High temperature slab monitoring device in heating furnace

Abstract

This utility model discloses a high-temperature slab monitoring device in a heating furnace, comprising a mounting base, a high-temperature monitoring mechanism, an actuator, a cooling mechanism, a protection mechanism, a control box, and an industrial computer. The mounting base is fixed to the furnace wall, with its opening coaxial with the furnace wall's monitoring channel. The actuator drives the high-temperature monitoring mechanism to extend into or retract from the furnace cavity via a motor and transmission components. The high-temperature resistant camera of the high-temperature monitoring mechanism is housed within a pinhole protective probe cover. The cooling mechanism cools the probe cover via water and gas pipelines, with an air filter installed at the gas inlet. The protection mechanism monitors the status using multiple sensors, triggering automatic camera retraction in case of abnormalities. The PLC controller in the control box receives signals and instructions, controlling the actuator according to preset logic. The industrial computer receives, processes, and displays the monitoring data. This utility model solves the problem that existing high-temperature slab monitoring methods in heating furnaces cannot meet the requirements for real-time, accurate detection and data acquisition.

Description

Technical Field

[0001] This utility model relates to the technical field of stainless steel hot-rolled slab production equipment, and in particular to a high-temperature slab monitoring device in a heating furnace. Background Technology

[0002] In recent years, with the rapid development of industrial production technology, the safety and efficiency of steel mills in high-temperature industrial production processes have attracted increasing attention. In particular, the heating furnace system, a critical link in steel mill production, directly affects the overall quality and efficiency of production. Due to the unique high-temperature environment of the heating furnace, previous regional monitoring methods often only obtained localized and limited information, which can no longer meet the needs of real-time, accurate monitoring and data acquisition.

[0003] Currently, the entire heat treatment operation in the heating furnace is performed manually on-site based on experience. This experience-based approach lacks sufficient real-time monitoring data to support process adjustments. During process adjustments, the inability to obtain accurate data in a timely manner makes it difficult to precisely control various parameters of the heating furnace, resulting in an unstable air-fuel ratio. This instability leads to a series of serious problems, such as over-burning of slabs, resulting in decreased slab quality that fails to meet subsequent processing requirements; reduced yield, leading to raw material waste and increased production costs; and unstable combustion within the furnace, which not only affects the furnace's service life but may also cause safety accidents, significantly hindering rolling mill production. Utility Model Content

[0004] The purpose of this invention is to provide a monitoring device for high-temperature slabs in a heating furnace. This device can solve the problem that existing monitoring methods for high-temperature slabs in heating furnaces cannot meet the requirements for real-time and accurate detection and data acquisition.

[0005] To solve the above problems, the technical solution adopted by this utility model is: this high-temperature slab monitoring device in a heating furnace includes a mounting base plate, a high-temperature monitoring mechanism, an execution mechanism, a cooling mechanism, a protection mechanism, a control box, and an industrial control computer; The mounting base plate is fixed to the furnace wall of the heating furnace, the furnace wall has a through monitoring channel, and the mounting base plate has an opening that is coaxial with the monitoring channel. The actuator is mounted on the mounting base plate and includes a drive motor and a transmission assembly. The transmission assembly is connected to the high-temperature monitoring mechanism and is used to drive the high-temperature monitoring mechanism to extend into or out of the heating furnace cavity along the axial direction of the opening and the monitoring channel. The high-temperature monitoring mechanism includes at least two high-temperature resistant cameras, which are installed inside pinhole protective probe covers. The length of the pinhole protective probe covers is adapted to the thickness of the furnace wall. The cooling mechanism includes a cooling water pipe and a cooling air pipe leading to the pinhole protective probe cover, and the air inlet end of the cooling air pipe is connected to an air filter. The protection mechanism includes a temperature sensor, a pressure sensor, a flow sensor, and a power monitoring module. The signal output terminal of the protection mechanism is connected to the control box and is used to trigger the camera to automatically exit when an abnormality is detected. The control box is equipped with a PLC controller, which receives signals from the protection mechanism and manual operation instructions, and controls the action of the actuator according to preset logic. The industrial control computer is communicatively connected to the signal output terminal of the high-temperature monitoring mechanism, and is used to receive, process, and display the monitoring screen and data inside the furnace.

[0006] In the above-mentioned technical solution of the high-temperature slab monitoring device in the heating furnace, a more specific technical solution may be: a high-temperature resistant metal pipe passing through the furnace wall is provided in the monitoring channel.

[0007] In some possible implementations, the transmission component is a chain drive mechanism.

