An online early warning system for out-of-tolerance cutting of continuous casting machine slabs

Abstract

The present invention provides an online early warning system for the over-tolerance of the cut length of the continuous casting machine, which relates to the technical field of the continuous casting machine cut length, and comprises: a casting stream PLC controller, a cutting PLC controller, an infrared camera cut length system, a plurality of encoders, a cutting machine and a photoelectric tube, wherein the encoder is arranged on the active roller of the casting machine, the encoder is connected to the casting stream PLC controller, the casting stream PLC controller is connected to the cutting PLC controller, and the cutting PLC controller is respectively connected to the infrared camera cut length system, the cutting machine and the photoelectric tube. When the cut length of the casting billet exceeds the abnormality, the present invention can remind the operator to deal with it before cutting, and correct the length in time, so as to reduce the quality accidents of the abnormal cut length of the casting billet, and improve the product yield rate, and has timeliness and effectiveness.

Description

Technical Field

[0001] The invention relates to the technical field of continuous casting machine slab cutting, and in particular to an online early warning system for slab cutting of a continuous casting machine with out-of-tolerance in length. Background Art

[0002] The continuous casting process is widely used in the steel and metallurgical industry. If the ingot is cut to a fixed length that is too long, the ingot cannot enter the heating furnace, which will increase the waste of steel. If it is too short, the amount of defective products will increase. Therefore, the cutting length of the ingot is a key factor in the yield rate of steel products.

[0003] At present, the cutting and sizing system used by domestic steel mills is mostly infrared camera sizing system. This system uses infrared camera to collect on-site images, extracts billet information from the images, tracks the position of the billet head until it reaches the sizing position, and then cuts the ingot. It has high sizing measurement and control accuracy.

[0004] However, the existing cutting and sizing system has certain shortcomings. First, due to the high temperature of the red billet during on-site production, the surface is about 700-900℃. When the camera shakes, shifts, and other faults occur, the image is blurred, and the processing and replacement of equipment, high-altitude high-temperature operations, and installation and debugging require high requirements. The imaging of the sizing system is unclear, and the sizing calibration is prone to unstable errors. The camera transmits analog signals, and occasionally there will be regular ripples flashing on the computer screen. During production, the on-site line signal is easily disturbed, causing the image to be blurred, which in turn affects the accuracy of the sizing cutting. Manual re-measurement of the length of the red billet in a high-temperature environment is neither convenient nor safe, and the results may not be accurate, resulting in inaccurate error compensation of the sizing system; secondly, after the hot billet is cut, the conveying billet slips or the conveying roller does not rotate, and the tail of the cut hot billet coincides with the uncut billet joint. At this time, the tracking line finds the head of the cut billet, and the sizing system determines that the cutting length has been reached. When the cutting machine returns to the original position, it automatically starts cutting, causing the billet to be cut seriously short. Finally, when the casting machine produces steel suitable for fast pouring, the pulling speed increases, the temperature of the red billet rises, the brightness of the red billet image on the computer screen of the sizing system will increase, and the tracking line will automatically move forward and cross the solid line of the red billet, causing the billet to be too short after cutting; when the casting machine alarms for steel leakage, or when changing the bag or the water inlet, or when the liquid level in the crystallizer fluctuates greatly, the pulling speed decreases, the brightness of the red billet decreases, and the tracking line of the sizing system will stop, causing the billet to be cut too long; in this case, if the operator adjusts the brightness parameters inappropriately, the tracking line of the sizing system will be insensitive and unable to track the jump in time, and the accuracy of the sizing length will decrease, causing the billet to be cut too long or too short, seriously affecting product quality. Summary of the invention

[0005] According to the above technical problems that the existing cutting and sizing systems have poor cutting accuracy and inaccurate cutting, an online early warning system for continuous casting machine slab cutting and sizing out-of-tolerance is provided. The present invention mainly uses the online early warning system to perform secondary detection on the length value of the pre-cut slab, thereby achieving the effect of increasing cutting accuracy.

[0006] The technical means adopted by the present invention are as follows:

[0007] An online early warning system for excessive tolerance in cutting and sizing of a continuous casting machine ingot, comprising: a casting strand PLC controller, a cutting PLC controller, an infrared camera sizing system, a plurality of encoders, a cutting machine and a photoelectric tube, wherein the encoder is arranged on an active roller of the casting machine, the encoder is connected to the casting strand PLC controller, the casting strand PLC controller is connected to the cutting PLC controller, and the cutting PLC controller is respectively connected to the infrared camera sizing system, the cutting machine and the photoelectric tube.

