Thermal imaging safety inspection management system for hot metal tanks

Abstract

The present invention relates to a hot metal tank thermal image safety detection management system, comprising a thermal imager installed beside a railroad track, an ultra-high frequency RFID reader / writer, a proximity switch, an RFID tag set on the hot metal tank, and a control system; the thermal imager obtains the temperature signal of the hot metal tank, the ultra-high frequency RFID reader / writer reads the RFID tag to obtain the hot metal tank number and the original parameters of the refractory material, the proximity switch obtains the hot metal tank position signal, the thermal imager, the ultra-high frequency RFID reader / writer, and the proximity switch are connected to the control system via an Ethernet interface, the temperature signal, the hot metal tank number, and the hot metal tank position signal are sent to the control system, and the control system performs signal analysis to determine and display the temperature distribution of the hot metal tank and the ablation of refractory bricks. The present invention can measure the refractory erosion of the hot metal tank online, without stopping the process, without emptying the hot metal, monitoring the entire process, and automatically evaluating the refractory erosion status of the hot metal tank.

Description

Technical Field

[0001] The invention belongs to the technical field of steel smelting, and in particular relates to a thermal imaging safety detection and management system for a molten iron tank. Background Art

[0002] The molten iron tank is a container for high-temperature liquid iron. It is transported to the steelmaking process by locomotives, and then poured into the steelmaking furnace (or intermediate ladle) by a crane. As a molten iron transportation container, especially the intermediate transportation container, the molten iron tank is the intermediate link of the company's iron and steel balance, and it is also a blind spot in the iron and steel balance scheduling and control process. The efficiency level of molten iron logistics is directly related to the company's production cost reduction ability.

[0003] The molten iron tank is mainly composed of refractory materials and steel shells. The refractory materials are constantly eroded during the use of the molten iron tank. When the erosion reaches a certain position, the refractory materials must be rebuilt. Excessive erosion of the refractory materials may burn through the refractory materials, causing safety accidents and economic losses. If the erosion of the refractory materials is not serious, repairing the refractory materials will cause economic waste. At present, the erosion of refractory materials mainly relies on manual judgment, which may cause misjudgment of the erosion state of the molten iron tank, resulting in the accident of burning through and iron leakage of the molten iron tank, causing serious economic losses and safety accidents. Summary of the invention

[0004] The purpose of the present invention is to provide a molten iron tank thermal imaging safety detection and management system in order to solve the above-mentioned problem. Through infrared thermal imaging technology, the iron tank is scanned 360° to obtain the surface temperature of the molten iron tank. Combined with the original parameter data of the molten iron tank, the ablation condition of the refractory bricks can be obtained, thereby avoiding the occurrence of safety accidents.

[0005] The present invention achieves the above-mentioned purpose through the following technical solutions:

[0006] A hot metal ladle thermal imaging safety detection and management system, comprising a thermal imager installed beside a rail, an ultra-high frequency RFID reader / writer, a proximity switch, an RFID tag arranged on the hot metal ladle, and a control system;

[0007] The thermal imager obtains the temperature signal of the molten iron ladle, the ultra-high frequency RFID reader / writer reads the RFID tag to obtain the ladle number and the original parameters of the refractory material, and the proximity switch obtains the position signal of the molten iron ladle. The thermal imager, ultra-high frequency RFID reader / writer, and proximity switch are connected to the control system via an Ethernet interface, and the temperature signal, the ladle number, and the ladle position signal are sent to the control system, which performs signal analysis to determine and display the temperature distribution of the molten iron ladle and the ablation of the refractory bricks.

[0008] As a further optimization solution of the present invention, the proximity switch is connected to the thermal imager, and the thermal imager is turned on and off by the proximity switch.

[0009] As a further optimization solution of the present invention, an alarm indicator light is also installed on one side of the rail, and the alarm indicator light is connected to a proximity switch.

[0010] As a further optimization scheme of the present invention, at least two thermal imagers are provided and evenly arranged on both sides of the rails. The molten iron ladle transported by the locomotive is scanned by the thermal imager while being transported on the rails to obtain infrared thermal images and video images of the molten iron ladle.

