CN116559175A - 一种机清铸坯表面质量在线检测自动分级判定方法 - Google Patents
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Abstract
本发明公开了一种机清铸坯表面质量在线检测自动分级判定方法,属于板坯连续铸钢技术领域。本发明的步骤为:S1:高端DI材、汽车板、家电板用低碳/超低碳钢铸坯经过火焰清理机清理后以一定速度在输出辊道上移动;S2:安装在输出辊道上下方与左右两侧四个方向的检测装置对铸坯四个面进行连续的图像数据采集;S3:计算机自动识别统计铸坯每个面当量直径≥2mm的夹杂和气泡的数量;S4:铸坯等级取铸坯夹杂等级与铸坯气泡等级两者中最差等级,铸坯等级1‑2级可以生产高端DI材,3‑4级可以生产高端汽车板,5‑6级可以生产高端家电板。本发明依据铸坯表面质量等级可显著提高铸坯热装热送率,稳步提升高端产品质量水平。
Description
技术领域
本发明涉及板坯连续铸钢技术领域,特别涉及一种机清铸坯表面质量在线检测自动分级判定方法。
背景技术
板坯连铸过程中,铸坯表层细小的夹杂和气泡等缺陷的产生具有一定的随机性和不确定性,如果不进行铸坯精整,缺陷会遗传至最终产品,严重时导致产品降级判废,造成巨大的经济损失,严重影响产品的品牌形象。随着用户对高端汽车板、家电板、DI材用钢表面质量要求的不断提高,铸坯需进行火焰清理以去除板坯表层皮下气泡、夹渣等缺陷,稳定提高成品卷表面质量,经过火焰清理的铸坯为机清铸坯。相对于人工清理,自动火焰清理具有热量损失小、生产效率高、清理效果好、劳动强度小等优点,它有助于提升产品质量、节能环保、改善作业环境和提高作业安全性。虽然铸坯经过火焰清理后大部分缺陷得以去除,但仍然会存在少量缺陷,需要进行检查,目前一般采用人工逐块逐面检查,存在劳动强度大、效率低等缺点,如何实现机清铸坯表面质量在线自动检查分级就成为极具意义的课题。
申请号为202221024496.2的专利公开了一种铸坯表面质量在线检测及下线装置,包括依次设置在输送辊道上方的铸坯表面质量检测仪和定位仪,以及设置在输送辊道的两侧的推钢机和跺板台;所述推钢机包括推钢头、固定支架、滑道、驱动臂、底座、轴承座、液压缸;所述固定支架和底座分别固定在地面上或地面的凹坑内,滑道设置在固定支架上,推钢头滑接在滑道上,推钢头的尾部与驱动臂的一端旋接配合,驱动臂的另一端与轴承座旋接配合;液压缸的一端与底座旋接配合,另一端与驱动臂旋接配合。本方案可在铸坯热送过程中,自动识别出缺陷铸坯,并自动实现缺陷铸坯下线功能,减少了成本,大大提高板坯质量、钢板表面质量,提高产品质量。
申请号为CN201210052743.4的专利公开了一种连铸坯表面质量的在线控制系统及控制方法,包括铸坯质量判定与产品质量诊断系统服务器、高温铸坯表面缺陷在线检测系统服务器和铸坯表面质量控制系统工艺站服务器。通过铸坯表面质量缺陷在线检测系统来提供的表面质量情况反馈给铸坯表面质量控制系统在线工艺站服务器,工艺站服务器再结合铸坯质量跟踪与判定系统判定出的工艺参数的异常情况,对存在的引起质量缺陷的问题进行准确的判断,及时调整工艺和设备参数,避免对下一道轧制工序产生造成更多的废品,降低生产成本和能耗、生产效率提升。
经检索,现有技术主要针对铸坯表面质量进行检测并及时下线进行处置,同时对相关工艺参数异常信息进行报警。然而对机清铸坯而言,目前还没有对其进行在线检测并自动判定分级的相关研究。
发明内容
本发明的目的在于提供一种机清铸坯表面质量在线检测自动分级判定方法,在线对机清铸坯表面质量进行自动检查并快速进行自动分级,实现物流快速高效运转,提高产品质量与交付周期,同时大幅提高铸坯热装率。
为实现上述目的,本发明提供如下技术方案:一种机清铸坯表面质量在线检测自动分级判定方法,包括以下步骤:
S1:高端DI材、汽车板、家电板用低碳/超低碳钢铸坯经过火焰清理机清理后以一定速度在输出辊道上移动;
S2:安装在输出辊道上下方与左右两侧四个方向的检测装置对铸坯四个面进行连续的图像数据采集,并经计算处理后识别出铸坯每个面上的夹杂与气泡数量、大小和位置等信息,同时测量铸坯宽度(W)、长度(L)和厚度(T);
S3:计算机自动识别统计铸坯每个面当量直径≥2mm的夹杂和气泡的数量,并按照下列公式计算夹杂指数与气泡指数,夹杂指数(个/M2)=夹杂个数÷面积;气泡指数(个/M2)=气泡个数÷面积;每块铸坯四个面中取最大的夹杂指数与气泡指数,分别记为Iin与Iho;