[0008] Furthermore, the infrared camera sizing system uses an infrared camera to collect on-site images, extracts billet head information from the on-site images, tracks billet head position according to billet information, and sends out pre-pressing and main pressing signals of the cutting machine cylinder to make the cutting gun and the billet run synchronously;

[0009] The encoder measures the length signal of the ingot and sends it to the casting strand PLC controller; the casting strand PLC controller receives the ingot length signal and calculates various specific length values, and the casting strand PLC controller sends various specific length values ​​to the cutting PLC controller;

[0010] The photoelectric tube detects the head position of the ingot and sends a signal to the cutting PLC controller;

[0011] The cutting PLC controller receives pre-pressing and main pressing signals, sends a cutting signal to the cutting machine, receives various specific length values ​​sent by the casting strand PLC controller, and calculates the length value of the pre-cut ingot according to the various specific length values, compares the length value of the pre-cut ingot with the length value measured by the sizing system, and sends an alarm signal to the host computer when the specified error is exceeded;

[0012] The cutting machine receives the cutting signal and cuts the ingot.

[0013] Furthermore, the specific length values ​​include Lzy, Lbk and Lgd;

[0014] The cutting PLC controller calculates the length of the pre-cut ingot by the following formula:

[0015] Ldc=(Lzy-Lbk)+Lgd

[0016] Among them, Ldc is the fixed length of the pre-cut ingot, that is, the length of the finished ingot block; Lzy is the instantaneous value of the total length of the ingot cast when the PLC controller of the cutting machine sends out the main clamping signal; Lbk is the instantaneous value of the total length of the ingot cast when the photoelectric tube detects the head of the production ingot; Lgd is the distance between the photoelectric tube detection point and the origin of the cutting gun.

[0017] Furthermore, the length of the ingot to be cut is measured by dispersed counting of the fixed large section and the movable small section of the ingot. The fixed large section value Lgd is detected by triggering the photoelectric tube, and the movable small section value ΔL is measured by the encoder. The sum of the detected fixed large section value Lgd and the movable small section value ΔL is the measured length Ldc of the ingot to be cut.

[0018] Furthermore, the photoelectric tube is arranged in front of the cutting machine, and the length value of the photoelectric tube from the cutting machine cutting gun origin is Lgd; when the cutting machine returns to the origin limit, the cutting gun position is the cutting gun origin.

[0019] Furthermore, the working steps of the online early warning system are as follows:

[0020] The infrared camera sizing system collects on-site images and tracks the position of the billet head according to the on-site images. When the distance between the billet head position and the cutting gun position reaches the set length value Lsd, the infrared camera sizing system sends a main clamping signal to the cutting PLC controller to make the cutting gun and the billet run synchronously.

[0021] The cutting PLC controller receives the main clamping signal, the encoder measures the length signal and sends it to the casting strand PLC controller, the casting strand PLC controller receives the billet length signal and calculates Lzy and Lbk and sends them to the cutting PLC controller;

[0022] The cutting PLC controller receives the values ​​of Lzy and Lbk and substitutes the values ​​of Lzy, Lbk, and Lgd according to the formula to calculate the length value Ldc of the pre-cut ingot;

[0023] The cutting PLC controller compares Ldc with Lsd, and performs normal cutting when the difference is within the specified error, and sends an alarm signal to the upper computer when the difference exceeds the specified error.

[0024] Compared with the prior art, the present invention has the following advantages:

[0025] Compared with the original system, the present invention provides an alarm for the deviation between the length of the online pre-cut ingot and the set length of the finished product, reminding the operator to respond in time and adjust the cutting length of the ingot, reducing the quality accidents of abnormal sizing of the ingot and improving the yield rate of the ingot products. After the system-related parameters of the present invention are set for the first time, they do not need to be adjusted frequently. The present invention requires low investment, is less susceptible to interference, has high precision, reliable system components, simple and small maintenance work, and also reduces the labor intensity of manual re-measurement, with significant economic benefits. Based on the principle of the present invention, it can become a device for cutting, sizing and measuring ingots with a slight modification and design.

[0026] In the traditional method of measuring the length of the ingot, since the pouring length encoder is installed on the active roller of the casting machine, the ingot and the roller may slip during production, and there will be a certain cumulative error in calculating the pouring length value. The present invention designs a dispersed counting measurement of the fixed large section and the movable small section of the ingot. The value of the fixed large section is detected by triggering a photoelectric tube, and the value of the movable small section is measured by a digital encoder, and the sum of the calculations is obtained. This reduces the error caused by the encoder counting and length measurement, improves the accuracy of measuring the length of the ingot to be cut, and has the advantages of reliable measurement, etc.