[0011] As a further optimization scheme of the present invention, the control system includes a computer terminal and a database management module, the database management module is integrated in the computer terminal, the Ethernet interface is connected to the computer terminal, and the output end of the computer terminal is connected to the alarm indicator light.

[0012] As a further optimization solution of the present invention, the database management module includes a database, an erosion model, a multi-level warning submodule and a chart drawing submodule;

[0013] The database is used to store the temperature signal, the molten iron tank number, and the molten iron tank position signal received by the control system;

[0014] The erosion model is used to obtain the temperature signal, the number of the molten iron tank, and the position signal of the molten iron tank in the database, determine the temperature value from the temperature signal and compare the value with the preset threshold value, and determine the alarm level according to the calculated temperature exceeding the value;

[0015] The multi-level early warning submodule receives the molten iron tank number, the molten iron tank position signal and the alarm level of the molten iron tank, and performs a multi-level corrosion alarm on the computer terminal according to the alarm level;

[0016] The chart drawing submodule obtains the temperature value, the number of the molten iron tank, the position signal of the molten iron tank, and the alarm level information of each molten iron tank to make a chart, and the obtained information chart is displayed on the computer terminal for the user to view.

[0017] As a further optimization scheme of the present invention, the corrosion model is obtained by utilizing a molten iron ladle corrosion test and establishing a relationship between temperature and infrared thermal image based on the test results.

[0018] The beneficial effects of the present invention are:

[0019] 1) The present invention utilizes thermal imagers, radio frequency identification and other technologies to measure the erosion of refractory materials in the molten iron tank online. After the molten iron tank is filled with molten iron, the system is installed on the route where the molten iron tank is transported to steelmaking, and an erosion model of the molten iron tank refractory materials and a multi-level early warning system are established. The tank number is automatically identified and the temperature of the molten iron tank is recorded and tracked. The process does not require stopping or emptying the molten iron, and the system is fully monitored 24 hours a day to fully automatically evaluate the erosion status of the molten iron tank refractory materials.

[0020] 2) The present invention can realize online tracking of the real-time status and position of the molten iron ladle, improve the production organization and scheduling management level before and after ironmaking, shorten the turnover time of the molten iron ladle, reduce the number of online turnover ladle, and thus realize the efficient operation of the molten iron ladle, and improve and relatively stabilize the terminal molten iron temperature;

[0021] 3) The present invention realizes efficient allocation of molten iron resources, providing guarantee and contribution to the cost reduction of the company's material structure;

[0022] 4) The present invention ensures the safety of the blast furnace, stable iron tapping and timely and rapid supply of molten iron required by the steel plant, and alleviates or solves the contradictions such as balanced and stable supply of molten iron and the conflict between the steelmaking system's rigidity scheduling and the molten iron waiting time;

[0023] 5) The present invention greatly reduces the difficulty of molten iron scheduling during the converter campaign, quickly finds and determines the upper limit of the number of backlogged molten iron tanks, and minimizes the impact and influence of the backlog of molten iron tanks on the blast furnace condition. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 is the overall system topology diagram of the present invention;

[0025] Figure 2 is the overall system block diagram of the present invention;

[0026] Figure 3 It is a block diagram of a database management module of the present invention;

[0027] In the figure: 1. Thermal imager; 2. UHF RFID reader / writer; 3. Proximity switch; 4. RFID tag; 5. Control system; 51. Computer terminal; 52. Database management module; 521. Database; 522. Erosion model; 523. Multi-level warning submodule; 524. Chart drawing submodule; 6. Ethernet interface; 7. Alarm indicator light. DETAILED DESCRIPTION

[0028] The present application is further described in detail below in conjunction with the accompanying drawings. It is necessary to point out here that the following specific implementation methods are only used to further illustrate the present application and cannot be understood as limiting the scope of protection of the present application. Technical personnel in this field can make some non-essential improvements and adjustments to the present application based on the above application content.

