CN114754839B - Liquid level monitoring device and system for ladle - Google Patents
Liquid level monitoring device and system for ladle Download PDFInfo
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- CN114754839B CN114754839B CN202210668184.3A CN202210668184A CN114754839B CN 114754839 B CN114754839 B CN 114754839B CN 202210668184 A CN202210668184 A CN 202210668184A CN 114754839 B CN114754839 B CN 114754839B
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- 239000007788 liquid Substances 0.000 title claims abstract description 70
- 238000012806 monitoring device Methods 0.000 title claims abstract description 30
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 154
- 229910052742 iron Inorganic materials 0.000 claims abstract description 77
- 238000012544 monitoring process Methods 0.000 claims abstract description 18
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 67
- 238000001816 cooling Methods 0.000 claims description 63
- 239000000428 dust Substances 0.000 claims description 53
- 239000010410 layer Substances 0.000 claims description 29
- 239000011229 interlayer Substances 0.000 claims description 19
- 230000001681 protective effect Effects 0.000 claims description 16
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 12
- 238000007664 blowing Methods 0.000 claims description 12
- 238000009434 installation Methods 0.000 claims description 12
- 238000004891 communication Methods 0.000 claims description 11
- 238000007789 sealing Methods 0.000 claims description 11
- 239000002184 metal Substances 0.000 claims description 9
- 229910052751 metal Inorganic materials 0.000 claims description 9
- 230000000007 visual effect Effects 0.000 claims description 9
- 238000012545 processing Methods 0.000 claims description 7
- 238000009413 insulation Methods 0.000 claims description 6
- 239000010425 asbestos Substances 0.000 claims description 4
- 229910052895 riebeckite Inorganic materials 0.000 claims description 4
- 239000000741 silica gel Substances 0.000 claims description 4
- 229910002027 silica gel Inorganic materials 0.000 claims description 4
- 230000002457 bidirectional effect Effects 0.000 claims description 3
- 230000003139 buffering effect Effects 0.000 claims description 2
- 238000001914 filtration Methods 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 abstract description 12
- 238000010079 rubber tapping Methods 0.000 abstract description 7
- 238000000034 method Methods 0.000 description 15
- 238000010586 diagram Methods 0.000 description 13
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- 238000009628 steelmaking Methods 0.000 description 8
- 238000005266 casting Methods 0.000 description 5
- 230000000694 effects Effects 0.000 description 5
- 238000005259 measurement Methods 0.000 description 5
- 230000007797 corrosion Effects 0.000 description 4
- 238000005260 corrosion Methods 0.000 description 4
- 230000009467 reduction Effects 0.000 description 4
- 239000011819 refractory material Substances 0.000 description 4
- 230000009466 transformation Effects 0.000 description 4
- 230000009286 beneficial effect Effects 0.000 description 3
- 239000000498 cooling water Substances 0.000 description 3
- 230000007613 environmental effect Effects 0.000 description 3
- 230000033764 rhythmic process Effects 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 238000004458 analytical method Methods 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 230000017525 heat dissipation Effects 0.000 description 2
- 230000001737 promoting effect Effects 0.000 description 2
- 238000003723 Smelting Methods 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 238000005253 cladding Methods 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 239000000112 cooling gas Substances 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
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Images
Classifications
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01F—MEASURING VOLUME, VOLUME FLOW, MASS FLOW OR LIQUID LEVEL; METERING BY VOLUME
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B08—CLEANING
- B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
- B08B5/00—Cleaning by methods involving the use of air flow or gas flow
- B08B5/02—Cleaning by the force of jets, e.g. blowing-out cavities
-
- 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
- B22D2/003—Arrangement of indicating or measuring devices, e.g. for temperature or viscosity of the fused mass for the level of the molten metal
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K7/00—Constructional details common to different types of electric apparatus
- H05K7/20—Modifications to facilitate cooling, ventilating, or heating
- H05K7/20218—Modifications to facilitate cooling, ventilating, or heating using a liquid coolant without phase change in electronic enclosures
- H05K7/20272—Accessories for moving fluid, for expanding fluid, for connecting fluid conduits, for distributing fluid, for removing gas or for preventing leakage, e.g. pumps, tanks or manifolds
-
- Y—GENERAL 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
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- Physics & Mathematics (AREA)
- Engineering & Computer Science (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Thermal Sciences (AREA)
- Electromagnetism (AREA)
- Fluid Mechanics (AREA)
- General Physics & Mathematics (AREA)
- Mechanical Engineering (AREA)
- Measurement Of Levels Of Liquids Or Fluent Solid Materials (AREA)
Abstract
The invention discloses a liquid level monitoring device and system for a ladle, which belong to the technical field of liquid level monitoring. The invention can measure and display the liquid level of the molten iron in the molten iron tank in real time, is convenient for operators to control the flow of the molten iron at the tapping hole, can prevent the molten iron from overflowing from the tank on one hand, avoids the occurrence of production accidents and provides guarantee for safe production; on the other hand, on the premise of ensuring safety, the molten iron loading capacity of the molten iron tank can be improved as much as possible.
Description
Technical Field
The invention belongs to the technical field of liquid level monitoring, and particularly relates to a liquid level monitoring device and system for a ladle.