[0027] The original infrared length measurement system has unstable error values ​​and often exceeds tolerances due to environmental factors and equipment influences. After the online early warning system for cutting length exceeding tolerance of the present invention is put into operation, the cutting length error can be stabilized within 3 cm. In the case of exceeding tolerance in the cutting length of the ingot, an alarm is given in time. Subsequent response measures ensure that the cutting precision of the ingot length is more accurate, so as to reduce the waste of ingot steel products and improve the product yield rate. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.

[0029] Figure 1 Schematic diagram of the system structure of the present invention.

[0030] Figure 2 This is a schematic diagram of the detection principle of the present invention.

[0031] In the figure: 1. Cutting PLC controller; 2. Casting strand PLC controller; 3. Infrared camera sizing system; 4. Encoder; 5. Cutting machine; 6. Photoelectric tube; 7. Cutting gun; 8. Ingot; 9. Host computer; 10. Cutting gun origin. DETAILED DESCRIPTION

[0032] It should be noted that, in the absence of conflict, the embodiments of the present invention and the features in the embodiments can be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0033] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. The following description of at least one exemplary embodiment is actually only illustrative and is by no means intended to limit the present invention and its application or use. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0034] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit exemplary embodiments according to the present invention. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprising" and / or "including" are used in this specification, it indicates the presence of features, steps, operations, devices, components and / or combinations thereof.

[0035] Unless otherwise specifically stated, the relative arrangement of the parts and steps described in these embodiments, the numerical expressions and numerical values ​​do not limit the scope of the present invention. At the same time, it should be clear that, for ease of description, the sizes of the various parts shown in the drawings are not drawn according to the actual proportional relationship. The technology, methods and equipment known to ordinary technicians in the relevant field may not be discussed in detail, but in appropriate cases, the technology, methods and equipment should be regarded as part of the authorization specification. In all examples shown and discussed here, any specific value should be interpreted as merely exemplary, rather than as a limitation. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar numbers and letters represent similar items in the following drawings, so once an item is defined in one drawing, it does not need to be further discussed in subsequent drawings.

[0036] like Figure 1 and Figure 2As shown, the present invention provides an online early warning system for out-of-tolerance cutting of ingots of continuous casting machine, comprising: a casting strand PLC controller 2, a cutting PLC controller 1, an infrared camera sizing system 3, a plurality of encoders 4, a cutting machine 5 and a photoelectric tube 6, wherein the encoder 4 is arranged on the active roller of the casting machine, the encoder 4 is connected to the casting strand PLC controller 2, the casting strand PLC controller 2 is connected to the cutting PLC controller 1, and the cutting PLC controller 1 is respectively connected to the infrared camera sizing system 3, the cutting machine 5 and the photoelectric tube 6. The infrared camera sizing system 3 uses an infrared camera to collect on-site images, extracts billet information from the on-site images, tracks the billet head position according to the billet information, and sends out pre-tightening and main tightening signals of the cutting machine cylinder; the encoder 4 measures the billet 8 length signal and sends it to the casting strand PLC controller 2; the casting strand PLC controller 2 receives the billet length signal and calculates the specific length values ​​of each item, and the casting strand PLC controller 2 sends the specific length values ​​of each item to the cutting PLC controller 1; the photoelectric tube 6 detects The head position of the billet 8 is measured and a signal is sent to the cutting PLC controller 1; the cutting PLC controller 1 receives the pre-pressing and main pressing signals, the cutting PLC controller 1 sends a cutting signal to the cutting machine 5, the cutting PLC controller 1 receives the specific length values ​​sent by the casting strand PLC controller 2 and calculates the length value of the pre-cut billet according to the specific length values, the cutting PLC controller 1 compares the length value of the pre-cut billet with the length value set for the fixed length, and sends an alarm signal to the host computer 9 when the specified error is exceeded; the cutting machine 5 receives the cutting signal and cuts the billet 8. The length of the billet to be cut is measured by the dispersed counting of the fixed large segment and the movable small segment of the billet, the fixed large segment value Lgd is triggered by the photoelectric tube 6, the movable small segment value ΔL is measured by the encoder 4, and the detected fixed large segment value Lgd and the movable small segment value ΔL are added to obtain the measured length Ldc of the billet to be cut. The photoelectric tube 6 is arranged in front of the cutting machine 5 , and the length value of the photoelectric tube 6 from the cutting machine cutting gun origin 10 is Lgd; when the cutting machine 5 returns to the origin limit position, the cutting gun 7 is the cutting gun origin 10 .