[0029] Example 1

[0030] like Figure 1-3 As shown, a thermal imaging safety detection and management system for a molten iron tank comprises a thermal imager 1 installed beside a railroad track, an ultra-high frequency RFID reader / writer 2, a proximity switch 3, an RFID tag 4 arranged on the molten iron tank, and a control system 5;

[0031] The thermal imager 1 obtains the temperature signal of the molten iron ladle, the UHF RFID reader / writer 2 reads the RFID tag 4 to obtain the molten iron ladle number and the original parameters of the refractory material, and the proximity switch 3 obtains the position signal of the molten iron ladle. The thermal imager 1, the UHF RFID reader / writer 2, and the proximity switch 3 are connected to the control system 5 via a network cable / optical fiber and an Ethernet interface 6. The temperature signal, the molten iron ladle number, and the molten iron ladle position signal are sent to the control system 5, which performs signal analysis to determine and display the temperature distribution of the molten iron ladle and the ablation of the refractory bricks.

[0032] The proximity switch 3 is connected to the thermal imager 1, and the thermal imager 1 is turned on and off by the proximity switch 3. An alarm indicator light 7 is also installed on one side of the rail, and the alarm indicator light 7 is connected to the proximity switch 3.

[0033] At least two thermal imagers 1 are provided and evenly arranged on both sides of the rails. The molten iron ladle transported by the locomotive is scanned by the thermal imager 1 while being transported on the rails to obtain infrared thermal images and video images of the molten iron ladle.

[0034] The control system 5 includes a computer terminal 51 and a database management module 52 . The database management module 52 is integrated into the computer terminal 51 . The Ethernet interface 6 is connected to the computer terminal 51 . The output end of the computer terminal 51 is connected to the alarm indicator light 7 .

[0035] The database management module 52 includes a database 521, an erosion model 522, a multi-level early warning submodule 523 and a chart drawing submodule 524; the database 521 is used to store the temperature signal, the molten iron tank number, the original refractory parameters, and the molten iron tank position signal received by the control system 5; the erosion model 522 is used to obtain the temperature signal, the molten iron tank number, the original refractory parameters, and the molten iron tank position signal of the molten iron tank in the database 521, judge the degree of refractory erosion by the temperature distribution state and the time of the molten iron tank, and compare it with the original refractory parameters to obtain the erosion difference, and determine the alarm level according to the erosion difference; the multi-level early warning submodule 523 receives the molten iron tank number, the molten iron tank position signal and the alarm level of the molten iron tank, and performs a multi-level erosion alarm on the computer terminal 51 according to the alarm level; the chart drawing submodule 524 obtains the temperature value, molten iron tank number, the original refractory parameters, the molten iron tank position signal, and the alarm level information of each molten iron tank to make a chart, and the obtained information chart is displayed on the computer terminal 51 for the user to view.

[0036] The corrosion model 522 is obtained by using a molten iron tank corrosion test and establishing a relationship between temperature and infrared thermal images based on the test results.

[0037] The specific implementation method is as follows: a ladle filled with molten iron is transported on the track under the traction of a locomotive. The safety detection and management system determines the position of the ladle through a proximity switch 3, and indicates the position of the ladle through an alarm indicator light 7. The thermal imager 1 uses an uncooled focal plane to receive infrared rays of a specified wavelength to obtain a temperature signal in the window, which is output through an Ethernet interface 6. Two or three thermal imagers 1 are configured according to process requirements to continuously collect the thermal map in the window; the RFID tag 4 preset on each ladle within the range can be quickly read by an ultra-high frequency RFID reader 2, so as to obtain the corresponding ladle number and original parameters of the refractory material; the proximity switch 3 obtains the position signal of the current ladle; all these signals are received by a computer terminal 51 and stored in a database 521, and the infrared thermal map and Video images, manage the current operating status of each molten iron tank through the database management module 52, automatically analyze and manage the status of the molten iron tank, including temperature distribution, ablation of refractory bricks, passing time, molten iron tank number, thermal image at that time, video image, maximum temperature and position of the molten iron tank, etc., determine the numerical value of the erosion distribution degree of the molten iron tank through the erosion model 522, and determine the erosion alarm level, and perform multi-level erosion alarm on the computer terminal 51 through the multi-level early warning sub-module 523. The alarm indicator light 7 can also be controlled through the computer terminal 51 to perform multi-level alarms with different lights, strobes, etc. Finally, the chart drawing sub-module 524 is used to produce charts based on the data obtained from the above modules and the information stored in the database 521, providing users with vivid and intuitive data to grasp the status of each molten iron tank in real time, so as to achieve safety and controllability, and automatically alarm in case of danger.

