A non-contact molten steel level detection system and method for steelmaking

Abstract

This invention provides a non-contact molten steel level detection system and method for steelmaking. The system includes sensors, a heat exchanger, a protective housing, a measuring channel, a Laval nozzle, a controller, a driver, and a ladle car. Multiple sensors are present, each housed within a corresponding protective housing. The heat exchanger is also housed within the protective housing, and the measuring channel is located below its respective protective housing. A Laval nozzle is installed within the measuring channel, which is mounted on a support structure above the ladle car. The sensors, ladle car, and driver are electrically connected to the controller. This invention changes the traditional contact-based molten steel level measurement method in steelmaking. The measurement process does not disrupt normal production, simplifies equipment, improves reliability, reduces equipment investment, wear and tear, and maintenance costs, and minimizes the equipment's footprint.

Description

Technical Field

[0001] This invention belongs to the field of mechatronics technology, and specifically relates to a non-contact molten steel level detection system and method for steelmaking. Background Technology

[0002] Against the backdrop of my country's steel industry shifting from pursuing "quantity" to improving "quality," the molten steel level data in the ladle is increasingly becoming an important parameter needed in multiple stages of the steelmaking process.

[0003] The steelmaking process is complex, with a large number of compactly arranged equipment and auxiliary machines at each stage, making space extremely limited. The steelmaking production rhythm is extremely tight, with many stages calculated in "minutes". The steelmaking production environment is harsh, with the temperature of molten steel in the ladle exceeding 1500℃, and the temperature above and around the ladle being extremely high. At the same time, in order to prevent the molten steel from forming a crust, stirring gas needs to be continuously blown into the bottom of the ladle, which will produce molten steel splashing, thick smoke, and thick dust.

[0004] Currently, the main methods for detecting molten steel levels in steelmaking production are manual observation, indirect calculation, and contact testing. All of these methods have significant drawbacks: manual observation is extremely dangerous and prone to significant errors; indirect calculation cannot fully account for all factors affecting the molten steel level, resulting in substantial errors; and contact testing increases production costs due to material consumption, occupies valuable space in the steelmaking area, and adds to the steelmaking process, delaying production. Summary of the Invention

[0005] To overcome the strong interference from molten steel splashing, high temperature, dense smoke, and dense dust above molten steel, which shortens the lifespan of sensors and results in poor real-time performance and reliability of the measured data, this invention provides a non-contact molten steel level detection system and method for steelmaking. This invention can measure the molten steel level data in the ladle without affecting the normal steelmaking process layout and production rhythm.

[0006] The technical solution adopted in this invention is: A non-contact molten steel level detection system for steelmaking includes sensors, a heat exchanger, a protective housing, a measuring channel, a Laval nozzle, a controller, a driver, and a ladle car. Multiple sensors are included, each housed within a corresponding protective housing. The heat exchanger is also housed within a protective housing. The measuring channel is located below the corresponding protective housing. A Laval nozzle is installed within the measuring channel, which is mounted on a support structure above the ladle car. The sensors, the ladle car, and the driver are electrically connected to the controller.

[0007] The upper end of the Laval nozzle is connected to a protective gas pipeline, which is equipped with a protective gas control valve. The protective gas control valve is electrically connected to the driver.

[0008] The lower end of the Laval nozzle is equipped with a protective sleeve.

[0009] The sensor in question is a laser sensor.

[0010] The heat exchanger is a spiral tube made of hollow copper tubing.

[0011] The inlet of the heat exchanger extends through the protective housing and is connected to the downstream of the cooling medium pipeline. A cooling medium control valve is provided on the downstream cooling medium pipeline, and the cooling medium control valve is electrically connected to the driver. The outlet of the heat exchanger passes through the side wall of the protective housing and is connected to the upstream of the cooling medium pipeline.

[0012] The protective housing has a light-transmitting hole at its lower end, and the light-transmitting hole is sealed with a transparent material.

[0013] The protective housing is made of a material that is IP67 dustproof and waterproof and can withstand high temperatures of 300°C, and the interior of the protective housing forms a sealed cavity.

[0014] The controller includes a data acquisition module, a data cache module, and a data processing module. It also has input / output functions. The controller acquires data through the data acquisition module and stores it in the data cache module. The data processing module processes the data in the data cache module.