Background
In order to improve the smelting level of the blast furnace, reduce energy consumption and environmental pollution, various large iron and steel enterprises in China gradually eliminate laggard small blast furnaces through technical transformation, and replace newly-built large-scale modern blast furnaces with better energy-saving and consumption-reducing and environment-friendly facilities. Along with the enlargement of the volume of the blast furnace, the tapping flow speed is accelerated, the iron receiving time of the mixer car in the blast furnace is shortened, and certain risk is brought to the safe tapping of the blast furnace. How to prevent the accidents of falling of molten iron (commonly called as 'running iron') in the tapping process of the blast furnace becomes the first safety requirement of the tapping of the blast furnace. In general iron works, when a blast furnace hot metal tank is filled with molten iron, the liquid level of the molten iron in the tank is mostly judged by adopting a manual visual inspection method, the potential safety hazard is prominent, and the production efficiency is not guaranteed; the following four problems are urgently to be solved: firstly, as the temperature of molten iron is up to 1300 ℃, iron flowers splash and dust are diffused in the process of containing, and the close-range observation is very dangerous; secondly, the size of molten iron flow is not fixed, manual observation is not timely, molten iron is out of control in the charging process, molten iron overflows, a molten iron tank car or weighing equipment is damaged, and even the overflowing molten iron is contacted with the wet ground or accumulated water of an iron pit to cause rapid expansion of water vapor to explode; thirdly, the full ladle rate of the ladle is always about 60 percent under the influence of the safety responsibility of the staff at the post, the use efficiency of the ladle is influenced due to too little molten iron contained in the ladle, the ladle merging and turning operation is required by downstream units, great influence is brought to the steelmaking production rhythm, and the production cost is invisibly increased; fourthly, based on the standard requirements of the safety and environmental protection department on the high-temperature molten metal operation, the current situation urgently needs technical transformation.
Disclosure of Invention
Based on the technical problems in the prior art, the invention provides a liquid level monitoring device and system for a foundry ladle, which can monitor the liquid level of molten iron in the foundry ladle in real time, so that the service efficiency of the foundry ladle is improved. The liquid level monitoring system for the foundry ladle is a radar level measurement and control system for increasing the full ladle rate of the foundry ladle.
According to a first aspect of the technical scheme, the liquid level monitoring device for the ladle comprises a radar level meter, a dust removal device and a cooling device, wherein the radar level meter and the dust removal device are both arranged in the cooling device;
the radar level meter comprises a universal flange, an antenna lens, a control circuit board and a shell, wherein the control circuit board is electrically connected with the antenna, the antenna transmits signals through the antenna lens, and the radar level meter is fixedly connected with the dust removal device through the universal flange;
the control circuit board comprises a main control circuit, a high-frequency circuit, a display circuit, a key circuit, a communication circuit and a power circuit, wherein the main control circuit is respectively connected with the high-frequency circuit and the communication circuit in a bidirectional way, the main control circuit is respectively electrically connected with the display circuit and the key circuit, and the power circuit provides power for the main control circuit;
the dust removal device comprises quartz glass, a first base, a second base and a silica gel gasket, the silica gel gasket is arranged on two sides of the quartz glass, the first base comprises an installation flange, a first inclined plane straight pipe and a first inclined plane flange, the dust removal device is connected with a universal flange of the radar level meter through the installation flange, and the installation flange is connected with the first inclined plane flange through the first inclined plane straight pipe; the second base comprises a second inclined flange, a second inclined straight pipe, a lower flange and an air blowing hole, the second inclined flange is connected with the first inclined flange, the second inclined flange is connected with the lower flange through the second inclined straight pipe, the dust removal device is fixedly connected with the cooling device through the lower flange, and the air blowing hole is formed in the middle of the second inclined straight pipe;
the cooling device comprises a double-layer shell, an upper sealing cover and a bottom flange seat, wherein the upper sealing cover is arranged above the double-layer shell, the bottom flange seat is arranged below the double-layer shell, and the bottom flange seat is connected with the dust removal device; the double-layer shell comprises an inner wall layer and an outer wall layer, and a cavity interlayer is arranged between the inner wall layer and the outer wall layer; the cooling device further comprises a water inlet pipeline, a water outlet pipeline, an air inlet pipeline and an inlet pipeline, wherein the inlet of the water inlet pipeline, the outlet of the water outlet pipeline, the inlet of the air inlet pipeline and the inlet of the inlet pipeline are all arranged on the same side of the cooling device, and the main bodies of the water inlet pipeline, the water outlet pipeline, the air inlet pipeline and the inlet pipeline are all arranged inside the cooling device; the water inlet pipeline comprises a straight pipeline and a bent pipeline, and the straight pipeline leads water flow to the bottom of the cavity interlayer on the opposite surface of the water inlet pipeline through the bent pipeline; the inlet of the water outlet pipeline is communicated with the cavity interlayer; an air inlet pipeline arranged on the cooling device extends into the inner cavity of the dust removal device through a pipeline; the inlet wire pipeline extends into the inner cavity of the dust removal device through the pipeline, and the inlet wire pipeline is used for accommodating various wire harnesses of the cooling device.
Preferably, the high-frequency circuit comprises a digital-to-analog converter, a voltage-controlled oscillator, a power divider, a transmitting amplifier, a receiving amplifier, a mixer, a filter, a signal amplifier and an analog-to-digital converter, the digital-to-analog converter is connected with the input end of the power divider through the voltage-controlled oscillator, the output end of the power divider is respectively connected with the input ends of the transmitting amplifier and the mixer, the receiving amplifier is connected with the input end of the mixer, and the output end of the mixer is connected with the main control circuit through the filter, the signal amplifier and the analog-to-digital converter in sequence.
Furthermore, the quartz glass included an angle of 13 ° with the horizontal plane.