[0008] In some possible implementations, the cooling mechanism further includes a scroll cooler for cooling the cooling medium.

[0009] In some possible implementations, the monitoring signal from the high-temperature monitoring device is transmitted to the industrial computer via a Cat 6e network cable. The industrial computer is also connected to a hard disk recorder and a monitor for storing and displaying monitoring information.

[0010] By adopting the above technical solution, this utility model has the following beneficial effects compared with the prior art: 1. A high-temperature resistant camera driven by an actuator allows the image sensor to be directly inserted into the high-temperature zone inside the furnace, overcoming the limitations of traditional area-based monitoring. This enables the acquisition of direct, panoramic images and temperature data of the slab heating status inside the furnace, providing real-time and accurate data support for process adjustments. Integrated water-cooling, air-cooling, and protection mechanisms effectively cool the camera and provide multiple safety protections for temperature, pressure, flow, and power. The camera automatically retracts when any parameter is abnormal, preventing damage due to high temperatures or cooling failure and ensuring long-term stable operation of the monitoring system in harsh environments. A PLC controller enables semi-automatic camera movement, allowing operators to remotely operate the system from the control box without approaching the high-temperature furnace. Automatic protective retraction based on preset logic reduces labor intensity and improves operational safety and accuracy. Through intuitive monitoring of the furnace's internal conditions, operators can promptly detect abnormalities such as slab overheating and unstable combustion, allowing for precise adjustment of process parameters such as the air-fuel ratio. This effectively improves slab heating quality and yield, while reducing energy consumption and production costs.

[0011] 2. Installing high-temperature resistant metal pipes in the monitoring channel can protect the furnace wall openings from deformation and damage, thus extending the furnace life.

[0012] 3. The chain drive mechanism, which has the advantages of compact structure, reliable transmission and strong load-bearing capacity, is suitable for realizing the long-stroke precise linear movement of the camera in a limited space, ensuring the smoothness and accuracy of the camera's insertion and withdrawal.

[0013] 4. The installation of a vortex cooler significantly improves the cooling efficiency of the cooling mechanism, enabling it to cope with the high-temperature environment of the outer wall of the heating furnace and ensuring that the temperature of the cooling medium supplied to the camera protective cover is low enough. This allows the camera to still receive effective thermal protection under extreme conditions, thus expanding the applicable temperature range of the equipment.

[0014] 5. The use of Cat 6e network cables for signal transmission ensures the stability and anti-interference capability of long-distance transmission of high-definition video data. Combined with a hard disk recorder and a large-capacity hard drive, it enables long-term and complete recording of monitoring data, facilitating subsequent tracing and analysis of the production process and abnormal events, and providing a data foundation for process optimization and quality control. The monitor configuration allows for real-time display of the monitoring images, enabling operators to immediately grasp the furnace's internal conditions. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the high-temperature slab monitoring device inside the heating furnace.

[0016] Figure 2 This is a schematic diagram of the structure for mounting the substrate.

[0017] Figure 3It is a control circuit diagram.

[0018] Figure 4 It is a PLC-controlled trapezoidal Figure 1 .

[0019] Figure 5 It is a PLC-controlled trapezoidal Figure 2 .

[0020] Figure 6 It is a PLC-controlled trapezoidal Figure 3 .

[0021] The following are the labels in the diagram: 1. Opening; 2. Mounting base plate; 3. Monitoring channel; 4. Actuator; 5. Pinhole protection probe cover; 6. Cooling water pipeline; 7. Cooler pipeline; 8. Control box; 9. Air filter. Detailed Implementation

[0022] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments: Figure 1 and Figure 2The high-temperature slab monitoring device inside the heating furnace shown mainly includes a mounting base plate 2, a high-temperature monitoring mechanism, an actuator 4, a cooling mechanism, a protection mechanism, a control box 8, and an industrial control computer. The mounting base plate 2 is securely installed at a predetermined position on the front end wall of the heating furnace via multiple positioning holes and fasteners. A through monitoring channel 3 is opened in the furnace wall, lined with a high-temperature resistant metal tube to protect the furnace wall structure and serve as a guide channel. A corresponding opening 1 on the mounting base plate 2 is coaxially aligned with this monitoring channel 3, ensuring the precise entry and exit path of the high-temperature monitoring mechanism. The high-temperature monitoring mechanism directly acquires real-time image information of the high-temperature slab inside the furnace. This mechanism installs a high-temperature resistant camera inside a pinhole protective probe cover 5, with the camera body remaining relatively safe on the outside of the furnace wall. Only the high-temperature resistant lens tip extends into the furnace chamber through the furnace wall opening to acquire images. The actuator 4 responds to control commands, driving the high-temperature monitoring mechanism to complete precise linear forward and backward movements. This mechanism is powered by a motor and uses a transmission component to convert rotational motion into smooth linear advance and retraction. The cooling system ensures the equipment operates normally in extreme high-temperature environments. Through circulating cooling water and clean compressed air, it forcibly cools the pinhole protective probe cover 5, which is located deep within the furnace, creating a localized low-temperature protective environment. This effectively isolates the core camera components from the high temperatures inside the furnace. The protection mechanism uses sensors distributed throughout key nodes to collect real-time status signals such as temperature, pressure, and flow rate, and feeds these signals back to the control center. The programmable logic controller (PLC) inside the control box 8 coordinates and controls the entire system according to preset protection logic and operating instructions. Finally, the industrial control computer, acting as an information processing and display terminal, receives, records, and displays the real-time images and data captured by the camera inside the furnace, providing operators with decision-making support and ensuring the traceability of historical data.

