Square billet continuous casting machine on-line arc alignment detection and adjustment method based on potentiometer feedback

Abstract

A square billet continuous casting machine on-line arc alignment detection and adjustment method based on potentiometer feedback relates to the technical field of square billet continuous casting machines, and comprises the following steps: acquiring displacement data of a support roller of a square billet continuous casting machine, and collecting the displacement data in real time through a displacement monitoring device; according to the displacement data and the environment data, the displacement deviation of the supporting roller is calculated, and the displacement deviation is used for judging whether the radian of the continuous casting machine is abnormal or not; if the displacement deviation exceeds a preset threshold value, an alarm signal is triggered, and the alarm signal is used for prompting radian abnormity; and according to the displacement deviation, the position of the supporting roller is automatically adjusted through an adjusting device till the displacement deviation meets the preset standard. The radian control precision is remarkably improved, the casting blank quality and the equipment utilization rate are improved, the waste rate is reduced, the radian problem of the continuous casting machine can be monitored on line, and the field working efficiency is greatly improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of square billet continuous casting machine online arc detection and adjustment, and particularly relates to a square billet continuous casting machine online arc detection and adjustment method based on potentiometer feedback. BACKGROUND

[0002] The square billet continuous casting machine is mostly an arc continuous casting machine. In the production process, due to equipment wear, deformation, sinking and other reasons, the arc deviation will occur, so that the quality of the produced casting billet fluctuates.

[0003] At present, there are many arc adjustment technologies to ensure the accuracy of the arc of the continuous casting machine. One is to rely on offline arc sample plates and other equipment, and to use the arc sample plate to adjust the arc while stopping the machine, for example, the Chinese utility model patent with the announcement number CN 203928930 U discloses an arc sample plate with a micrometer, which mainly uses the arc sample plate with good arc as a standard arc line to adjust the supporting roller and other equipment with arc deviation. The second is the Chinese invention patent with the announcement number CN 103286284 B, which discloses a large square billet continuous casting machine and its online fast overall arc adjustment method. The large square billet continuous casting machine includes a crystallizer, a fan-shaped section, a two-cooling second section, a two-cooling chamber cross beam, an arc sample plate, a vibration table, a vibration table support beam, the lower end of the crystallizer, the fan-shaped section and the two-cooling second section are arranged in an arc shape, the arc sample plate is located on the upper side of the fan-shaped section and the two-cooling second section, the vibration table is located on the vibration table support beam, and the two-cooling chamber cross beam is located on the front side of the vibration table. In addition, it also includes a support seat arranged on the lower side of the two-cooling chamber cross beam, and a jack arranged horizontally and at the bottom of the support seat, with the free end pointing to the front side of the vibration table. The invention can realize fine adjustment, and the arc adjustment operation is simple, fast, small in error, safe and essential, and can effectively prevent the harm caused by the misoperation of the lifting of the crystallizer and the fan-shaped section. However, the main method is still to use the arc sample plate to adjust the arc while stopping the machine. The use of the arc sample plate mainly has a lag in finding the arc deviation, and it takes a long time to adjust the arc, needs to be lifted by the crane, is installed segmentally, the arc is measured, and then the deviated equipment is adjusted.

[0004] Traditional arc detection and adjustment methods have significant shortcomings in actual production, and are difficult to meet the needs of modern industry for high precision and high efficiency. Existing detection methods mainly rely on manual measurement or simple mechanical devices, and generally have low precision and slow response. For example, traditional detection usually compares the arc with an arc template after regular shutdown, which not only consumes time, but also causes equipment utilization to decrease due to shutdown. In addition, the process of manually adjusting the position of the support roller relies on the experience of the operator, and the consistency of the adjustment results is difficult to guarantee. In the high-temperature and high-dust continuous casting environment, the measurement equipment is easily disturbed, resulting in unreliable data. These limitations result in large fluctuations in the quality of the cast slab during production and a high scrap rate. The core technical difficulty lies in how to obtain the small displacement data of the support roller in real time in the high-temperature and high-interference continuous casting environment and convert it into a reliable control signal. Accurate measurement of small displacement is the basis of arc control, but high temperature can cause sensor signal drift, and dust and vibration can further reduce measurement accuracy. For example, in actual production, the support roller undergoes micron-level displacement changes due to thermal expansion or mechanical wear. If these changes cannot be accurately captured, the arc deviation will gradually accumulate, resulting in surface defects or internal cracks of the cast slab. The instability of signal acquisition and conversion directly affects the real-time and accuracy of arc adjustment.

[0005] Therefore, how to realize real-time high-precision measurement of small displacement in a complex environment and ensure the stability of the signal under high-temperature interference has become a key problem in arc control of the continuous casting machine. SUMMARY

[0006] The technical problem solved by the present application is that the traditional square billet continuous casting machine arc detection has low precision, manual adjustment has low efficiency, and needs to be stopped for arc comparison. The present application provides a square billet continuous casting machine online arc detection and adjustment method based on potentiometer feedback.

[0007] Technical scheme: A square billet continuous casting machine online arc detection and adjustment method based on potentiometer feedback, specifically comprising the following steps: Step S1, acquiring displacement data of the support roller of the square billet continuous casting machine, the displacement data being collected in real time by a displacement monitoring device; Step S2, calculating the displacement deviation of the support roller according to the displacement data and environmental data, the displacement deviation being used to judge whether the arc of the continuous casting machine is abnormal; Step S3, if the displacement deviation exceeds a preset threshold, an alarm signal is triggered, the alarm signal being used to prompt the arc abnormality; Step S4, automatically adjusting the position of the support roller by an adjustment device according to the displacement deviation until the displacement deviation meets a preset standard.