Further, an air inlet pipeline arranged on the cooling device extends into an inner cavity of the dust removal device through a pipeline; the cooling device is formed by metal processing to form a cavity interlayer, circulating water is filled in the cavity interlayer to achieve the purposes of heat insulation and cooling, and the entering water flow is guided to the bottom of the cavity interlayer by the water inlet pipeline, the straight pipeline and the bent pipeline and is on the opposite surface of the water inlet pipeline, and then flows out through the water outlet pipeline.
Preferably, the liquid level monitoring device for the foundry ladle further comprises a touch display screen, and the touch display screen is arranged above the radar level gauge.
Furthermore, the digital-to-analog converter controls the voltage-controlled oscillator to generate a high-frequency signal, the high-frequency signal feeds a part of the high-frequency signal to the antenna after being amplified by the transmitting amplifier through the power divider, the other part of the high-frequency signal is coupled to the mixer and mixed with the signal amplified by the receiving amplifier, a baseband difference frequency signal is obtained after filtering of the mixer, and the baseband difference frequency signal is transmitted to the main control circuit for processing after being converted by the signal amplifier and the analog-to-digital converter. And controlling the digital-to-analog converter to send a high-frequency signal through the main control MCU.
Further, the digital-to-analog converter, the voltage-controlled oscillator, the power divider, the transmitting amplifier, the receiving amplifier, the mixer, the filter, the signal amplifier and the analog-to-digital converter are integrally manufactured on the CMOS millimeter wave radio frequency chip.
According to a second aspect of the technical scheme of the invention, the liquid level monitoring system for the foundry ladle comprises a PLC, a display screen, an audible and visual alarm and the liquid level monitoring device for the foundry ladle, wherein the liquid level monitoring device is connected with the input end of the PLC, and the output end of the PLC is respectively and electrically connected with the display screen and the audible and visual alarm.
Preferably, the device also comprises a pressure transmitter and a temperature sensor which are respectively electrically connected with the PLC.
Preferably, the liquid level monitoring device further comprises a protective cover, the protective cover is arranged above the ladle, and the liquid level monitoring device is fixedly installed on the protective cover.
Compared with the prior art, the invention has the following beneficial effects:
1. the liquid level monitoring device comprises a radar level meter, a dust removal device and a cooling device, wherein the radar level meter monitors the liquid level height of molten iron in a ladle in real time, the dust removal device and the cooling device effectively isolate dust and reduce the temperature by using air and circulating water, and the temperature of the radar level meter in a high-temperature environment is effectively reduced, so that the radar level meter accurately measures the liquid level of the molten iron in the ladle, the full-tank rate is improved, the use efficiency of the ladle is improved, the temperature drop loss of the molten iron is reduced, the scrap steel ratio is reduced, the potential safety hazard is reduced, the merging and overturning at a steel-making and electric furnace are reduced, the heat loss and the dust emission are reduced, and the electric energy and the transportation cost are effectively saved.
2. The liquid level monitoring system can solve the current situation that the weight detection of the current molten iron is lagged, realizes that a non-full ladle molten iron car receives iron in different blast furnaces, improves the use efficiency of the molten iron ladle, avoids the influence of the non-full ladle molten iron on the production rhythm, reduces the temperature drop loss of tapping due to non-full ladle waiting, and the like, plays a role in optimizing production, and mainly comprises the following components: (1) the method has the advantages of reducing the temperature drop loss of the molten iron, reducing the scrap steel ratio, improving the ladle filling rate, meeting the production requirements of steel making and special steel plants, realizing the controllability of molten iron pouring and loading, reducing the temperature drop loss caused by ineffective labor such as ladle merging and the like, and laying a foundation for the subsequent reduction of the scrap steel ratio; (2) the method improves the service efficiency of the ladle and quantifies the corrosion condition of the refractory of the ladle. The normal corrosion condition of refractory materials can be judged in an auxiliary mode through the detection of the liquid level of the molten iron, the condition that the ladle is overhauled or under-repaired is avoided, the damage of the excessive molten iron to the weak part of the refractory materials at the ladle opening of the molten iron is avoided, and in addition, the liquid level is accurate in the molten iron putting process, the burning loss of a molten iron car caused by the excessive molten iron and the safety risk of the high-liquid-level ladle in the transportation process can be avoided; (3) the liquid level of the molten iron is accurately metered and recorded by adopting advanced measuring equipment and an auxiliary informatization means, so that the analysis is convenient, a good foundation is laid for promoting the operation idea of 'one ladle to the bottom' of the molten iron, and the requirement of blast furnace iron making transformation and upgrading is met; (4) and environmental protection benefit: the ladle merging and turning at the steel making and electric furnace are reduced, and the heat loss and the dust emission are reduced; (5) and safety benefit: potential safety hazards caused to operators by molten iron splashing, dust, high temperature and other factors are avoided; according to the invention, the intelligent liquid level detection device is added to the ladle, so that the weight coincidence rate of the molten iron is improved from 30% to 80%, and the ladle rate is reduced from 40% to 20%; according to statistical data in recent years, the system can effectively improve the full ladle coincidence rate of the ladle by adding, the proportion of +/-2.5 tons is 80%, and the coincidence rate is obviously improved compared with the current 30%.
Drawings
The present invention will be described in further detail with reference to the accompanying drawings.
Fig. 1 is a schematic structural view of a liquid level monitoring device for a ladle according to the present invention.
FIG. 2 is a schematic structural view of the radar level gauge according to the present invention.