[0037] The specific length values ​​include Lzy, Lbk and Lgd;

[0038] The working steps of the online early warning system are as follows:

[0039] The infrared camera sizing system 3 collects the on-site image and tracks the position of the billet head according to the on-site image. When the billet head position reaches the set length value Lsd 7 positions away from the cutting gun, the infrared camera sizing system 3 sends a main clamping signal to the cutting PLC controller 1 to make the cutting gun and the billet run synchronously;

[0040] The cutting PLC controller 1 receives the main clamping signal, the encoder 4 sends the measurement signal to the casting strand PLC controller 2, the casting strand PLC controller 2 receives the billet length signal and calculates Lzy and Lbk and sends them to the cutting PLC controller 1;

[0041] The cutting PLC controller 1 receives the values ​​of Lzy and Lbk and substitutes the values ​​of Lzy, Lbk, and Lgd according to the formula to calculate the length value Ldc of the pre-cut ingot;

[0042] The cutting PLC controller 1 compares Ldc with Lsd, and performs cutting normally when the difference is within a specified error, and sends an alarm signal to the upper computer 9 when the difference exceeds the specified error.

[0043] The length of the fixed section Lgd determines the installation position of the photoelectric tube 6. Its length value is based on the minimum fixed length value of the finished ingot, minus the pre-pressing value of the cutting machine cylinder in advance, so as to meet the minimum fixed length cutting.

[0044] The present invention obtains a value Lgd by subtracting the pre-pressure setting value of the cylinder pressure before cutting from the shortest length value of the finished ingot according to the production requirements. A photoelectric tube 6 for detecting the head of the ingot is installed in front of the cutting machine at a distance of Lgd from the origin of the cutting gun of the cutting machine. It should be noted that when the cutting machine 7 returns to the origin limit, the cutting gun 7 is the cutting gun origin 10.

[0045] The PLC program control design is as follows: when the head of the red billet moves forward, the photoelectric tube 6 detection circuit is triggered, and the cutting machine PLC controller 1 records an instantaneous value Lbk of the total casting length transmitted by the casting strand PLC controller 2. When the infrared camera sizing system 3 sends the cylinder main clamping signal to the cutting machine PLC controller 1, the instantaneous value Lzy of the total casting length is recorded again. The difference between the two instantaneous values ​​of length Lzy and Lbk is the value ΔL of the active segment of the billet. The sum of ΔL plus the fixed segment value Lgd is the length value Ldc of the pre-cut billet, as shown in Figure 2 As shown,

[0046] Ldc=(Lzy–Lbk)+Lgd

[0047] Among them, Ldc: the cut length of the pre-cut ingot, that is, the length of the finished ingot block; Lzy: when the PLC of the cutting machine issues the main cylinder clamping command, the instantaneous count value of the total length of the ingot cast; Lbk: when the photoelectric tube detects the head of the production ingot, the instantaneous count value of the total length of the ingot cast; Lgd: is the distance between the photoelectric tube and the origin of the cutting gun. The point obtained by subtracting 500mm from the cut length of the shortest finished ingot is the installation position of the photoelectric tube, which can meet the minimum cut length.

[0048] The Ldc value counted by the encoder 4 is compared with the length value Lsd. If the deviation is within a certain range, an alarm is triggered and displayed on the host computer 9. It can also be an audible and visual alarm. At this time, the cutting gun is still preheating and not cutting. The operator can take countermeasures according to the alarm and increase or decrease the cutting length of the ingot. The deviation value can be set by the production process department according to the needs.

[0049] Since the encoder 4 for counting the pouring length is installed on the active roller of the casting machine, the roller may slip on the billet when rotating, causing the billet to stop moving, and the encoder 4 increases the count as the roller rotates, resulting in a certain cumulative error in the calculation of the pouring length value. The design of the present invention adopts the distributed counting of the fixed large segment value of the billet and the movable small segment value, which reduces the error caused by the encoder 4 counting and measuring the length, improves the accuracy of measuring the length of the billet to be cut, and has the advantages of reliable measurement, etc.

[0050] The total length of the billet is counted by the combination of several encoders of the casting machine. If one of them is damaged, other encoders will be automatically selected for counting. The counting is reliable. The length value is transmitted to the cutting machine PLC controller 1 through the network by the casting strand PLC controller 2. The infrared camera sizing system 3 measures the billet length value in real time during production and exchanges information with the cutting machine PLC controller 1. The host computer 9 displays the production status data in a timely manner for the operator to view and operate.