[0008] As a preferred, in step S1, acquiring the displacement data of the support roller of the square billet continuous casting machine specifically comprises the following steps: Step S11, the micro displacement of the supporting roller is amplified by an amplification lever connected with the supporting roller; Step S12, the amplified displacement is transmitted to a special potentiometer which converts the displacement into a voltage signal; Step S13, the voltage signal is acquired by a receiver, which represents the displacement data of the supporting roller; Step S14, the voltage signal is compared with a preset reference value to determine the displacement data.

[0009] As preferred, in step S2, the displacement deviation of the supporting roller is calculated according to the displacement data and environmental data, which specifically includes the following steps: Step S21, environmental data collected by a temperature sensor is acquired, which includes the temperature value of the working environment of the continuous casting machine; Step S22, the displacement deviation value is calculated by a preset algorithm according to the displacement data and the temperature value; Step S23, the displacement deviation value is compared with a preset threshold to determine whether the camber is abnormal; Step S24, if the displacement deviation value exceeds the preset threshold, an alarm trigger signal is generated.

[0010] As preferred, in step S3, the alarm signal is triggered, which specifically includes the following steps: Step S31, an alarm signal is generated by a receiver, which includes the displacement deviation value and abnormal position information; Step S32, the alarm signal is transmitted to a control terminal which displays the camber abnormality information; Step S33, according to the alarm signal, the time of abnormality occurrence and the identification of the supporting roller are recorded; Step S34, an adjustment instruction is sent to a multi-axis mechanical motion platform through the control terminal.

[0011] As preferred, in step S4, the position of the supporting roller is automatically adjusted by an adjustment device, which specifically includes the following steps: Step S41, an adjustment instruction is received by a multi-axis mechanical motion platform, which includes the displacement deviation value and the target adjustment amount; Step S42, according to the adjustment instruction, the multi-axis mechanical motion platform moves the supporting roller in multi-axis direction; Step S43, the adjusted displacement data is monitored in real time to determine the new displacement deviation value; Step S44, if the new displacement deviation value does not reach the preset standard, the adjustment is repeated until the preset standard is met.

[0012] As preferred, in step S11, the tiny displacement of the support roller is amplified by the amplification lever, specifically comprising the following steps: Step S111, fix the amplification lever to the moving part of the support roller, and the amplification multiple of the amplification lever is a preset value; Step S112, connect the output end of the amplification lever with a special potentiometer through mechanical connection; Step S113, when the support roller is displaced, the displacement is amplified to a measurable range by the amplification lever; Step S114, record the amplified displacement in real time by the special potentiometer, and generate a corresponding voltage signal.

[0013] As preferred, in step S22, according to the displacement data and the temperature value, the displacement deviation value is calculated by a preset algorithm, specifically comprising the following steps: Step S221, input the displacement data and the temperature value into a preset algorithm model, and the preset algorithm model includes a temperature compensation function; Step S222, correct the interference of the high-temperature environment on the displacement data by the temperature compensation function; Step S223, calculate the actual displacement deviation value of the support roller according to the corrected displacement data; Step S224, determine the degree of camber deviation of the continuous casting machine by comparing the actual displacement deviation value with a standard camber value; Step S225, store the camber deviation degree to a receiver for subsequent adjustment reference.

[0014] Beneficial effects: the present application collects the displacement data of the support roller in real time, converts the tiny displacement into a high-precision electric signal by the amplification lever and the special potentiometer, corrects the interference of the high-temperature environment by the temperature compensation algorithm, and accurately calculates the camber deviation. When the deviation exceeds the standard, the present application automatically triggers an alarm and accurately adjusts the position of the support roller through the multi-axis mechanical motion platform, realizes closed-loop control, completes the adjustment without stopping, realizes online monitoring, and solves the camber problem of the continuous casting machine. The present application significantly improves the camber control precision, improves the quality of the cast slab by more than 60%, increases the equipment utilization rate from 85% to 95%, reduces the energy consumption per unit product by 8%, and reduces the waste rate by 15%. BRIEF DESCRIPTION OF DRAWINGS

[0015] Figure 1 A flowchart of a square billet continuous casting machine online camber detection and adjustment method based on potentiometer feedback. DETAILED DESCRIPTION

[0016] In order for those skilled in the art to better understand the technical solutions in the specification, the technical solutions in the specification will be clearly and completely described below in combination with the drawings in the specification. Obviously, the described embodiments are only part of the embodiments of the specification, not all. Based on the embodiments in the specification, all other embodiments obtained by those of ordinary skill in the art without creative labor should belong to the protection scope of the specification.

[0017] As shown in the figure, the present application is a square billet continuous casting machine on-line arc detection and adjustment method based on potentiometer feedback, specifically contains as follows: Figure 1 Step S1, obtaining the displacement data of the support roller of the square billet continuous casting machine, the displacement data is collected in real time by the displacement monitoring device.

[0018] In the square billet continuous casting production process, the position accuracy of the support roller directly affects the forming quality and internal organization uniformity of the cast blank. The displacement monitoring device, as the core component of the whole detection system, needs to have the characteristics of high precision and high stability. The device is mainly composed of a mechanical amplification mechanism, a potentiometer conversion unit and a signal processing module, which can convert the small displacement change of the support roller into a measurable electrical signal.

[0019] Specifically as follows:

[0020] Step S11, amplifying the small displacement of the support roller through an amplification lever, the amplification lever is connected with the support roller.

[0021] The amplification lever, as the core component of the mechanical amplification mechanism, adopts the principle of precise lever to amplify the small displacement of the support roller. In one embodiment, the amplification lever adopts a double-arm unequal length design, the short arm is rigidly connected with the moving part of the support roller, and the long arm is connected with the sliding contact of the special potentiometer. When the support roller displaces, the short arm drives the long arm to produce a larger displacement, realizing the mechanical amplification function. The material selection of the amplification lever needs to consider the thermal stability and mechanical strength in high temperature environment, usually made of heat-resistant alloy steel, and the surface is specially treated to improve the wear resistance and corrosion resistance.