FIG. 3 is a schematic structural view of the dust removing apparatus of the present invention.
FIG. 4 is a schematic structural diagram of a first base in the dust removing device of the present invention.
FIG. 5 is a schematic structural diagram of a second base in the dust removing device of the present invention.
Fig. 6, 7 and 8 are schematic structural views of the cooling device of the present invention.
FIG. 9 is a schematic view of the structure of a control circuit board in the radar level gauge according to the present invention.
Fig. 10 is a schematic circuit diagram of the high frequency circuit in the control circuit board of the present invention.
FIG. 11 is a circuit diagram of the high frequency circuit in the control circuit board according to the present invention.
Fig. 12 is a circuit connection diagram of the main control circuit in the control circuit board according to the present invention.
FIG. 13 is a circuit diagram of the display circuit of the control circuit board according to the present invention.
FIG. 14 is a circuit diagram of the key circuit of the control circuit board according to the present invention.
FIG. 15 is a circuit diagram of a communication circuit in the control circuit board according to the present invention.
FIG. 16 is a schematic diagram of a liquid level monitoring system for a ladle in accordance with the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some embodiments, but not all embodiments, of the present invention; all other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 1, a liquid level monitoring apparatus for a ladle includes: radar level meter 1, dust collector 2 and cooling device 3, radar level meter 1, dust collector 2 are all installed inside cooling device 3, radar level meter 1 fixed mounting is on dust collector 2, dust collector 2 fixed mounting is on the inside base of cooling device 3. The liquid level monitoring device for the foundry ladle is applied to a full-ladle-rate radar level measurement and control system to obtain the liquid level monitoring system for the foundry ladle, and the liquid level monitoring system for the foundry ladle is a radar level measurement and control system for lifting the full-ladle rate of the foundry ladle.
Specifically, the radar level gauge 1 monitors the molten iron liquid level height in the ladle in real time, the dust removal device 2 and the cooling device 3 effectively isolate dust and reduce the temperature by utilizing air and circulating water, and the temperature of the radar level gauge 1 in a high-temperature environment is effectively reduced, so that the radar level gauge 1 accurately measures the molten iron liquid level in the ladle, the full-ladle rate is improved, the service efficiency of the ladle is improved, the molten iron temperature drop loss is reduced, the scrap steel ratio is reduced, the potential safety hazard is reduced, the merging and ladle overturning at steel making and electric furnaces are reduced, the heat loss and the dust emission are reduced, and the electric energy and the transportation cost are effectively saved.
Referring to FIG. 2, the radar level gauge 1 comprises a universal flange 11, an antenna 12, an antenna lens 13, a control circuit board 14 and a housing 15, wherein the control circuit board 14 is electrically connected with the antenna 12, the antenna 12 transmits signals through the antenna lens 13, and the radar level gauge 1 is fixedly connected with the dust removing device 2 through the universal flange 11.
Referring to fig. 3 to 5, the dust removing device 2 includes: the dust removal device 2 is connected with a universal flange 11 of the radar level gauge 1 through the mounting flange 221, and the mounting flange 221 is connected with a first inclined plane flange 223 through the first inclined plane straight pipe 222; the second base 23 comprises a second inclined flange 231, a second inclined straight pipe 232, a lower flange 233 and an air blowing hole 234, the second inclined flange 231 is connected with the first inclined flange 223, the second inclined flange 231 is connected with the lower flange 233 through the second inclined straight pipe 232, the dust removing device 2 is fixedly connected with the cooling device 3 through the lower flange 233, the air blowing hole 234 is arranged in the middle of the second inclined straight pipe 232, the included angle between the quartz glass 21 and the horizontal plane is 13 degrees, and the penetration of radar waves is facilitated; the middle part of the second inclined straight pipe 232 is provided with four air blowing holes 234 which are uniformly distributed, so that air can be blown downwards from four sides conveniently, and an air curtain is formed to effectively isolate dust.
Referring to fig. 6-8, the cooling device 3 includes a double-layer shell 31, an upper sealing cover 32 and a bottom flange seat 39, the upper sealing cover 32 is disposed above the double-layer shell 31, the bottom flange seat 39 is disposed below the double-layer shell 31, and the bottom flange seat 39 is connected to the dust removing device 2; the double-walled shell 31 comprises an inner wall layer 311 and an outer wall layer 312, and a cavity interlayer 313 is arranged between the inner wall layer 311 and the outer wall layer 312. Further, the cooling device 3 includes a water inlet pipeline 33, a water outlet pipeline 34, an air inlet pipeline 35 and an air inlet pipeline 36, an inlet of the water inlet pipeline 33, an outlet of the water outlet pipeline 34, an inlet of the air inlet pipeline 35 and an inlet of the air inlet pipeline 36 are all on the same side of the cooling device, and main bodies of the water inlet pipeline 33, the water outlet pipeline 34, the air inlet pipeline 35 and the air inlet pipeline 36 are all arranged inside the cooling device; the water inlet pipeline 33 comprises a straight pipeline 331 and an elbow pipeline 332, and the straight pipeline 331 guides water flow to the bottom of the cavity interlayer 313 on the opposite surface of the water inlet pipeline 33 through the elbow pipeline 332; the inlet of the water outlet pipeline is communicated with the cavity interlayer; an air inlet pipeline 35 arranged on the cooling device extends into the inner cavity of the dust removal device through a pipeline, in addition, an inlet pipeline 36 extends into the inner cavity of the dust removal device through a pipeline, and the inlet pipeline is used for accommodating various wire harnesses of the cooling device; specifically, the cooling device 3 is formed by metal processing to form a cavity interlayer 313, circulating water is filled in the cavity interlayer to achieve the purposes of heat insulation and cooling, and the entering water flow is led to the bottom of the cavity interlayer 313 and is on the opposite surface of the water inlet pipeline 33 through the water inlet pipeline 33, the straight pipeline 331 and the bent pipeline 332; then the water flows out through the water outlet pipeline 34, the water inlet pipeline 33 and the water outlet pipeline 34 are arranged on one side of the protective tray 37, so that dead water in the interlayer is reduced, more than 90% of water is circulated, and the temperature is effectively reduced. The cooling device further comprises a protective tray 37 and an asbestos pad 38, wherein the asbestos pad 38 is filled between the upper sealing cover 32 and the double-layer shell 31 and used for buffering the pressure between the upper sealing cover 32 and the double-layer shell 31 and playing a role in heat insulation. The protection tray is the surrounding form, and the protection tray cladding is shown in fig. 6 at cooling device's lower part, and the protection tray supports and protects cooling device, avoids cooling device to receive damage when external impact.