[0015] A non-contact method for detecting the molten steel level in steelmaking, comprising the following steps: Step 1, Preparations before testing: Controller, laser sensor, and driver are in standby mode; Step 2: When the ladle is within the detection range of this system, the controller commands the driver to open the cooling medium control valve and the protective gas control valve. The laser sensor operates within the working temperature range, the measurement channel is free from interference, and the laser sensor begins detection. Step 3: The controller begins reading data from the laser sensor; the data recorded by the controller begins to be stored in the data cache module. Step four: When the ladle leaves the detection range of this system, the data recorded by the controller stops being stored in the data cache module; the controller stops reading data from the laser sensor. Step 5: The laser sensor stops detecting; the controller closes the cooling medium control valve and the protective gas control valve according to the preset logic; the steel liquid level data is obtained through the model algorithm in the data processing module, and the detection of the steel liquid level is completed.

[0016] The beneficial effects of this invention are as follows: This invention measures the molten steel level in the ladle in real time in a non-contact manner along the path of the ladle entering and leaving the station. The data is accurate and reliable, reducing the risk factors of human intervention, lowering production costs, and providing strong support for fully automated steelmaking.

[0017] In this invention, the precision laser sensor provides excellent protection in harsh environments with high temperatures and dense smoke, greatly increasing the sensor's lifespan and ensuring stable and reliable data.

[0018] When the invention is put into operation, the controller commands the protective gas control valve to open, and the Laval nozzle set in front of the measurement channel of the laser sensor increases the flow rate of the protective gas. The airflow is large and can blow away the splashed molten steel, thick smoke and dust, thus preventing interference from molten steel splash, thick smoke and thick dust.

[0019] This invention changes the traditional contact-type molten steel level measurement method in the steelmaking process. The measurement process does not affect the normal production rhythm, simplifies the equipment, improves reliability, reduces equipment investment, wear and maintenance costs, and reduces the equipment footprint.

[0020] The present invention will be further described below with reference to the accompanying drawings of the embodiments. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the structure of the present invention.

[0022] Figure 2 This is a schematic diagram of a heat exchanger.

[0023] Figure 3 This is a schematic diagram of the Laval nozzle structure.

[0024] In the figure, the reference numerals are: 1. Sensor; 2. Heat exchanger; 3. Protective housing; 4. Measurement channel; 5. Laval nozzle; 6. Controller; 7. Data buffer module; 8. Data processing module; 9. Driver; 10. Cooling medium control valve; 11. Protective gas control valve; 12. Molten steel level; 13. Ladle car. Detailed Implementation Plan

[0025] Example 1: To overcome the strong interference from molten steel splashing, high temperature, dense smoke, and dense dust above the molten steel, which shortens the sensor's lifespan and reduces the real-time performance and reliability of the measured data, this invention provides... Figure 1-3 The present invention discloses a non-contact molten steel level detection system and method for steelmaking. The present invention can measure the molten steel level data in the ladle without affecting the normal steelmaking process layout and production rhythm.

[0026] A non-contact molten steel level detection system for steelmaking includes a sensor 1, a heat exchanger 2, a protective housing 3, a measuring channel 4, a Laval nozzle 5, a controller 6, a driver 9, and a ladle car 13. Multiple sensors 1 are included, each housed within a corresponding protective housing 3. The heat exchanger 2 is housed within the protective housing 3, and the measuring channel 4 is located below the corresponding protective housing 3. The measuring channel 4 contains a Laval nozzle 5 and is mounted on a support structure above the ladle car 13. The sensor 1, ladle car 13, and driver 9 are electrically connected to the controller 6.

[0027] like Figure 1 As shown, several sensors 1 are fixedly arranged in the path space of the ladle car 13 entering and leaving the station. When the ladle enters the detection range of this system, the system starts working. The controller 6 starts collecting data from the sensors 1 from time t0 and stores the data in the data cache module 7. When the ladle leaves the detection range of this system, the controller stops collecting data from the sensors 1 at time t1. The data processing module 8 reads the data from t0 to t1 in the data cache module 7 and calculates the molten steel level data through the model algorithm. In this invention, the driver 9, the data processing module 8 reading the data cache module 7, and the model algorithm are all prior art and will not be further described in this invention.