[0022] Step S111, fixing the amplification lever to the moving part of the support roller, the amplification multiple of the amplification lever is a preset value.

[0023] ​The fixing method of the amplification lever directly affects the measurement accuracy and system stability. In specific implementation, the amplification lever is connected with the moving part of the supporting roller through a high-strength bolt set, and a spherical bearing structure is adopted at the connection point to reduce friction resistance and mechanical clearance. The setting of the amplification multiple needs to comprehensively consider the measurement accuracy requirement and the measurement range of the potentiometer, and is usually set to between 10 times and 50 times. For example, when the supporting roller has a displacement of 0.1 millimeter, after 20 times amplification, the displacement at the potentiometer end reaches 2 millimeters, and such displacement can be accurately detected by the potentiometer and converted into a corresponding voltage signal.

[0024] In step S112, the output end of the amplification lever is connected with a special potentiometer through mechanical connection.

[0025] The mechanical connection part adopts a precise transmission mechanism to ensure that the output displacement of the amplification lever can be accurately transmitted to the special potentiometer. The connection mechanism includes a connecting rod, a guide sleeve and an elastic compensation device. The connecting rod is made of high-strength lightweight material and has good rigidity and thermal stability. The guide sleeve ensures that the connecting rod maintains linear motion during movement, avoiding the influence of lateral deviation on measurement accuracy. The elastic compensation device is used to absorb mechanical vibration and impact in the system and protect the potentiometer from external interference.

[0026] In step S113, when the supporting roller has displacement, the displacement is amplified to a measurable range by the amplification lever.

[0027] When the continuous casting machine is subjected to various external forces during production, the supporting roller will have slight displacement changes. These displacement changes are usually in the range of tens of micrometers to several millimeters, and direct measurement is difficult. Through the mechanical amplification of the amplification lever, the originally slight displacement is amplified to the effective measurement range of the potentiometer. In one embodiment, when the supporting roller has an upward displacement of 0.05 millimeters, after 30 times amplification, the displacement at the potentiometer end reaches 1.5 millimeters, which is completely within the linear measurement range of the potentiometer and can obtain accurate measurement results.

[0028] In step S114, the amplified displacement is recorded in real time by the special potentiometer to generate a corresponding voltage signal.

[0029] The special potentiometer is a precision measuring device specially designed for high-temperature and high-vibration environments, and has excellent linearity and stability. The resistance wire inside the potentiometer is made of noble metal alloy, which has good electrical conductivity and corrosion resistance. The sliding contact adopts a multi-point contact design to ensure the stability of the contact resistance. When the sliding contact is moved by the amplification lever, the voltage signal output by the potentiometer has a strict linear relationship with the displacement. In one embodiment, the measurement range of the potentiometer is 0 to 10 millimeters, the corresponding output voltage range is 0 to 10 volts, and the linearity is better than 0.1%, which can meet the requirements of high-precision measurement.

[0030] Step S12, the amplified displacement is transmitted to a special potentiometer, which converts the displacement into a voltage signal.

[0031] The conversion process of displacement to voltage is a key link in the whole measurement system. The special potentiometer works on the principle of voltage division. When the sliding contact moves on the resistance wire, the output voltage is proportional to the contact position. In order to improve the conversion accuracy, the potentiometer is internally provided with a temperature compensation circuit, which can automatically correct the influence of temperature change on resistance value. In high temperature environment, the resistance value of the resistance wire will change. The temperature compensation circuit detects the environmental temperature through the built-in temperature sensor and corrects the output voltage according to the preset temperature coefficient.

[0032] Step S13, the voltage signal is obtained by the receiver, which represents the displacement data of the support roller.

[0033] As the core equipment of signal acquisition and processing, the receiver has high-precision analog-to-digital conversion function and powerful signal processing capability. The receiver is internally integrated with low-noise amplifier, anti-interference filter and high-resolution analog-to-digital converter. The low-noise amplifier amplifies the weak voltage signal output by the potentiometer, improving the signal-to-noise ratio. The anti-interference filter filters out electromagnetic interference and high-frequency noise in the industrial environment, ensuring the purity of the signal. The analog-to-digital converter converts the analog voltage signal into digital signal, with conversion accuracy reaching 16 bits, which can distinguish small voltage changes.

[0034] In one embodiment, the receiver adopts multi-channel parallel acquisition mode, which can simultaneously monitor the displacement data of multiple support rollers. Each channel is equipped with independent signal conditioning circuit, including programmable gain amplifier and programmable filter. The programmable gain amplifier can automatically adjust the amplification factor according to the signal intensity of different measurement points, ensuring that the output signal is within the optimal dynamic range. The cutoff frequency of the programmable filter can be adjusted according to the interference characteristics of the field environment, effectively suppressing interference signals of specific frequency.

[0035] Step S14, the voltage signal is compared with the preset reference value to determine the displacement data.

[0036] The preset reference value is a standard reference value determined according to the design parameters and process requirements of the continuous casting machine, representing the voltage signal corresponding to the position of the support roller in the ideal state. The setting of the reference value needs to consider the mechanical structure, process parameters and product quality requirements of the continuous casting machine. In the system initialization stage, the support roller is calibrated by precise measurement tools to establish the correspondence between displacement and voltage signal, and the voltage value corresponding to the standard position is set as the reference value.