[0023] The high-temperature monitoring mechanism in this embodiment is equipped with two high-temperature resistant cameras and lenses, which are installed inside a pinhole protective probe cover 5. The length of the probe cover is adapted to the thickness of the furnace wall, ensuring that when the camera is pushed in, the lens can just pass through the furnace wall and extend into the furnace chamber to form an image, while the camera body is protected on the relatively safe outside of the furnace wall. In this way, the opening size of the furnace wall can be minimized, reducing the impact on the structural integrity and insulation performance of the furnace body, and relaxing the requirements for the temperature resistance performance of the camera itself, increasing the flexibility of equipment selection.

[0024] To ensure the high-temperature monitoring device can safely enter and smoothly retract into the furnace, this device is equipped with an actuator fixed to the mounting base plate. This actuator mainly consists of a small, high-power motor and a chain drive assembly. The motor serves as the power source, converting the rotational motion into the linear motion of the probe cover via chain drive, thereby precisely controlling the insertion and withdrawal of the camera.

[0025] Given the harsh environment near the heating furnace, the cooling system is crucial for ensuring the normal operation of the camera and related equipment. This embodiment employs a combination of water and air cooling, supplemented by active cooling. Specifically, cooling water pipes 6 and cooling air pipes 7 are laid to the pinhole protective probe cover 5, forming a protective enclosure. Preferably, a portion of the pipes can also be coiled around the mounting base plate 2. An air filter 9 is connected to the inlet of the cooling air pipe 7 to ensure that the incoming cooling air is clean and free of impurities. The cooling system can also be equipped with a vortex cooler, which can deeply cool the cooling water, effectively coping with the high radiant temperature of the furnace body. This ensures that even under extreme operating conditions, the cooling medium supplied to the camera protective cover maintains a sufficiently low temperature, providing reliable thermal protection for the delicate internal optical and electronic equipment.

[0026] This device also incorporates a multi-layered protection mechanism, integrating temperature sensors, pressure sensors, flow sensors, and a power monitoring module. These sensors are used to monitor the temperature and pressure of the cooling medium, the flow rate of the cooling water, and the system power supply status in real time. They are located within the probe cover or cooling pipes. All sensor signals are connected to a programmable logic controller (PLC) in the control box. The PLC, acting as the control hub, is pre-programmed with comprehensive control and protection logic. Operators can remotely issue forward and backward commands via buttons on the control box. Upon receiving the command, the PLC first checks if the camera is in a permissible operating state (e.g., it must have been fully withdrawn before moving forward) and comprehensively assesses whether various protection parameters are normal. Only when all conditions are met will the PLC drive the actuator. Crucially, if any protection parameter (such as cooling water interruption, over-temperature, or under-pressure) becomes abnormal, the PLC will immediately trigger the protection program, automatically controlling the camera to quickly withdraw from the high-temperature area, thereby minimizing equipment damage.

[0027] Control based on preset logic of the camera control process, refer to Figures 3 to 6 The control method involves manual operation at the control box, as detailed below: (1) Camera forward movement: Press the forward button on the equipment. X004 receives an input. After passing through the entry limit protection (X000), the forward movement stops when the camera reaches the limit. If the camera does not reach the limit, the forward delay disconnects (T0) and checks whether the lens is in the exit state (Y005). If it is not in the exit state, the camera cannot enter. If it is in the exit state, the camera continues to check whether the temperature protection (X002) exceeds the limit, the pressure protection (Y001), the power protection (M110) exceeds the protection value, and the flow protection (X007) exceeds the protection value. If all of these exceed the normal values, the lens entry (Y004) signal will not output, and the lens cannot enter the furnace. If all of these are within the normal range, the lens entry (Y004) signal will output, and the normally open contact of the lens entry signal (Y004) will close, allowing the camera to extend into the industrial furnace. After reaching the entry limit, the entry limit protection (X000) will disconnect, the high-temperature camera will extend into the limit, and the extension action will stop.