[0038] The above-mentioned embodiments only express several implementation methods of the present invention, and the description thereof is relatively specific and detailed, but it cannot be understood as limiting the scope of the present invention. It should be pointed out that, for ordinary technicians in this field, several variations and improvements can be made without departing from the concept of the present invention, which all belong to the protection scope of the present invention.

Claims

1. A thermal imaging safety detection management system for molten iron tanks, characterized by: It comprises a thermal imager (1) installed beside a rail, an ultra-high frequency RFID reader / writer (2), a proximity switch (3), an RFID tag (4) arranged on a molten iron tank, and a control system (5); The thermal imager (1) obtains the temperature signal of the molten iron tank, the ultra-high frequency RFID reader (2) reads the RFID tag (4) to obtain the molten iron tank number and the original parameters of the refractory material, and the proximity switch (3) obtains the position signal of the molten iron tank. The thermal imager (1), the ultra-high frequency RFID reader (2), and the proximity switch (3) are connected to the control system (5) via an Ethernet interface (6). The temperature signal, the molten iron tank number, and the molten iron tank position signal are sent to the control system (5), and the control system (5) performs signal analysis to determine and display the temperature distribution of the molten iron tank and the ablation of the refractory bricks; A warning indicator light (7) is also installed on one side of the rail, and the warning indicator light (7) is connected to the proximity switch (3); At least two thermal imagers (1) are provided and are evenly arranged on both sides of the rails. When the molten iron ladle transported by the locomotive is transported on the rails, it is scanned by the thermal imager (1) to obtain an infrared thermal image and a video image of the molten iron ladle; The control system (5) comprises a computer terminal (51) and a database management module (52), wherein the database management module (52) is integrated in the computer terminal (51), the Ethernet interface (6) is connected to the computer terminal (51), and the output end of the computer terminal (51) is connected to the alarm indicator light (7); The database management module (52) comprises a database (521), an erosion model (522), a multi-level warning submodule (523) and a chart drawing submodule (524); the database (521) is used to store the temperature signal, the molten iron tank number, the original parameters of the refractory material and the molten iron tank position signal received by the control system (5); the erosion model (522) is used to obtain the temperature signal, the molten iron tank number, the original parameters of the refractory material and the molten iron tank position signal of the molten iron tank in the database (521), and judge the erosion degree of the refractory material according to the temperature distribution state and the time of the molten iron tank passing through the molten iron tank. and compares it with the original parameters of the refractory material to obtain the corrosion difference, and determines the alarm level according to the corrosion difference; the multi-level early warning submodule (523) receives the molten iron tank number, the molten iron tank position signal and the alarm level of the molten iron tank, and performs a multi-level corrosion alarm on the computer terminal (51) according to the alarm level; the chart drawing submodule (524) obtains the temperature value of each molten iron tank, the molten iron tank number, the original parameters of the refractory material, the molten iron tank position signal, and the alarm level information to make a chart, and the obtained information chart is displayed on the computer terminal (51) for the user to view.

2. The thermal imaging safety detection management system for molten iron tanks according to claim 1 is characterized by: The proximity switch (3) is connected to the thermal imager (1), and the thermal imager (1) is controlled to be turned on and off via the proximity switch (3).

3. The thermal imaging safety detection management system for molten iron tanks according to claim 1 is characterized by: The corrosion model (522) is obtained by using a molten iron ladle corrosion test and establishing a relationship between temperature and infrared thermal images based on the test results.

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