[0037] The comparison process adopts digital signal processing technology to determine the actual displacement data through high-precision numerical operation. The receiver compares the collected voltage signal with the reference value stored in the memory, calculates the voltage difference value, and then converts the voltage difference value into actual displacement data according to the pre-calibrated conversion coefficient. In order to improve the measurement accuracy, the comparison process also includes multiple sampling averaging, outlier rejection and digital filtering and other processing steps.

[0038] In step S2, a displacement deviation of the support roller is calculated according to the displacement data and the environmental data, and the displacement deviation is used to determine whether the arc of the continuous casting machine is abnormal.

[0039] The calculation of the displacement deviation is the core algorithm of the entire detection system, and the influence of the displacement data and the environmental factors needs to be considered comprehensively. In the continuous casting production process, the high-temperature environment will cause the equipment to expand, which will affect the accuracy of displacement measurement. Therefore, environmental data must be introduced for compensation and correction to obtain the true displacement deviation value.

[0040] Specifically as follows:

[0041] In step S21, environmental data collected by a temperature sensor is obtained, and the environmental data includes a temperature value of a working environment of the continuous casting machine.

[0042] The temperature sensor adopts a high-precision thermal resistance or thermocouple device, which can work stably in a high-temperature environment. The sensor is installed at key positions of the continuous casting machine, including the vicinity of the support roller, the rack structure and the cooling system and other areas. In one embodiment, the system is configured with multiple temperature measurement points to form a temperature monitoring network, which can comprehensively reflect the temperature distribution of the continuous casting machine.

[0043] The selection of the temperature sensor needs to consider the measurement range, accuracy requirement and environmental adaptability. For the continuous casting machine application, the working temperature range is usually between 0 and 200 degrees Celsius, and the measurement accuracy requirement is 0.1 degrees Celsius. The sensor shell is made of stainless steel material, which has good corrosion resistance and mechanical strength. The sensor is filled with inert gas to prevent oxidation and corrosion.

[0044] In step S22, a displacement deviation value is calculated according to the displacement data and the temperature value through a preset algorithm.

[0045] The preset algorithm is a mathematical model established based on the principles of thermodynamics and mechanical structure analysis, which can accurately calculate the influence of temperature on displacement measurement. The algorithm considers the thermal expansion coefficient of the material, the geometric parameters of the structure and the temperature distribution characteristics. In specific implementation, the algorithm first calculates the thermal expansion amount of each component according to the measured temperature value, and then subtracts the influence of thermal expansion on displacement measurement from the original displacement data to obtain the corrected displacement data.

[0046] Step S221, input the displacement data and temperature value into a preset algorithm model, wherein the preset algorithm model comprises a temperature compensation function.

[0047] The temperature compensation function is a mathematical relationship established according to the specific structure of the continuous casting machine and the material properties. The function considers the thermal expansion characteristics of key components such as the supporting roller, the frame, the amplification lever, and the influence of temperature change on the performance of the potentiometer. In one embodiment, the temperature compensation function adopts a polynomial form, including linear terms, quadratic terms and cross terms, which can accurately describe the complex relationship between temperature and displacement measurement error.

[0048] The algorithm model also includes the consideration of dynamic response characteristics, because the temperature change has a certain hysteresis, and the temperature response speed of each part of the device is different. The model can predict the dynamic influence of temperature change on displacement measurement by introducing time constant and transfer function, and improve the accuracy of compensation.

[0049] Step S222, correct the interference of high temperature environment on displacement data through the temperature compensation function.

[0050] The correction process adopts real-time calculation method, and calculates the temperature compensation amount according to the current temperature measurement value and historical temperature data. The calculation of compensation amount considers both instantaneous temperature influence and cumulative temperature influence. The instantaneous temperature influence is mainly the influence of current temperature on the size of each part of the measurement system, which is calculated by linear thermal expansion formula. The cumulative temperature influence considers the influence of long-term temperature change on the performance of the device, including material aging, mechanical looseness and other factors.

[0051] In one embodiment, when the environmental temperature rises from 20 degrees Celsius to 150 degrees Celsius, the thermal expansion of the supporting roller and the related mechanical structure will cause a system error of about 2 millimeters in displacement measurement. Through the correction of the temperature compensation function, this error can be reduced to within 0.05 millimeters, greatly improving the measurement accuracy.

[0052] Step S223, calculate the actual displacement deviation value of the supporting roller according to the corrected displacement data.

[0053] The calculation of actual displacement deviation value needs to compare the corrected displacement data with the theoretical design value. The theoretical design value is the ideal position of the supporting roller determined according to the process requirements and product quality standards of the continuous casting machine. The calculation process includes coordinate transformation, geometric correction and statistical analysis, etc. Coordinate transformation unifies the displacement data of each measurement point to the same coordinate system, which is convenient for overall analysis. Geometric correction considers the geometric relationship of the continuous casting machine structure, and converts local displacement data into overall arc deviation.

[0054] Step S224, determine the arc deviation degree of the continuous casting machine by comparing the actual displacement deviation value with the standard arc value.

[0055] The standard camber value is a camber control index formulated according to the requirements of the continuous casting process and the product quality standards, and is usually expressed in the form of camber radius or camber deviation. The comparison process adopts a multi-level judgment mechanism to divide the camber deviation degree into four levels: normal, slight deviation, moderate deviation, and severe deviation. Each level corresponds to different processing strategies and response measures.

[0056] In one embodiment, when the camber deviation is less than 0.5 mm, it is determined to be a normal state, the deviation is between 0.5 and 1.0 mm for slight deviation, the deviation is between 1.0 and 2.0 mm for moderate deviation, and the deviation is more than 2.0 mm for severe deviation. Different deviation levels correspond to different alarm levels and adjustment strategies to ensure that the system can respond to various abnormal situations in a timely manner.

[0057] Step S225, store the camber deviation degree to the receiver for subsequent adjustment reference.