In the embodiment, two temperature reduction measures are adopted, namely, on one hand, gas is cooled, the gas enters the inner cavity of the dust removing device through the gas inlet pipeline 35 and is exhausted from the gas blowing hole 234 at the lower part, and a gas curtain is formed at the lower part while the gas is exhausted to prevent dust from adhering to the surface of the quartz glass 21; on the other hand, the temperature of the circulating water is reduced, water flow enters the cavity interlayer 313 from the water inlet pipeline 33 and then is discharged from the top water outlet pipeline 34, so that the cavity interlayer 313 is filled with movable water, and the effects of temperature insulation and temperature reduction are achieved.
The radar level gauge further comprises a touch display screen, wherein the touch display screen is arranged above the radar level gauge 1, and a key and a touch screen are arranged on the touch display screen; the touch screen can be used for randomly setting the upper limit alarm value of the molten iron liquid level, and has the function of audible and visual alarm of full tank, so that the operator is prompted to be full of the tank at the moment, and the raw materials are prevented from overflowing to cause accidents. In addition, the temperature and pressure monitoring and alarming function guarantee measures are added, and when the temperature on site is too high, the pressure of cooling water is too low, and the pressure of cooling gas is too low, alarm information can be sent out to prompt post personnel to take corresponding measures.
The cooling device is used for protecting the radar level meter and preventing the radar level meter from being influenced by high temperature, the cooling device is arranged at a data front end measuring end, and the touch display screen is arranged inside the PLC main control cabinet. Pressure transmitter sets up on the water supply pipe, temperature sensor sets up just inside the radar level meter, audible-visual annunciator setting is on PLC master control cabinet top.
Referring to fig. 9, the control circuit board 14 includes a main control circuit 141, a high frequency circuit 142, a display circuit 143, a key circuit 144, a communication circuit 145 and a power circuit 146, the main control circuit 141 is respectively connected to the high frequency circuit 142 and the communication circuit 145 in a bidirectional manner, the main control circuit 141 is respectively connected to the display circuit 143 and the key circuit 144 in an electrical manner, the power circuit 146 provides power for the main control circuit 141, and the main control circuit 141 is connected to the PLC in a communication manner through the communication circuit 145.
Referring to fig. 10, fig. 10 is a schematic circuit diagram of a high-frequency circuit 142, the high-frequency circuit 142 includes a CMOS millimeter-wave radio-frequency chip, the CMOS millimeter-wave radio-frequency chip is provided with a digital-to-analog converter 41, a voltage-controlled oscillator 42, a power divider 43, a transmitting amplifier 44, a receiving amplifier 45, a mixer 46, a filter 47, a signal amplifier 48 and an analog-to-digital converter 49, the digital-to-analog converter 41 is connected to an input end of the power divider 43 through the voltage-controlled oscillator 42, an output end of the power divider 43 is connected to input ends of the transmitting amplifier 44 and the mixer 46, the receiving amplifier 45 is connected to an input end of the mixer 46, and an output end of the mixer 46 is connected to a main control circuit 141 through the filter 47, the signal amplifier 48 and the analog-to-digital converter 49 in sequence; specifically, the digital-to-analog converter 41 controls the voltage-controlled oscillator 42 to generate a high-frequency signal, the high-frequency signal passes through the power divider 43, a part of the high-frequency signal is amplified by the transmission amplifier 44 and then fed to the antenna 12, another part of the high-frequency signal is coupled to the mixer 46, mixed with the signal amplified by the receiving amplifier 45, filtered by the filter 47 to obtain a baseband difference frequency signal, and then converted by the signal amplifier 48 and the analog-to-digital converter 49 and sent to the main control circuit 141 for processing. The digital-to-analog converter 41 is controlled by the main control MCU to send a high-frequency signal; the digital-to-analog converter 41, the voltage-controlled oscillator 42, the power divider 43, the transmit amplifier 44, the receive amplifier 45, the mixer 46, the filter 47, the signal amplifier 48, and the analog-to-digital converter 49 are preferably fabricated integrally on a CMOS millimeter-wave radio frequency chip.