[0028] (2) Camera retraction: Press the retraction button on the device. Input X005 is received. After passing through the exit limit protection (X005), the retraction stops when the camera is in position. If the camera is not in position, the camera will be deactivated after a retraction delay (T1) to detect whether the lens is in the entry state (Y004). If it is not in the entry state, the camera cannot retract. If it is in the entry state, the camera exits (Y005) signal is output. The normally open contact of the camera exits (Y005) signal closes, realizing the operation of the camera to exit the heating furnace. When the camera reaches the exit limit, the exit limit (X001) is deactivated, the high-temperature camera exits to position, and the exit action stops.

[0029] Finally, the high-definition video signals captured by the camera are transmitted to the industrial control computer via a Cat6e network cable with strong anti-interference capabilities. The industrial control computer is responsible for receiving, processing, and displaying the video data, and is usually connected to a large-screen monitor for operators to observe the furnace conditions in real time. Simultaneously, the system can also be equipped with a hard disk recorder and a large-capacity hard drive for long-term storage of monitoring videos and historical data. This facilitates daily monitoring and provides a valuable data foundation for subsequent analysis of heating processes, tracing production anomalies, and optimizing furnace condition control, achieving end-to-end management from real-time monitoring to data analysis.

[0030] This high-temperature slab monitoring device for the heating furnace introduces visual monitoring into the interior of the high-temperature industrial furnace. It not only enables intuitive and real-time monitoring of the slab heating status but also ensures high system reliability through automated control and multiple safety protections. In practical use, this device effectively helps operators accurately control key process parameters such as the air-fuel ratio within the furnace, preventing slab overheating, reducing fuel consumption by approximately 0.1 m³ / t, and increasing the yield by approximately 0.1%. While improving product quality and stability, it also brings significant economic and safety benefits.

Claims

1. A monitoring device for high-temperature slabs inside a heating furnace, characterized in that: It includes a mounting base plate, a high-temperature monitoring mechanism, an actuator, a cooling mechanism, a protection mechanism, a control box, and an industrial computer; The mounting base plate is fixed to the furnace wall of the heating furnace, the furnace wall has a through monitoring channel, and the mounting base plate has an opening that is coaxial with the monitoring channel. The actuator is mounted on the mounting base plate and includes a drive motor and a transmission assembly. The transmission assembly is connected to the high-temperature monitoring mechanism and is used to drive the high-temperature monitoring mechanism to extend into or out of the heating furnace cavity along the axial direction of the opening and the monitoring channel. The high-temperature monitoring mechanism includes at least two high-temperature resistant cameras, which are installed inside pinhole protective probe covers. The length of the pinhole protective probe covers is adapted to the thickness of the furnace wall. The cooling mechanism includes a cooling water pipe and a cooling air pipe leading to the pinhole protective probe cover, and the air inlet end of the cooling air pipe is connected to an air filter. The protection mechanism includes a temperature sensor, a pressure sensor, a flow sensor, and a power monitoring module. The signal output terminal of the protection mechanism is connected to the control box and is used to trigger the camera to automatically exit when an abnormality is detected. The control box is equipped with a PLC controller, which receives signals from the protection mechanism and manual operation instructions, and controls the action of the actuator according to preset logic. The industrial control computer is communicatively connected to the signal output terminal of the high-temperature monitoring mechanism, and is used to receive, process, and display the monitoring screen and data inside the furnace.

2. The high-temperature slab monitoring device in the heating furnace according to claim 1, characterized in that: The monitoring channel is equipped with a high-temperature resistant metal pipe that passes through the furnace wall.

3. The high-temperature slab monitoring device in the heating furnace according to claim 1, characterized in that: The transmission component is a chain drive mechanism.

4. The high-temperature slab monitoring device in the heating furnace according to claim 1, characterized in that: The cooling mechanism also includes a scroll cooler for cooling the cooling medium.

5. The high-temperature slab monitoring device in the heating furnace according to claim 1, characterized in that: The monitoring signal from the high-temperature monitoring device is transmitted to the industrial control computer via a Cat 6e network cable. The industrial control computer is also connected to a hard disk recorder and a monitor for storing and displaying monitoring information.

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