[0058] The storage function adopts a high-reliability data storage scheme, including two levels of real-time data caching and historical data archiving. The real-time data cache stores measurement data and analysis results in the recent period of time for real-time monitoring and rapid response. The historical data archive saves long-term operation data in a large-capacity storage device for trend analysis and equipment maintenance.

[0059] The data storage format includes time stamp, measurement value, deviation value, temperature data, and device status information, forming a complete data record. The storage system also has data backup and recovery functions to ensure the security of important data. In one embodiment, the system adopts a dual-machine hot backup scheme, the main device and the standby device run simultaneously, when the main device fails, the standby device can seamlessly take over to ensure the continuous operation of the system.

[0060] Step S23, compare the displacement deviation value with the preset threshold value to determine whether the camber is abnormal.

[0061] The determination of the preset threshold value needs to consider factors such as product quality requirements, equipment precision, and process stability. The threshold value setting adopts a multi-level structure, including a pre-warning threshold value, an alarm threshold value, and an emergency shutdown threshold value. The pre-warning threshold value is used to discover potential problems early, the alarm threshold value is used to handle abnormal situations in a timely manner, and the emergency shutdown threshold value is used to prevent the occurrence of serious accidents.

[0062] The comparison process adopts an intelligent judgment algorithm, which not only considers the current deviation value, but also analyzes the trend and duration of the deviation. When the deviation value approaches the threshold value, the system will increase the monitoring frequency to improve the accuracy of the judgment. In one embodiment, the system uses a sliding window average algorithm to statistically analyze the continuous measurement results, avoiding misjudgment caused by transient interference.

[0063] Step S24, if the displacement deviation value exceeds the preset threshold, an alarm trigger signal is generated.

[0064] The generation of the alarm trigger signal adopts a multiple confirmation mechanism to ensure the accuracy and reliability of the alarm. When the deviation value is detected to exceed the threshold, the system first performs a secondary confirmation measurement to exclude the possibility of measurement error. After confirmation, the system generates an alarm signal of the corresponding level according to the deviation degree. The alarm signal includes detailed information such as alarm type, deviation value, occurrence time, device location, etc.

[0065] In one embodiment, the alarm trigger signal adopts a digital encoding method, and different encodings correspond to different alarm types and processing priorities. The system also has an alarm escalation function. When a low-level alarm is not handled in time, it will be automatically upgraded to a high-level alarm, ensuring that abnormal situations are promptly noticed and handled.

[0066] Step S3, if the displacement deviation exceeds the preset threshold, an alarm signal is triggered, which is used to prompt the radian anomaly.

[0067] The alarm system is an important part of the entire detection and adjustment system, responsible for timely informing the operating personnel and the control system of the detected abnormal situations. The alarm system adopts multiple alarm methods, including audible and visual alarms, display screen prompts, and network communication, to ensure that the alarm information can be timely conveyed to the relevant personnel.

[0068] Specifically as follows:

[0069] Step S31, an alarm signal is generated through the receiver, which includes the displacement deviation value and the abnormal position information.

[0070] The alarm generation module built-in the receiver can automatically generate standardized alarm signals according to the detection results. The alarm signal adopts a structured data format, containing key information such as alarm time, device number, abnormal type, deviation value, and position coordinates. The signal generation process also includes data verification and integrity check to ensure the accuracy and integrity of the alarm information.

[0071] The abnormal position information is determined by the coordinate positioning system, which can accurately indicate the position of the support roller where the anomaly occurs. In one embodiment, each support roller of the continuous casting machine is assigned a unique position code, including horizontal position, vertical position, and height information. When an anomaly is detected, the system can quickly locate the specific support roller, providing accurate position reference for subsequent adjustment operations.

[0072] Step S32, the alarm signal is transmitted to the control terminal, and the control terminal displays the radian anomaly information.

[0073] The control terminal, as the main interface for human-computer interaction, adopts a high-resolution display screen and an intuitive graphical interface design. The terminal can display the running state of the continuous casting machine, the displacement data of each supporting roller, and alarm information in real time. The display interface is designed in layers, with the main interface displaying an overall status overview and the detailed interface displaying specific data and analysis results.

[0074] The display of alarm information uses eye-catching colors and icons to ensure that operating personnel can quickly identify abnormal conditions. In one embodiment, normal status is displayed in green, minor abnormalities are displayed in yellow, and serious abnormalities are displayed in red with a flashing prompt. The control terminal also has a historical alarm query function, and operating personnel can view past alarm records and handling situations.

[0075] Step S33, according to the alarm signal, record the time of abnormal occurrence and the identification of the supporting roller.

[0076] The abnormality recording function uses an automated data recording method to ensure that all abnormal events can be recorded completely. The recorded content includes the exact time of abnormal occurrence, the device identification involved, the abnormal type, the deviation value, and detailed information such as environmental conditions. The recorded data is stored in a standardized format, facilitating subsequent statistical analysis and fault diagnosis.

[0077] The supporting roller identification system uses a hierarchical coding method to uniquely identify each supporting roller in the continuous casting machine. The identification includes machine group number, segment number, roller number, and other multi-level information, forming a complete device genealogy. In one embodiment, the identification format is "machine group number-segment number-roller number", such as "CC1-S3-R15" representing the 15th supporting roller of the 3rd segment of the 1st continuous casting machine.

[0078] Step S34, send adjustment instructions to the multi-axis mechanical motion platform through the control terminal.

[0079] The generation of adjustment instructions is based on the abnormality detection results and the preset adjustment strategy, which can automatically calculate the required adjustment amount and adjustment direction. The instruction generation process takes into account the current deviation value, target position, adjustment accuracy, and safety limits. The instruction is transmitted using a standardized communication protocol to ensure reliable communication between the control terminal and the multi-axis mechanical motion platform.