Referring to FIG. 11, FIG. 11 is a circuit diagram of the high frequency circuit 142, specifically, the clock system generates 76-81GHz from the external 40MHz clock signal; the transmitting subsystem consists of three parallel transmitting chains, each with independent phase and amplitude control; the receive subsystem consists of four parallel channels, a single receive channel consisting of a low noise amplifier LNA, mixer, IF filter, analog-to-digital converter and decimation filter, and the radio processor subsystem (BIST) comprises a digital front end, a ramp generator and an internal processor for controlling/configuring the low-level RF/analog and ramp generator registers.
The CMOS millimeter wave radio frequency chip based on independent research and development adopts a millimeter wave band with higher frequency, has better use effect in the environments of remote target detection, strong smoke, strong dust, high temperature and high pressure, and can detect a target with lower detection precision than a microwave radar and realize more accurate positioning; the high integration, higher signal-to-noise ratio, smaller dead zone, the dead zone is as small as 8 cm; the working bandwidth of 5GHz enables the product to have higher measurement resolution and measurement precision; the 3-degree antenna beam angle has smaller influence on the instrument by interference in the installation environment, and the installation is more convenient and faster; the maximum measuring range can be 120 meters, and the precision is +/-3 mm; the wavelength is shorter, and the surface of the medium has better reflection characteristic, so that a universal flange is not required to be specially used for aiming; and remote debugging and remote upgrading are supported, the waiting time is reduced, and the working efficiency is improved.
Referring to fig. 12-15, fig. 12-15 are schematic circuit diagrams of a main control circuit 141, a display circuit 143, a key circuit 144, and a communication circuit 145, respectively, wherein a model of a monolithic computer U1 in the main control circuit 141 is STM32L151RGT 6; CN1 in the display circuit 143 is a liquid crystal interface, and H2 in the communication circuit 145 is connected with a measuring unit.
Referring to fig. 16, fig. 16 is a schematic structural diagram of a liquid level monitoring system for a ladle, which includes a PLC, a display screen 6, an audible and visual alarm 5, and a liquid level monitoring device for the ladle, wherein the liquid level monitoring device is connected to an input end of the PLC, and an output end of the PLC is electrically connected to the display screen and the audible and visual alarm, respectively.
Specifically, the liquid level monitoring device is arranged above the ladle and used for monitoring the liquid level height of molten iron in the ladle in real time and sending the collected liquid level height of the molten iron to the PLC, the PLC performs calculation and processing and displays monitoring data through the display screen 6, and the real-time liquid level can be displayed through the large-screen LED display screen 6, so that the display is clear and convenient to view on site; when the liquid level height of the molten iron is larger than a set early warning value, the audible and visual alarm 5 carries out audible and visual alarm flicker early warning prompt to remind a post worker to make preparation work and measures in advance; according to the embodiment, the PLC control system is utilized to continuously display the liquid level height of the molten iron in the ladle and give an alarm for prompting, so that potential safety hazards caused by overflow of the molten iron from a molten iron tank car can be effectively avoided, the appropriate molten iron receiving amount can be controlled, the full tank rate of the ladle is ensured, and the process connection between a blast furnace and steel making and the high-efficiency low-cost operation are met.
Further, a liquid level monitoring system for the ladle still includes pressure transmitter and temperature sensor, pressure transmitter and temperature sensor are connected with the PLC electricity respectively.
Furthermore, the system also reserves a data remote interface on the PLC host, and can lead data signals to a computer of a blast furnace main control room so as to ensure the requirement of production from one tank to the bottom and accurately derive the real-time data of the liquid level.
The liquid level monitoring device is characterized by also comprising a protective cover, wherein the protective cover is arranged above the ladle, and the liquid level monitoring device is fixedly arranged on the protective cover; specifically, the protective cover is positioned above the ladle, the radar level gauge can be integrally installed on the protective cover, a hole needs to be formed in the protective cover above the hot metal ladle for installation, the molten iron flow and the middle position of the wall of the hot metal ladle are taken as centers, and the hot metal car track is taken as a zero reference surface and is vertically installed; the protective cover is added to prevent molten iron from splashing and damaging the radar level gauge, and each blast furnace casting house is respectively provided with 1 molten iron car stop line corresponding to the corresponding molten iron ladle level.
Further, the liquid level monitoring device can be vertically embedded on a blast furnace casting house platform, and an embedded installation mode is selected, so that the liquid level monitoring device has the advantages that: the upper part of the device is flush with the platform surface, so that the equipment and the wire pipe are not leaked, and the whole body is attractive; the operations such as personnel operation, equipment lifting and the like are not influenced; the liquid level monitoring device can also be vertically arranged above the platform of the blast furnace casting house, the height of the platform is raised by about 600mm, the installation mode is selected, and the liquid level monitoring device has the advantages that: 1) the inspection, the check and the maintenance are convenient; 2) the product is beneficial to heat dissipation, wiring and cooling only by gas cooling; 3) the size of the opening on the casting house platform is small, and only a mounting hole with the diameter of about 100mm needs to be formed on the platform; in the practical application process, the installation mode can be selected according to the requirement.
In the practical application process, a liquid level monitoring device is mostly embedded and installed on a blast furnace casting house platform and is not beneficial to heat dissipation, so that the optimal cooling effect is achieved by adopting double cooling of gas cooling and circulating water cooling, wherein the gas cooling is realized by gas cooling and blowing, nitrogen or filtered compressed air is used for blowing the surface of the radar level gauge, the whole equipment structure adopts a two-stage three-layer compressed air cooling/cleaning/sealing design, an electromagnetic transmitter is sealed in an air cooling cover, the compressed air is directly blown, and the compressed air near a lens antenna is connected into an equipment protection component in a 0-degree and 90-degree mode and then is used for continuously blowing and cooling the front radar level gauge, so that the effects of pressing dust downwards in real time and cooling the transmitter are achieved; the circulating water cooling is carried out by adopting the design that a protective sleeve of the device is processed by metal to form a cavity interlayer, the circulating cooling water is added in the middle for water cooling, the device is protected by another layer, and the cooling water enters the liquid level monitoring device through the water inlet pipeline and flows out through the water outlet pipeline for water circulating cooling.