[0051] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. An online early warning system for out-of-tolerance cutting of continuous casting machine ingots, characterized in that: include: A strand casting PLC controller (2), a cutting PLC controller (1), an infrared camera sizing system (3), a plurality of encoders (4), a cutting machine (5) and a photoelectric tube (6), wherein the encoder (4) is arranged on an active roller of the casting machine, the encoder (4) is connected to the strand casting PLC controller (2), the strand casting PLC controller (2) is connected to the cutting PLC controller (1), and the cutting PLC controller (1) is respectively connected to the infrared camera sizing system (3), the cutting machine (5) and the photoelectric tube (6); The infrared camera sizing system (3) uses an infrared camera to collect on-site images, the infrared camera sizing system (3) extracts steel billet information from the on-site images, the infrared camera sizing system (3) tracks the billet head position according to the steel billet information, and the infrared camera sizing system (3) sends out a pre-pressing signal and a main pressing signal of a cutting machine cylinder; The encoder (4) measures the length signal of the ingot (8) and sends it to the casting strand PLC controller (2); the casting strand PLC controller (2) receives the ingot length signal and calculates various specific length values, and the casting strand PLC controller (2) sends various specific length values ​​to the cutting PLC controller (1); The photoelectric tube (6) detects the position reached by the head of the ingot (8) and sends the position signal to the cutting PLC controller (1); The cutting PLC controller (1) receives pre-pressing and main pressing signals, the cutting PLC controller (1) sends a cutting signal to a cutting machine (5), the cutting PLC controller (1) receives various specific length values ​​sent by a casting strand PLC controller (2) and calculates the length value of the pre-cut ingot according to the various specific length values, the cutting PLC controller (1) compares the length value of the pre-cut ingot with the length value set for the fixed length, and sends an alarm signal to a host computer (9) when a specified error is exceeded; The cutting machine (5) receives the cutting signal and cuts the ingot (8); The specific length values ​​include Lzy, Lbk and Lgd; The cutting PLC controller (1) calculates the length of the pre-cut ingot by the following formula: Ldc=(Lzy-Lbk)+Lgd Among them, Ldc is the length value of the pre-cut ingot, that is, the length value of the finished ingot block; Lzy is the instantaneous count value of the total length of the ingot when the main clamping signal of the cutting machine PLC controller is issued; Lbk is the instantaneous count value of the total length of the ingot when the photoelectric tube detects the head of the production ingot; Lgd is the distance between the photoelectric tube and the origin of the cutting gun.

2. The continuous casting machine slab cutting length out-of-tolerance online early warning system according to claim 1 is characterized in that: The length of the pre-cut ingot is measured by discrete counting of the fixed large segment and the movable small segment of the ingot. The fixed large segment value Lgd is detected by triggering the photoelectric tube (6), and the movable small segment value ΔL is measured by the encoder (4). The detected fixed large segment value Lgd and the movable small segment value ΔL are added to obtain the length Ldc of the pre-cut ingot.

3. The online early warning system for out-of-tolerance cutting of continuous casting machine slabs according to claim 1 is characterized in that: The photoelectric tube (6) is arranged in front of the cutting machine (5), and the length value of the photoelectric tube (6) from the cutting machine cutting gun origin (10) is Lgd; when the cutting machine (5) returns to the origin limit position, the cutting gun (7) is the cutting gun origin (10).

4. The continuous casting machine slab cutting length out-of-tolerance online early warning system according to claim 1 is characterized in that: The working steps of the online early warning system are as follows: The infrared camera sizing system (3) collects on-site images and tracks the position of the billet head according to the on-site images. When the distance between the billet head and the cutting gun (7) reaches the set length value Lsd, the infrared camera sizing system (3) sends a main clamping signal to the cutting PLC controller (1) to prepare for cutting the billet. The cutting PLC controller (1) receives the main clamping signal, the encoder (4) measures the length signal and sends it to the casting strand PLC controller (2), the casting strand PLC controller (2) receives the casting strand length signal and calculates Lzy and Lbk and sends them to the cutting PLC controller (1); The cutting PLC controller (1) receives Lzy and Lbk and substitutes the values ​​of Lzy, Lbk, and Lgd according to a formula to calculate the length value Ldc of the pre-cut ingot; The cutting PLC controller (1) compares Ldc with Lsd, and performs normal cutting when the difference is within a specified error, and sends an alarm signal to a host computer (9) when the difference exceeds the specified error.

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