[0080] Step S4, according to the displacement deviation, automatically adjust the position of the supporting roller through the adjustment device until the displacement deviation meets the preset standard.

[0081] The automatic adjustment system is the execution terminal of the entire detection and adjustment method, responsible for accurately adjusting the position of the support roller according to the detection result. The system adopts a closed-loop control strategy and can realize high-precision position adjustment and real-time feedback control. The adjustment device is mainly composed of a multi-axis mechanical motion platform, a servo drive system, a position feedback system, and a safety protection system, and has multi-degree-of-freedom adjustment capability and high-precision positioning function.

[0082] The specific implementation is as follows:

[0083] In step S41, the multi-axis mechanical motion platform receives an adjustment instruction, and the adjustment instruction includes a displacement deviation value and a target adjustment amount.

[0084] The multi-axis mechanical motion platform is a precision mechanical device specially designed for the adjustment of the continuous casting machine support roller, and has three-axis or multi-axis motion capability. The platform adopts modular design, and each axis direction is equipped with an independent drive system and control unit. In one embodiment, the platform has three basic degrees of freedom of X-axis horizontal movement, Y-axis vertical movement, and Z-axis longitudinal movement, and the adjustment accuracy of each axis direction reaches 0.01 millimeters. The platform can also add a rotating shaft as needed to realize the angle adjustment function of the support roller.

[0085] The receiving of the adjustment instruction adopts a high-speed digital communication interface, supports real-time data transmission and bidirectional communication. The instruction analysis module can convert the received adjustment instruction into specific motion parameters of each axis direction, including target position, motion speed, acceleration, and motion trajectory, etc. Before the execution of the instruction, the system will perform safety check to ensure that the adjustment operation will not exceed the safe working range of the device.

[0086] The calculation of the target adjustment amount is based on the displacement deviation value and the preset adjustment algorithm. The algorithm considers factors such as the current position of the support roller, the target position, the adjustment accuracy requirement, and the dynamic response characteristics. In one embodiment, when the support roller is detected to be offset upward by 1.5 millimeters, the system calculates that the adjustment amount needs to be adjusted downward by 1.5 millimeters, while considering the elastic deformation and dynamic overshoot that may be generated during the adjustment process, and the actual adjustment amount may be slightly larger than the theoretical calculation value.

[0087] In step S42, the multi-axis mechanical motion platform is controlled to move the support roller in multiple-axis directions according to the adjustment instruction.

[0088] The multi-axis motion control adopts advanced numerical control technology and can realize multi-axis coordinated motion and precise position control. The control system adopts a distributed architecture, and each axis direction is equipped with an independent servo controller, which is unified and coordinated by the main controller. The servo controller adopts a high-performance digital signal processor and has fast response and high-precision control capability.

[0089] The motion control process is divided into two stages: coarse adjustment and fine adjustment. In the coarse adjustment stage, a higher motion speed is adopted to quickly approach the target position, improving the adjustment efficiency. When approaching the target position, the system automatically switches to the fine adjustment mode, adopting a lower motion speed and higher control accuracy to ensure the accuracy of the final position. In one embodiment, the motion speed in the coarse adjustment stage is 10 mm per minute, and the motion speed in the fine adjustment stage is reduced to 1 mm per minute.

[0090] Multi-axis coordinated motion uses interpolation algorithms to ensure that the motion in each axis remains synchronized and coordinated. When multiple directions need to be adjusted simultaneously, the system can calculate the optimal motion trajectory to avoid interference between axes. The interpolation algorithm also considers the dynamic characteristics of the mechanical structure, improving the smoothness and accuracy of the motion through a combination of feedforward control and feedback control.

[0091] Step S43, real-time monitoring of the adjusted displacement data to determine the new displacement deviation value.

[0092] Real-time monitoring during adjustment uses the same measurement system as the initial detection, ensuring consistency and comparability of measurement results. The monitoring frequency is set according to the adjustment speed and accuracy requirements, usually ranging from 10 to 100 times per second. High-frequency monitoring can quickly detect abnormal conditions during adjustment, avoiding over-adjustment or under-adjustment.

[0093] The calculation of the new displacement deviation value uses the same algorithm and compensation method as step S2, ensuring the accuracy of the results. The calculation process also considers the impact of adjustment operations on the measurement system, including mechanical vibration, temperature change, and electromagnetic interference. In one embodiment, the system waits for a certain stabilization time after adjustment, usually 10 to 30 seconds, before measuring displacement, ensuring that the measurement results reflect the stable state after adjustment.

[0094] The real-time monitoring system also has trend analysis capabilities, which can predict adjustment effects and remaining deviations. By analyzing the trend of displacement data during adjustment, the system can determine whether further adjustment is needed in advance, improving adjustment efficiency and accuracy. Trend analysis uses digital filtering and curve fitting techniques to extract useful trend information from noisy measurement data.

[0095] Step S44, if the new displacement deviation value does not meet the preset standard, repeat the adjustment until it meets the preset standard.

[0096] Repeated adjustment uses an iterative control strategy, with each adjustment based on the latest measurement results and deviation analysis. The iterative process includes four steps: deviation evaluation, adjustment amount calculation, adjustment execution, and effect verification, forming a closed-loop control loop. The system sets a maximum iteration limit, usually 5 to 10 times, to prevent the system from falling into an infinite loop.

[0097] The adjustment accuracy is determined by multiple criteria, including absolute deviation, relative deviation, and stability index. The absolute deviation requires the adjusted displacement deviation to be less than a preset threshold, typically 0.1 to 0.5 mm. The relative deviation requires the adjustment to improve by a certain percentage, typically more than 80%. The stability index requires the adjusted displacement data to remain stable within a certain time, with a fluctuation range not exceeding the allowed value.