The liquid level monitoring system of this embodiment can solve the lagging current situation of current molten iron weight detection, realizes that non-full packet molten iron car receives the iron at different blast furnaces, improves the ladle availability factor, avoids non-full packet molten iron to influence the production rhythm, reduces because of non-full packet waits that the temperature drop of tapping etc. has played the effect of optimizing production, mainly has: (1) reducing the temperature drop loss of molten iron and reducing the scrap steel ratio. The ladle filling rate is improved, the production requirements of steel making and special steel plants are met, the controllability of molten iron pouring and loading is realized, the temperature drop loss caused by ineffective labor such as ladle merging and the like is reduced, and a foundation is laid for the subsequent reduction of the scrap steel ratio; (2) the method improves the service efficiency of the ladle and quantifies the corrosion condition of the refractory of the ladle. Through the detection of the liquid level of the molten iron, the normal corrosion condition of the refractory material can be judged in an auxiliary mode, the condition that the ladle is overhauled or is under-repaired is avoided, and the damage of the excessive molten iron to the weak part of the refractory material at the ladle opening of the molten iron is avoided. In addition, the liquid level is accurate in the molten iron charging process, so that the burning loss of a molten iron car caused by excessive molten iron charging and the safety risk of a high-liquid-level ladle in transportation can be avoided; (3) the method has the advantages that the liquid level of the molten iron is accurately metered and recorded by adopting advanced measuring equipment and auxiliary informatization means, so that analysis is facilitated, a good foundation is laid for promoting the operation concept of 'one to the bottom' of the molten iron, and the method meets the transformation and upgrading requirements of blast furnace iron making; (4) and environmental protection benefit: the ladle merging and turning at the steel making and electric furnace are reduced, and the heat loss and the dust emission are reduced; (5) and safety benefit: potential safety hazards caused to operators by molten iron splashing, dust, high temperature and other factors are avoided; in the embodiment, the intelligent liquid level detection device is added to the ladle, so that the weight coincidence rate of the molten iron is improved to 80% from 30%, and the ladle rate is reduced to 20% from 40%; from the statistical data in recent years, the system can effectively improve the full ladle coincidence rate of the foundry ladle by adding, the requirement that the percentage of +/-2.5 tons is 80 percent is met, and the coincidence rate is obviously improved compared with the 30 percent at present.
In the description of the present invention, it is to be understood that the terms "upper", "lower", "inside", and the like, indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, are only for convenience in describing the present invention and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed in a specific orientation, and be operated, and thus, should not be construed as limiting the present invention. Furthermore, the terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of the feature.
In the present invention, unless otherwise expressly specified or limited, the terms "mounted," "connected," "secured," and the like are to be construed broadly and can, for example, be fixedly connected, detachably connected, or integrally formed; can be mechanically or electrically connected; they may be directly connected or indirectly connected through intervening media, or they may be connected internally or in any other suitable relationship, unless expressly stated otherwise. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.
In the present invention, unless otherwise explicitly specified or limited, a first feature may be "on" or "under" a second feature, and the first and second features may be in direct contact, or the first and second features may be in indirect contact via an intermediate. Also, a first feature "on," "over," and "above" a second feature may be directly or diagonally above the second feature, or may simply indicate that the first feature is at a higher level than the second feature. A first feature "under," "beneath," and "under" a second feature may be directly under or obliquely under the second feature, or may simply mean that the first feature is at a lesser elevation than the second feature.
Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and these modifications or substitutions do not depart from the spirit of the corresponding technical solutions of the embodiments of the present invention.