[0028] In this invention, the ladle car 13 is located within a supporting structure, and the measuring channel 4 is located at the upper end of the supporting structure. The sides of the ladle car 13 are either soil structures or other structures through which the ladle car 13 can pass. The upper end of the soil structure supports the measuring channel 4 through a support surface required on site. In this invention, the measuring channel 4 is a channel with a large opening at the top and a small opening at the bottom. Its shape is set according to requirements.

[0029] When the system is in operation, the measurement channel 4 of sensor 1 and the Laval nozzle 5 increase the flow rate of the protective gas, providing protection against molten steel splashing, high temperatures, dense smoke, and dense dust interference. In this invention, a heat exchanger 2 carrying a cooling medium is installed in the protective housing 3. The flow of the cooling medium is controllable, and the interior of the protective housing 3 is at room temperature. Sensor 1, the protective housing 3, and the heat exchanger 2 enable sensor 1 to operate in a dust-free, room-temperature environment. The protective housing 3 provides a room-temperature environment and is a sealed, dust-proof space. The system can acquire molten steel level data in the ladle without stopping during the movement of the ladle car 13. When the system is not in operation, it can automatically stop the protective gas and cooling medium, saving energy and reducing consumption.

[0030] This invention provides a non-contact molten steel level detection system and method for steelmaking, which occupies less space in the steelmaking area, does not affect the production rhythm of steelmaking operations, can overcome various strong interferences, and can quickly measure accurate molten steel level data while ensuring the stability of the detection system equipment.

[0031] Example 2: Based on Embodiment 1, in this embodiment, preferably, the upper end of the Laval nozzle 5 is connected to a protective gas pipeline, and a protective gas control valve 11 is provided on the pipeline. The protective gas control valve 11 is electrically connected to the driver 9.

[0032] Preferably, the lower end of the Laval nozzle 5 is provided with a protective sleeve.

[0033] In this invention, the protective sleeve protects the Laval nozzle 5 and extends the service life of the Laval nozzle 5.

[0034] In this invention, such as Figure 3 As shown, the Laval nozzle 5 has a funnel-shaped upper and lower end, with the inner diameter being smallest at the junction of the two funnels. The inner diameter of the uppermost end of the Laval nozzle 5 is larger than the inner diameter at the junction of the two funnels in the middle, and the inner diameter of the lowermost end of the Laval nozzle 5 is larger than the inner diameter of the uppermost end of the Laval nozzle 5. This variable diameter Laval nozzle 5 allows the airflow velocity to vary with the change in the nozzle cross-sectional area, enabling the airflow to accelerate from subsonic to sonic speeds, and even to supersonic speeds. Only when the airflow reaches high speeds does it possess power.

[0035] Preferably, the sensor 1 is a laser sensor, and the operating temperature of the laser sensor is 0℃~+50℃.

[0036] Preferred, such as Figure 2 As shown, the heat exchanger 2 is a spiral tube made of hollow copper tubes.

[0037] Preferably, the inlet of the heat exchanger 2 extends through the protective housing 3 and is connected to the downstream of the cooling medium pipeline. A cooling medium control valve 10 is provided on the downstream cooling medium pipeline, and the cooling medium control valve 10 is electrically connected to the driver 9. The outlet of the heat exchanger 2 passes through the side wall of the protective housing 3 and is connected to the upstream of the cooling medium pipeline.

[0038] Preferably, the lower end of the protective housing 3 has a light-transmitting hole, which is sealed with a transparent material to allow the laser light from the sensor to pass through.

[0039] Preferably, the protective housing 3 is made of a material that is IP67 dustproof and waterproof and can withstand high temperatures of 300°C, and the interior of the protective housing 3 forms a sealed cavity.

[0040] Preferably, the controller 6 includes a data acquisition module, a data cache module 7, and a data processing module 8. The controller 6 also has input / output functions. The controller 6 acquires data through the data acquisition module and stores it in the data cache module 7. The data processing module 8 is used to process the data in the data cache module 7.

[0041] In this invention, the controller 6 comprises at least a data acquisition module, a data cache module, and a data processing module, and also has I / O (input / output) functions. The data acquisition module of the controller 6 is used to acquire data and store the acquired data in the data cache module 7; wherein the data acquired by the controller 6 includes data from the laser sensor between t0 and t1; the data processing module 8 is used to process the data in the data cache module 7 and calculate the molten steel level data according to the model algorithm in the data processing module; the I / O function can obtain the position signal of the ladle car 13, send commands to the driver 9, and upload the obtained molten steel level data.