[0098] In one embodiment, when the initial deviation is 2.0 mm, the deviation is reduced to 0.3 mm after the first adjustment, and further reduced to 0.05 mm after the second adjustment, meeting the preset standard requirements. The entire adjustment process takes about 5 minutes, and the adjustment accuracy meets the design requirements. The system also records detailed data for each adjustment, which is used for subsequent performance analysis and optimization improvement.

[0099] The repeated adjustment process also includes learning and optimization functions. The system can analyze historical adjustment data, identify patterns and characteristics in the adjustment process, and continuously optimize adjustment algorithms and parameter settings. The learning algorithm uses machine learning techniques to automatically adjust control parameters based on different working conditions and equipment states, improving adjustment effectiveness and efficiency.

[0100] Preferably, the system also has predictive adjustment functions. By analyzing the displacement data trends and environmental conditions, the system can predict future deviations that may occur, and adjust in advance to avoid deviations exceeding the allowed range. The prediction algorithm is based on time series analysis and dynamic modeling techniques, which can accurately predict short-term displacement trends.

[0101] In one embodiment, the system detects that the ambient temperature is rising rapidly, and according to the temperature change trend and thermal expansion model, predicts that the support roller displacement will shift 0.8 mm in 30 minutes. The system initiates the adjustment program in advance to complete the position adjustment before the deviation actually occurs, maintaining the stable operation of the continuous casting machine.

[0102] Specifically, the entire adjustment process also includes safety protection measures. The system sets multiple safety limits, including software limits and hardware limits, to prevent overtravel or collision accidents during the adjustment process. Software limits are implemented through program logic, setting position limits according to the device's working range and safety requirements. Hardware limits are implemented through mechanical devices or sensors, which automatically stop movement and issue an alarm when the moving parts approach dangerous positions.

[0103] The adjustment device is also equipped with an emergency stop function, and the operator can stop the adjustment operation at any time. After emergency stop, the system will maintain the current position and record the state information at the time of stop, facilitating subsequent fault analysis and recovery operation. The system also has power failure protection function, which can safely stop the movement and keep the position locked when the power supply is interrupted.

[0104] It should be noted that the maintenance and calibration of the adjustment device is also an important part of ensuring the long-term stable operation of the system. The system is provided with a regular calibration program, which checks the precision of the displacement measurement system and the adjustment device through standard measurement tools. The calibration process includes zero point calibration, full scale calibration and linearity verification steps to ensure that the system always maintains high precision.

[0105] In an embodiment, the system is calibrated once a month and quickly calibrated once a week. The calibration results are automatically recorded in the system database to form a calibration history file. When the calibration result exceeds the allowed range, the system will automatically alarm and prompt maintenance or replacement of related parts.

[0106] Exemplarily, the whole billet continuous casting machine online arc detection and adjustment method based on potentiometer feedback has achieved remarkable results in practical application. After adopting this method, the position control precision of the support roller of a billet continuous casting machine of a certain steel enterprise has been improved by 3 times, from ±1.0 mm to ±0.3 mm. The internal quality of the cast slab has been significantly improved, and the center segregation and crack defects have been reduced by more than 60%.

[0107] This method also significantly improves production efficiency and equipment utilization. The traditional manual detection and adjustment method needs to be stopped, and each adjustment takes more than 2 hours. After adopting the online detection and automatic adjustment method, the adjustment process is completed during production, without the need to stop, greatly improving the continuous operation capacity of the equipment. Statistical data shows that the equipment utilization rate has increased from 85% to more than 95%.

[0108] In a possible implementation, the method can also be integrated with other quality control systems to form a comprehensive quality management system. Through data sharing with the temperature control system, cooling system and cutting system, more comprehensive quality control and optimization can be achieved. The integrated system can automatically adjust various parameters according to product specification requirements and process conditions to achieve optimal production effect.

[0109] The scalability of the system is also one of its important features. The basic system can monitor and adjust a single support roller, and by adding measurement points and adjustment devices, it can be extended to monitor and adjust all support rollers of the entire continuous casting machine. The extended system can realize coordinated control of the overall curvature, further improving the quality of the cast slab and the stability of production.

[0110] Specifically, the economic benefits of this method are also very significant. By improving product quality and production efficiency, reducing waste and equipment maintenance costs, system investment can be recovered within 1 to 2 years. Long-term operation can also extend the service life of equipment, reduce replacement and maintenance costs. According to the statistics of a certain enterprise, the annual cost savings after adopting this method exceed 5 million yuan.

[0111] The advanced technology of this method also lies in its intelligent degree. The system has self-learning and self-optimization capabilities, and can continuously improve control algorithms and parameter settings based on production experience and historical data. The application of artificial intelligence technology enables the system to handle complex nonlinear relationships and multivariate coupling problems, achieving more accurate control results.

[0112] In one embodiment, the system uses a neural network algorithm to establish a nonlinear mapping relationship between displacement deviation and adjustment amount. Through training with a large amount of historical data, the neural network can accurately predict the optimal adjustment strategy under different working conditions. Practical application shows that the adjustment strategy based on neural network has improved the accuracy of more than 40% compared with traditional linear control methods.

[0113] The reliability design of the system is also an important feature. Key components are configured redundantly, and when the main equipment fails, the standby equipment can automatically be put into use to ensure continuous operation of the system. The fault diagnosis system can monitor the equipment status in real time, detect potential problems in time and provide early warning.

[0114] It should be noted that this method also has a good human-computer interaction interface. The operation interface uses graphical design, and the running state and adjustment process of the continuous casting machine are displayed intuitively. The operator can set parameters and manually operate through the touch screen or keyboard. The system also provides detailed operation manuals and training programs to ensure that the operator can master the use of the system.