Claims (6)
1. A liquid level monitoring device for a ladle is characterized by comprising a radar level meter, a dust removal device and a cooling device, wherein the radar level meter and the dust removal device are both arranged in the cooling device; the radar level meter monitors the liquid level height of molten iron in the ladle in real time, and the dust removal device and the cooling device effectively isolate dust and reduce the temperature by using air and circulating water, so that the temperature of the radar level meter in a high-temperature environment is reduced;
the radar level meter comprises a universal flange, an antenna lens, a control circuit board and a shell, wherein the control circuit board is electrically connected with the antenna, the antenna transmits signals through the antenna lens, and the radar level meter is fixedly connected with the dust removal device through the universal flange;
the control circuit board comprises a main control circuit, a high-frequency circuit, a display circuit, a key circuit, a communication circuit and a power circuit, wherein the main control circuit is respectively connected with the high-frequency circuit and the communication circuit in a bidirectional way, the main control circuit is respectively electrically connected with the display circuit and the key circuit, and the power circuit provides power for the main control circuit;
the dust removal device comprises quartz glass, a first base, a second base and silica gel gaskets, wherein the silica gel gaskets are arranged on two sides of the quartz glass, and the included angle between the quartz glass and the horizontal plane is 13 degrees; the first base comprises an installation flange, a first inclined plane straight pipe and a first inclined plane flange, the dust removal device is connected with a universal flange of the radar level meter through the installation flange, and the installation flange is connected with the first inclined plane flange through the first inclined plane straight pipe; the second base comprises a second inclined flange, a second inclined straight pipe, a lower flange and an air blowing hole, the second inclined flange is connected with the first inclined flange, the second inclined flange is connected with the lower flange through the second inclined straight pipe, the dust removing device is fixedly connected with the cooling device through the lower flange, and the air blowing hole is formed in the middle of the second inclined straight pipe; the middle part of the second inclined straight pipe is provided with four uniformly distributed air blowing holes, so that air can be blown downwards from four sides to form an air curtain to effectively isolate dust;
the cooling device comprises a double-layer shell, an upper sealing cover and a bottom flange seat, wherein the upper sealing cover is arranged above the double-layer shell, the bottom flange seat is arranged below the double-layer shell, and the bottom flange seat is connected with the dust removal device; the double-layer shell comprises an inner wall layer and an outer wall layer, and a cavity interlayer is arranged between the inner wall layer and the outer wall layer; the cooling device further comprises a water inlet pipeline, a water outlet pipeline, an air inlet pipeline and an inlet pipeline, wherein the inlet of the water inlet pipeline, the outlet of the water outlet pipeline, the inlet of the air inlet pipeline and the inlet of the inlet pipeline are all arranged on the same side of the cooling device, and the main bodies of the water inlet pipeline, the water outlet pipeline, the air inlet pipeline and the inlet pipeline are all arranged inside the cooling device; the water inlet pipeline comprises a straight pipeline and a bent pipeline, and the straight pipeline leads water flow to the bottom of the cavity interlayer on the opposite surface of the water inlet pipeline through the bent pipeline; the inlet of the water outlet pipeline is communicated with the cavity interlayer; an air inlet pipeline arranged on the cooling device extends into the inner cavity of the dust removal device through a pipeline; the inlet line extends into the inner cavity of the dust removal device through a pipeline and is used for accommodating various wire harnesses of the cooling device; the cooling device further comprises a protection tray and an asbestos pad, wherein the asbestos pad is filled between the upper sealing cover and the double-layer shell and used for buffering the pressure between the upper sealing cover and the double-layer shell and playing a role in heat insulation; the protective tray is in a surrounding shape and is coated on the lower part of the cooling device;
the high-frequency circuit comprises a digital-to-analog converter, a voltage-controlled oscillator, a power divider, a transmitting amplifier, a receiving amplifier, a mixer, a filter, a signal amplifier and an analog-to-digital converter, the digital-to-analog converter is connected with the input end of the power divider through the voltage-controlled oscillator, the output end of the power divider is respectively connected with the input ends of the transmitting amplifier and the mixer, the receiving amplifier is connected with the input end of the mixer, and the output end of the mixer is connected with the main control circuit through the filter, the signal amplifier and the analog-to-digital converter in sequence; the digital-to-analog converter controls the voltage-controlled oscillator to generate a high-frequency signal, the high-frequency signal feeds a part of the high-frequency signal to the antenna after being amplified by the transmitting amplifier through the power divider, the other part of the high-frequency signal is coupled to the frequency mixer and mixed with the signal amplified by the receiving amplifier, a baseband difference frequency signal is obtained after filtering of the frequency mixer, and the baseband difference frequency signal is transmitted to the main control circuit for processing after being converted by the signal amplifier and the analog-to-digital converter; controlling the digital-to-analog converter to send a high-frequency signal through the main control MCU;
the liquid level monitoring device for the foundry ladle further comprises a touch display screen, and the touch display screen is arranged above the radar level gauge.
2. The apparatus according to claim 1, wherein the cooling device is formed by metal processing to form a cavity sandwich, the cavity sandwich is filled with circulating water to achieve the purpose of heat insulation and cooling, and the incoming water flow is guided to the bottom of the cavity sandwich at the opposite surface of the water inlet pipeline by the water inlet pipeline, the straight pipeline and the bent pipeline and then flows out through the water outlet pipeline.
3. The apparatus of claim 1, wherein the digital-to-analog converter, the voltage controlled oscillator, the power divider, the transmitter amplifier, the receiver amplifier, the mixer, the filter, the signal amplifier, and the analog-to-digital converter are fabricated on a CMOS millimeter wave RF chip.
4. A liquid level monitoring system for a ladle, characterized in that it comprises a PLC, a display screen, an audible and visual alarm and the liquid level monitoring device for a ladle as claimed in any one of claims 1 to 3, the liquid level monitoring device being connected to an input of the PLC, an output of the PLC being electrically connected to the display screen and the audible and visual alarm, respectively.
5. The liquid level monitoring system for the ladle according to claim 4, further comprising a pressure transmitter and a temperature sensor, the pressure transmitter and the temperature sensor being electrically connected to the PLC, respectively.
6. The liquid level monitoring system for the ladle according to claim 4, further comprising a protective cover disposed over the ladle, the liquid level monitoring device being fixedly mounted on the protective cover.
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| CN117451133B (en) * | 2023-12-26 | 2024-04-02 | 苏州市瑞思特智能制造有限公司 | Intelligent and safe production monitoring system and method for liquid level of hot-metal ladle |
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Denomination of invention: A liquid level monitoring device and system for molten iron ladle Effective date of registration: 20231127 Granted publication date: 20220902 Pledgee: Industrial and Commercial Bank of China Limited Tangshan Fengnan Branch Pledgor: HEBEI HUACHUANG MEASUREMENT AND CONTROL TECHNOLOGY Co.,Ltd. Registration number: Y2023980067677 |
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