[0042] In this invention, the driver 9 receives a signal from the controller and sends a signal to drive the cooling medium control valve 10 and the protective gas control valve 11 to open / close.

[0043] In this invention, when the ladle car 13 arrives at or leaves the detection range of the system, the controller 6 controls the liquid level detection system to run / stop, and the heat exchanger 2 and Laval nozzle 5 are logically interlocked to run / stop.

[0044] When the system is put into operation, the controller 6 commands the protective gas control valve 11 to open. The Laval nozzle 5, located at the front of the laser sensor's measurement channel 4, increases the protective gas flow rate, providing protection against molten steel splashes, dense smoke, and dust interference. The controller 6 also commands the cooling medium control valve 10 to open, activating the heat exchanger 2. This ensures the laser sensor operates within a dust-free environment and at its normal operating temperature range within the protective housing 3, guaranteeing the laser sensor's lifespan and the real-time performance and reliability of the measured data.

[0045] When the system stops working, the controller 6 commands the protective gas control valve 11 and the cooling medium control valve 10 to close after a delay, which can save energy and reduce consumption.

[0046] A non-contact method for detecting the molten steel level in steelmaking, comprising the following steps: Step 1, Preparations before testing: Controller 6, laser sensor and driver 9 are in standby mode; Step 2: When the ladle is within the detection range of this system, the controller 6 commands the driver 9 to open the cooling medium control valve 10 and the protective gas control valve 11. The laser sensor operates within the working temperature range, the measurement channel 4 is free from interference, and the laser sensor begins detection. Step 3: Controller 6 begins reading data from the laser sensor; the data recorded by controller 6 is then stored in the data cache module 7. Step four: When the ladle leaves the detection range of this system, the data recorded by controller 6 stops being stored in data cache module 7; controller 6 stops reading data from laser sensor. Step 5: The laser sensor stops detecting; the controller 6 closes the cooling medium control valve 10 and the protective gas control valve 11 according to the preset logic; the molten steel level data is obtained through the model algorithm in the data processing module 8, and the detection of the molten steel level is completed.

[0047] This invention aims to occupy less space in the steelmaking area, without affecting the production rhythm of steelmaking operations, overcome various strong interferences, and quickly obtain accurate molten steel level data while ensuring the stability of the detection system equipment.

[0048] like Figure 1 As shown, the working process of this invention is as follows: According to the position of the ladle car 13, the controller 6 controls the cooling medium control valve 10 and the protective gas control valve 11 through the driver 9. The cooling medium, through the heat exchanger 2, enables the laser sensor installed in the protective housing 3 to operate in a dust-free and normal-temperature environment. The protective gas, through the measurement channel 4 and the Laval nozzle 5, increases its flow rate to ensure that the measurement is not interfered with. The controller 6 collects the laser sensor data and stores the data in the data cache module 7. When the ladle car 13 leaves the detection range of this system, the controller 6 stops collecting the laser sensor data. The data calculation module 8 reads the data in the data cache module 7 and calculates the molten steel level data through the model algorithm.

[0049] This invention can measure the molten steel level in the ladle in real time in a non-contact manner along the path of the ladle entering and leaving the station. The data is accurate and reliable, reducing the risk factors of human intervention, lowering production costs, and providing strong support for fully automated steelmaking.

[0050] This invention utilizes spatially distributed laser sensors combined with a controller algorithm to rapidly and efficiently measure molten steel level data. This method overcomes strong interference from molten steel splashing, high temperatures, high brightness, dense smoke, and dense dust, ensuring the lifespan of sensor 1 and the real-time and reliable nature of the measured data. The key feature of this invention is its transformation of the traditional contact-based molten steel level measurement method in steelmaking. The measurement process does not disrupt normal production, simplifies equipment, improves reliability, reduces equipment investment, wear and tear, and maintenance costs, and minimizes the equipment's footprint.

[0051] This invention is a non-contact molten steel level detection system for steelmaking. The measurement process is safe and reliable, requires no consumables, and can be arranged in the existing three-dimensional space of the ladle car 13 without occupying additional space in the steelmaking area. The molten steel level can be detected without stopping the ladle car 13, without affecting the existing production rhythm.

