original ladle lining, measuring the residual thickness of the slag steel in the suspected area, and calculating the residual quality of the slag steel. The measuring 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 monitoring of the residue of the slag steel in the lining of the ladle.
Examples
As can be seen from fig. 1: the thermal state monitoring system for the empty ladle and the tapping process of the ladle 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 functions of limiting and locking, the cradle head device 6 can be controlled in a 300-degree rotation mode, the electric sliding table 7 is fixedly connected with the cradle head device 6, the cradle head 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 4, and the high-temperature thermal infrared imager 3 and the high-temperature laser ranging 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 4 through a data line and a power line so as to transmit, control and provide power for the data; the high-temperature thermal infrared imager 1 and the high-temperature thermal infrared imager 2 are respectively provided with a cradle head device 6 and an electric sliding table 7; the high-temperature thermal infrared imager 1, the high-temperature thermal infrared imager 2, the cradle head device 6, the electric sliding table 7 and the cooling device 9 are connected with the field control box 10 through data wires and power wires so as to facilitate data transmission, control and power supply. 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 by the terminal industrial personal computer, and analyzing and displaying the data by 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 stored according to the steel ladle number classification, and various data information can be extracted from the database according to time sequence or steel ladle number.
The invention is implemented in particular: the whole system device is arranged near the waiting position of the steel ladle tapped by the converter, the empty steel ladle starts to be detected after being positioned in the later stage of steel making of the converter, and data information of the empty steel ladle, the tapping process and the tapping completion is acquired, as shown in figure 2.
Identifying ladle numbers by high definition industrial camera 5 monitoring and image processing analysis as shown in fig. 3 and 4; after detecting that the ladle is in place, all measuring equipment measuring windows are opened through a 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 a data collecting unit and a communication unit.
And (3) 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 mouth, starting data acquisition, and detecting the temperature of the lining of the ladle and the residue of slag and molten steel. The detection steps are as shown in fig. 3 and 5: 1. starting a high-temperature thermal infrared imager 3 and a high-definition industrial camera 5 to image the ladle lining, collecting the temperature distribution, the thermal imaging image and the visible light image of the ladle lining, and performing image fusion according to the method of FIG. 3; 2. and (3) because the emissivity of different substances is different, the residual areas of the slag molten steel are obtained through the image processing of the visible light image and the thermal image, and the three-dimensional positions of the areas are found by combining the image coordinates and the real three-dimensional coordinates. 3. And according to the three-dimensional coordinates of the suspected region 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 of the lining of the region and the region area are collected. 4. And (5) comparing the original thickness of the steel ladle lining, and calculating the residual mass of the molten slag and the heat required by the residual molten slag.
And the empty ladle mass of the ladle is weighed by the weighing device 8, compared with the measured and calculated ladle mass, if the difference is too large, the ladle mass is required to be manually inspected and repaired.
In the tapping process, the high-temperature thermal infrared imager 1 or the high-temperature thermal infrared imager 2 is adjusted to be opposite to the vicinity of the tapping steel flow, and the temperature of molten steel and the temperature change of the outer wall of the steel ladle are detected.
When tapping is finished, the steel ladle passes through the thermal state monitoring system again, the weighing device measures the quality after tapping, and the high-definition industrial camera and the laser range finder measure the total height and thickness of steel slag liquid in the steel ladle.
The temperature data, the image data, the position thickness data and the quality data are transmitted to an industrial personal computer database and stored according to the steel ladle number classification, each steel ladle is recorded, new data are acquired and then are compared with the previous data, and the use condition of the steel ladle is tracked.
The industrial personal computer is mainly divided into 4 parts, namely an imaging condition of a high-temperature thermal infrared imager 1, a high-temperature thermal infrared imager 2 and a high-definition industrial camera 5; 2. displaying data of the laser range finder and the weighing device; 3. displaying slag and molten steel residues of the high-temperature thermal infrared imager 3 and the laser ranging scanner 4; 4. and 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 a corresponding change curve chart by using the main control computer.