S4:不同的指数对应不同的铸坯等级,不同的铸坯等级对应不同的铸坯的用途和去向,当Iin=0时,对应铸坯夹杂等级为1级(1级为最优等级),当0<Iin≤0.3、0.3<Iin≤0.8、0.8<Iin≤1.6、1.6<Iin≤3.2、Iin>3.2时,分别对应铸坯夹杂等级为2级、3级、4级、5级、6级;当Iho=0时,对应铸坯气泡等级为1级(1级为最优等级),当0<Iho≤2、2<Iho≤5、5<Iho≤15、15<Iho≤30、Iho>30时,分别对应铸坯气泡等级为2级、3级、4级、5级、6级;铸坯等级取铸坯夹杂等级与铸坯气泡等级两者中最差等级,铸坯等级1-2级可以生产高端DI材,3-4级可以生产高端汽车板,5-6级可以生产高端家电板,依据铸坯表面质量等级可显著提高铸坯热装热送率,稳步提升高端产品质量水平。
与现有技术相比,本发明的有益效果是:
本发明可高效准确对铸坯表面质量进行自动分级判定,实现物流快速高效运转,提高产品质量与交付周期,大幅提升铸坯热装热送率,同时稳步提升高端产品质量。
附图说明
图1为本发明的方法流程图。
具体实施方式
下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
实施例1
请参阅图1,本实施例将宽度为1600mm,长度为10000mm,厚度为230mm的机清铸坯经在线检测,四个面都没有当量直径≥2mm的夹杂和气泡,则此块铸坯四个面中夹杂指数Iin最大值等于0,气泡指数Iho最大值等于0,则此块铸坯等级为1级,可以直接热装轧制高端DI材,经检查产品钢卷表面质量优良,满足使用要求。
实施例2
本实施例将宽度为1200mm,长度为10000mm,厚度为230mm的机清铸坯经在线检测,其上表面、下表面、左侧面、右侧面分别存在10、12、2、1个当量直径≥2mm的夹杂,其上表面、下表面、左侧面、右侧面四个面面积分别为12M2、12M2、2.3M2、2.3M2,则四个面夹杂指数相应为0.83、1、0.87、0.43;夹杂指数Iin最大值等于1.0,其上表面、下表面、左侧面、右侧面分别存在84、60、15、10个当量直径≥2mm的气泡,则四个面气泡指数相应为7、5、6.5、4.3;气泡指数Iho最大值等于7,则此块铸坯等级为4级,可以直接热装轧制高端汽车板,经检查产品钢卷表面质量满足使用要求。
实施例3
本实施例将宽度为1800mm,长度为10000mm,厚度为230mm的机清铸坯经在线检测,其上表面、下表面、左侧面、右侧面分别存在24、30、8、6个当量直径≥2mm的夹杂,其上表面、下表面、左侧面、右侧面四个面面积分别为18M2、18M2、2.3M2、2.3M2,则四个面夹杂指数相应为1.3、1.6、3.5、2.6;夹杂指数Iin最大值等于3.5,其上表面、下表面、左侧面、右侧面分别存在100、120、65、74个当量直径≥2mm的气泡,则四个面气泡指数相应为5.5、6.6、28、32;气泡指数Iho最大值等于32,则此块铸坯等级为6级,可以直接热装轧制高端家电板,经检查产品钢卷表面质量满足使用要求。
本实施例的一种机清铸坯表面质量在线检测自动分级判定方法,可高效准确对铸坯表面质量进行自动分级判定,实现物流快速高效运转,提高产品质量与交付周期,大幅提升铸坯热装热送率,同时稳步提升高端产品质量。
以上所述,仅为本发明较佳的具体实施方式,但本发明的保护范围并不局限于此,任何熟悉本技术领域的技术人员在本发明揭露的技术范围内,根据本发明的技术方案及其发明构思加以等同替换或改变,都应涵盖在本发明的保护范围之内。
Claims (1)
1.一种机清铸坯表面质量在线检测自动分级判定方法,其特征在于,包括以下步骤:
S1:高端DI材、汽车板、家电板用低碳/超低碳钢铸坯经过火焰清理机清理后以一定速度在输出辊道上移动;
S2:安装在输出辊道上下方与左右两侧四个方向的检测装置对铸坯四个面进行连续的图像数据采集,并经计算处理后识别出铸坯每个面上的夹杂与气泡数量、大小和位置等信息,同时测量铸坯宽度(W)、长度(L)和厚度(T);
S3:计算机自动识别统计铸坯每个面当量直径≥2mm的夹杂和气泡的数量,并按照下列公式计算夹杂指数与气泡指数,夹杂指数(个/M2)=夹杂个数÷面积;气泡指数(个/M2)=气泡个数÷面积;每块铸坯四个面中取最大的夹杂指数与气泡指数,分别记为Iin与Iho;
S4:不同的指数对应不同的铸坯等级,不同的铸坯等级对应不同的铸坯的用途和去向,当Iin=0时,对应铸坯夹杂等级为1级(1级为最优等级),当0<Iin≤0.3、0.3<Iin≤0.8、0.8<Iin≤1.6、1.6<Iin≤3.2、Iin>3.2时,分别对应铸坯夹杂等级为2级、3级、4级、5级、6级;当Iho=0时,对应铸坯气泡等级为1级(1级为最优等级),当0<Iho≤2、2<Iho≤5、5<Iho≤15、15<Iho≤30、Iho>30时,分别对应铸坯气泡等级为2级、3级、4级、5级、6级;铸坯等级取铸坯夹杂等级与铸坯气泡等级两者中最差等级,铸坯等级1-2级可以生产高端DI材,3-4级可以生产高端汽车板,5-6级可以生产高端家电板,依据铸坯表面质量等级可显著提高铸坯热装热送率,稳步提升高端产品质量水平。
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