[0052] The examples above are merely illustrative of the present invention and do not constitute a limitation on the scope of protection of the present invention. All designs that are identical or similar to the present invention fall within the scope of protection of the present invention. Device system structures and method steps not described in detail in this invention are prior art and will not be further described in this invention.

Claims

1. A non-contact molten steel level detection system for steelmaking, characterized in that: Includes sensor (1), heat exchanger (2), protective housing (3), measurement channel (4), Laval nozzle (5), controller (6), driver (9) and ladle car (13); The sensor (1) is multiple, and each sensor (1) is installed in the corresponding protective housing (3). The heat exchanger (2) is installed in the protective housing (3). The measurement channel (4) is installed below the corresponding protective housing (3). The measurement channel (4) is equipped with a Laval nozzle (5). The upper end of the Laval nozzle (5) is funnel-shaped, and the lower end is also funnel-shaped. The inner diameter at the connection of the two funnels is the smallest. The inner diameter at the uppermost end of the Laval nozzle (5) is larger than the inner diameter at the connection of the two funnels in the middle. The inner diameter at the lowermost end of the Laval nozzle (5) is larger than the inner diameter at the uppermost end of the Laval nozzle (5). The measurement channel (4) is installed on the support structure above the ladle car (13). The sensor (1), the ladle car (13) and the driver (9) are respectively electrically connected to the controller (6). The measuring channel (4) is a channel with a large opening at the top and a small opening at the bottom; the measuring channel (4) of the sensor (1) and the Laval nozzle (5) increase the flow rate of the protective gas and have the function of preventing steel splashing, high temperature, dense smoke and dense dust interference. The sensor (1) is a laser sensor; the heat exchanger (2) is a spiral tube made of hollow copper tube; the protective shell (3) has a light-transmitting hole at the lower end, and the light-transmitting hole is sealed with transparent material. The upper end of the Laval nozzle (5) is connected to a protective gas pipeline, and a protective gas control valve (11) is provided on the pipeline. The protective gas control valve (11) is electrically connected to the driver (9). The inlet of the heat exchanger (2) passes through the protective shell (3) and is connected to the downstream of the cooling medium pipeline. A cooling medium control valve (10) is provided on the downstream cooling medium pipeline. The cooling medium control valve (10) is electrically connected to the driver (9). The outlet of the heat exchanger (2) passes through the side wall of the protective shell (3) and is connected to the upstream of the cooling medium pipeline.

2. The non-contact molten steel level detection system for steelmaking according to claim 1, characterized in that: The lower end of the Laval nozzle (5) is provided with a protective sleeve.

3. The non-contact molten steel level detection system for steelmaking according to claim 1, characterized in that: The protective housing (3) is made of a material that is IP67 dustproof and waterproof and can withstand high temperatures of 300°C. The protective housing (3) forms a sealed cavity inside.

4. The non-contact molten steel level detection system for steelmaking according to claim 1, characterized in that: The controller (6) includes a data acquisition module, a data cache module (7) and a data processing module (8). The controller (6) also has input / output functions. The controller (6) acquires data through the data acquisition module and stores it in the data cache module (7). The data processing module (8) is used to process the data in the data cache module (7).

5. The detection method of the non-contact molten steel level detection system for steelmaking according to any one of claims 1-4, characterized in that: The specific steps are as follows: Step 1, Preparations before detection: Controller (6), laser sensor and driver (9) are in standby mode; Step 2: When the ladle is within the detection range of this system, the controller (6) commands the driver (9) to open the cooling medium control valve (10) and the protective gas control valve (11). The laser sensor operates within the working temperature range, the measurement channel (4) is free from interference, and the laser sensor begins detection. Step 3: The controller (6) begins to read the laser sensor data; the data recorded by the controller (6) begins to be stored in the data cache module (7); Step four: When the ladle leaves the detection range of this system, the data recorded by the controller (6) stops being stored in the data cache module (7); the controller (6) stops reading the laser sensor data; Step 5: The laser sensor stops detecting; the controller (6) closes the cooling medium control valve (10) and the protective gas control valve (11) according to the preset logic; the steel liquid level data is obtained by the model algorithm in the data calculation module (8) to complete the detection of the steel liquid level.

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