Finally, it should be noted that: the foregoing is merely a preferred example of the present invention, and the present invention is not limited thereto, but it is to be understood that modifications and equivalents of some of the technical features described in the foregoing embodiments may be made by those skilled in the art, although the present invention has been described in detail with reference to the foregoing embodiments. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims (7)

1. A thermal state monitoring system for empty ladle and tapping process of a ladle, the system comprising:
The thermal imaging units are used for collecting images of the thermal imaging system and collecting steel ladle outer wall temperature data and tapping molten steel temperature data;
The imaging ranging unit is used for acquiring visible light images and thermal imager images, and acquiring ladle lining temperature, ladle residual slag steel quality, liquid slag temperature after tapping, ladle liquid level height and ladle slag liquid thickness;
The quality unit is used for collecting quality data in the tapping process;
The terminal data processing and controlling unit is connected with the components, controls and adjusts the running state and data transmission interaction, identifies and stores ladle dynamics, ladle quality, ladle inner and outer wall temperature, molten steel temperature and slag liquid thickness, determines the slag steel residue of the ladle lining and the heat required by melting,
Wherein, terminal data processing and control unit discernment ladle includes: determining the arrival/departure condition of the ladle and identifying the number of the ladle;
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 ladle numbering region from the first fused image;
Identifying the ladle number through a trained deep learning neural network model;
The method for determining the steel ladle lining slag liquid steel residual quantity by the terminal data processing and controlling unit comprises the following steps:
acquiring a second visible light image and a second thermal imager image through an imaging ranging unit, preprocessing, and then respectively performing morphological-based image segmentation to respectively obtain a visible light slag steel residual area and a thermal imager slag steel residual area;
Carrying out image feature registration on the visible light slag steel residual region and the thermal imager slag steel residual region to form a second fusion image, and determining a plurality of suspected regions 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 respective areas of the plurality of suspected regions;
Sequentially measuring and collecting the thickness of the plurality of suspected areas through an imaging ranging unit;
determining the average thickness of each suspected area according to the original thickness of the ladle lining, thereby determining the total residual mass of the ladle lining slag steel and determining the heat required by melting the ladle lining slag steel residual;
The terminal data processing and control unit determines the arrival/departure condition of the ladle through a third visible light image acquired by the imaging ranging unit.
2. The thermal condition monitoring system of claim 1, wherein the plurality of thermal imaging units comprises a first thermal imaging unit and a second thermal imaging unit of identical construction configured to:
the first infrared thermal imager is used for acquiring images of the thermal imager and acquiring steel ladle outer wall temperature data and tapping molten steel temperature data;
the first/second cradle head is provided with a first/second thermal infrared imager;
the first sliding table and the second sliding table are arranged at the lower part of the first cloud deck and the second cloud deck.
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 ladle;
The third thermal infrared imager is used for collecting images of the thermal infrared imager and collecting the temperature of the lining of the steel ladle and the temperature of liquid slag after tapping;
The laser ranging scanner is used for measuring the liquid level height of the steel ladle and the thickness of slag liquid of the steel ladle;
The third cradle head is provided with the high-definition industrial camera, the third thermal infrared imager and the laser ranging scanner;
the third sliding table is arranged at the lower part of the third cradle head;
Further, 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;
The collecting device is used for collecting the alloy addition amount, the carburant mass and the slag former mass in the tapping process.
4. 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;
The collecting device is used for collecting the alloy addition amount, the carburant mass and the slag former mass in the tapping process.
5. The thermal condition monitoring system of claim 1, wherein the plurality of thermal imaging units and imaging ranging units are each configured with a cooling protection device.
6. The thermal state monitoring system of claim 1, wherein the terminal data processing and control unit comprises:
The control unit comprises a PLC module and auxiliary electric 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 the data information receiving;
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, and identifies and stores ladle dynamics, ladle quality, ladle inner and outer wall temperature, molten steel temperature and slag liquid thickness and determines heat required by ladle lining slag steel residue and melting.
7. A thermal state monitoring method for a ladle blank and tapping process, characterized in that the thermal state monitoring method operates based on a thermal state monitoring system according to any one of claims 1 to 6, the thermal state monitoring method comprising:
determining the arrival of a ladle, and starting a hot state monitoring system;
Acquiring a first visible light image and a first thermal imager image, thereby determining a ladle number;
collecting steel ladle outer wall temperature data, steel ladle lining temperature data, tapping molten steel temperature data and tapping liquid slag temperature;
Collecting the liquid level height of the steel ladle and the thickness of slag liquid of the steel ladle;
measuring the empty ladle quality of the ladle and the total ladle quality after tapping, and collecting the alloy addition amount, the carburant quality and the slag former quality in the tapping process;
Collecting a second visible light image and a second thermal imager image, thereby determining a plurality of regions of suspected slag steel residues, sequentially measuring the thicknesses of the regions of suspected slag steel residues, determining the average thickness of each region of suspected slag steel residues according to the original thickness of the ladle lining, thereby determining the total mass of the slag steel residues of the ladle lining, and determining the heat required by melting the slag steel residues of the ladle lining;
And transmitting the data to an industrial personal computer database, classifying and storing according to ladle numbers, recording each ladle, comparing the new data with the previous data after acquiring the new data, and tracking the use condition of the ladle.
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