[0115] The environmental benefits of this method are also worth noting. By improving product quality and production efficiency, waste generation and energy consumption are reduced. Precise position control reduces equipment wear and tear and lubricating oil consumption, reducing the impact on the environment. Statistics show that after adopting this method, the energy consumption per unit of product is reduced by 8%, and the waste rate is reduced by 15%.

[0116] In one possible implementation, this method can also be combined with a remote monitoring system to realize remote monitoring and technical support. Through Internet connection, technical experts can remotely access system data for fault diagnosis and technical guidance. This mode is particularly suitable for large steel enterprises with multiple factory areas, and can realize the sharing and optimal allocation of technical resources.

[0117] The method also has high standardization, conforms to relevant international standards and industry specifications. The system design follows relevant standards of industrial automation and quality management, and has good compatibility and interoperability. Standardized interfaces and protocols enable the system to integrate with equipment from different manufacturers, reducing implementation costs and technical risks.

[0118] The above only describes the preferred embodiments of one or more embodiments of the present specification, and does not limit one or more embodiments of the present specification. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of one or more embodiments of the present specification shall be included in the protection scope of one or more embodiments of the present specification.

Claims

1. A billet continuous caster on-line arc detection and adjustment method based on potentiometer feedback, characterized in that, Specifically comprising the following steps: Step S1, obtaining displacement data of the support roller of the billet continuous casting machine, the displacement data being collected in real time by a displacement monitoring device; Step S2, calculating displacement deviation of the support roller according to the displacement data and environmental data, the displacement deviation being used to judge whether the arc of the continuous casting machine is abnormal; Step S3, if the displacement deviation exceeds a preset threshold, an alarm signal is triggered, the alarm signal being used to prompt the arc abnormality; Step S4, automatically adjusting the position of the support roller by an adjusting device according to the displacement deviation until the displacement deviation meets a preset standard.

2. A billet caster on-line arc alignment detection and adjustment method based on potentiometer feedback according to claim 1, characterized in that, In step S1, the displacement data of the support roller of the billet continuous casting machine is obtained, specifically comprising the following steps: Step S11, amplifying the micro displacement of the support roller by an amplifying lever, the amplifying lever being connected with the support roller; Step S12, transmitting the amplified displacement to a special potentiometer, the special potentiometer converting the displacement into a voltage signal; Step S13, obtaining the voltage signal by a receiver, the voltage signal representing the displacement data of the support roller; Step S14, comparing the voltage signal with a preset reference value to determine the displacement data.

3. A billet caster on-line arc alignment detection and adjustment method based on potentiometer feedback according to claim 1, characterized in that, In step S2, the displacement deviation of the support roller is calculated according to the displacement data and environmental data, specifically comprising the following steps: Step S21, obtaining environmental data collected by a temperature sensor, the environmental data including the temperature value of the working environment of the continuous casting machine; Step S22, calculating the displacement deviation value by a preset algorithm according to the displacement data and the temperature value; Step S23, comparing the displacement deviation value with a preset threshold to determine whether the arc is abnormal; Step S24, if the displacement deviation value exceeds the preset threshold, an alarm triggering signal is generated.

4. A billet caster on-line arc alignment detection and adjustment method based on potentiometer feedback according to claim 1, characterized in that, In step S3, the alarm signal is triggered, specifically comprising the following steps: Step S31, generating an alarm signal by a receiver, the alarm signal including the displacement deviation value and abnormal position information; Step S32, transmitting the alarm signal to a control terminal, the control terminal displaying the arc abnormality information; Step S33, recording the time of the abnormality occurrence and the identification of the support roller according to the alarm signal; Step S34, sending an adjusting instruction to a multi-axis mechanical motion platform through the control terminal.

5. A billet caster on-line arc alignment detection and adjustment method based on potentiometer feedback according to claim 1, characterized in that, In step S4, the position of the support roller is automatically adjusted by an adjusting device, specifically comprising the following steps: Step S41, receiving an adjusting instruction by a multi-axis mechanical motion platform, the adjusting instruction including the displacement deviation value and a target adjusting amount; Step S42, controlling the multi-axis mechanical motion platform to move the support roller in a multi-axis direction according to the adjusting instruction; Step S43, monitoring the adjusted displacement data in real time to determine a new displacement deviation value; Step S44, if the new displacement deviation value does not meet a preset standard, repeating the adjustment until the preset standard is met.

6. A billet caster on-line arc alignment detection and adjustment method based on potentiometer feedback according to claim 2, characterized in that, In step S11, the micro displacement of the support roller is amplified by an amplifying lever, specifically comprising the following steps: Step S111, fixing the amplifying lever to a moving part of the support roller, the amplification multiple of the amplifying lever being a preset value; Step S112, connecting the output end of the amplifying lever with a special potentiometer through mechanical connection; Step S113, when the support roller is displaced, the displacement is amplified to a measurable range by the amplification lever; Step S114, the amplified displacement is recorded in real time by the special potentiometer to generate a corresponding voltage signal.

7. A billet caster on-line arc alignment detection and adjustment method based on potentiometer feedback according to claim 3, characterized in that, In step S22, according to the displacement data and the temperature value, a displacement deviation value is calculated by a preset algorithm, which specifically includes the following steps: Step S221, input the displacement data and temperature value into a preset algorithm model, and the preset algorithm model includes a temperature compensation function; Step S222, correct the interference of the high-temperature environment on the displacement data by the temperature compensation function; Step S223, calculate the actual displacement deviation value of the support roller according to the corrected displacement data; Step S224, determine the degree of arc deviation of the continuous casting machine by comparing the actual displacement deviation value with a standard radian value; Step S225, store the arc deviation degree to the receiver for subsequent adjustment reference.

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