A method for online width adjustment status monitoring and early warning of continuous casting machine

Abstract

This invention relates to a method for online width adjustment status monitoring and early warning in continuous casting machines. The method includes the following steps: S1: collecting historical crystallizer width adjustment data of the continuous casting machine; S2: automatically filtering historical crystallizer width adjustment data under non-width adjustment conditions based on the width adjustment signal; S3: calculating the taper ratio C of different steel grades under width adjustment conditions. R S4: Establish a calculation model for the single-sided deviation of the crystallizer under width adjustment conditions; S5: Collect crystallizer width adjustment data in real time and output the single-sided deviation sets at the bottom of the crystallizer and the bottom of the foot roller under width adjustment conditions in real time; S6: Perform real-time width adjustment alarm judgment based on the single-sided deviation sets at the bottom of the crystallizer and the bottom of the foot roller under width adjustment conditions. This invention establishes a calculation model for the single-sided deviation of the crystallizer under width adjustment conditions to monitor and warn of the width adjustment status of the continuous casting machine online, preventing continuous casting leakage.

Description

Technical Field

[0001] This invention relates to the field of manufacturing technology, and in particular to a method for online width adjustment status monitoring and early warning of a continuous casting machine. Background Technology

[0002] Continuous casting is a production process in which high-temperature molten steel is continuously poured into cast billets with a specific cross-sectional shape and size. The complete set of continuous casting equipment used to achieve this process is commonly known as a continuous casting machine. It typically includes functional equipment modules such as pouring equipment, the continuous casting machine body, cutting equipment, and related equipment. The continuous casting machine production process includes: continuously pouring high-temperature molten steel into one or more crystallizers; the molten steel gradually solidifies into a billet shell along the perimeter of the crystallizer; once the molten steel level reaches a certain height and the billet shell has solidified to a certain thickness, a straightening machine pulls the billet out, and it undergoes a secondary cooling zone to completely solidify. Finally, a cutting device cuts it to specific lengths according to rolling requirements.

[0003] To improve the productivity and slab yield of slab continuous casting machines, online width adjustment has become one of the main functions of current slab casting machines. Furthermore, with increasing market share and the practical need for cost-effective production, the frequency of online width adjustment is also increasing. However, due to the different width adjustment designs of each continuous casting machine, and the increasing deterioration of the equipment after long-term use, problems such as steel leakage and defects in the quality of the width-adjusted billets occur frequently. Although all parties have made great efforts to address these production operation accidents and quality defects, such accidents still occur frequently due to the opacity and instability of the width adjustment system itself, coupled with interference from external conditions such as steel grade and casting speed. For example, after the continuous casting production line of a steel plant in China was upgraded in 2005, it adopted the high-speed width adjustment method of Nippon Steel in Japan. From 2006 to 2008, there were more than ten steel leakage accidents after the width adjustment was completed. The main reasons were the mismatch between the width adjustment and the casting speed, and the steel leakage caused by the foot rolls on the side of the crystallizer being compressed to a certain position during the width adjustment process and failing to automatically spring back due to the jamming of the foot roll frame. From 2015 to 2017, there were nearly 20 more steel leakage accidents related to width adjustment, mainly due to unclear operation control of the online width adjustment process. For example, in many large steel mills in China, the width adjustment function of the crystallizer in the steelmaking department is limited by the operating system and hardware conditions, and can only achieve the function of "width to narrow" adjustment at a low casting speed of 0.8 meters per minute. The width adjustment mode is singular, the casting speed is low, and the number of unsteady billets remains high. The difficulties and problems encountered in online width adjustment in slab continuous casting exist to varying degrees in various casting machines. In order to break through the technical bottleneck, domestic steel companies have launched technical research in this field, but have not yet been able to completely solve the above-mentioned technical problems.

[0004] Therefore, it is necessary to provide a method for online width adjustment status monitoring and early warning of continuous casting machines, so as to prevent steel leakage during continuous casting by establishing a calculation model of the single-sided deviation of the crystallizer under width adjustment status. Summary of the Invention

[0005] The purpose of this invention is to provide a method for online monitoring and early warning of the width adjustment status of a continuous casting machine. By establishing a calculation model of the single-sided deviation of the crystallizer under the width adjustment status, the method can monitor and warn of the width adjustment status of the continuous casting machine online, thereby preventing steel leakage during continuous casting.

[0006] To address the problems existing in the prior art, this invention provides a method for online width adjustment status monitoring and early warning of continuous casting machines, comprising the following steps:

[0007] S1: Collect historical crystallizer width adjustment data of continuous casting machine;

[0008] S2: Automatically filter historical crystallizer width modulation data in non-width modulation states based on the width modulation signal;

[0009] S3: Calculate the taper ratio C of different steel grades under the widening condition. R ;

[0010] S4: Establish a calculation model for the single-sided deviation of the crystallizer under the width adjustment state;

[0011] S5: Real-time acquisition of crystallizer width adjustment data, and real-time output of the set of single-sided deviations at the bottom of the crystallizer under width adjustment state and the set of single-sided deviations at the bottom of the foot roller under width adjustment state;

[0012] S6: Real-time width adjustment alarm determination is performed based on the set of single-sided deviations at the bottom of the crystallizer under width adjustment state and the set of single-sided deviations at the bottom of the foot roller under width adjustment state.

[0013] Optionally, in the online width adjustment status monitoring and early warning method for the continuous casting machine, in S1, the historical crystallizer width adjustment data includes the east and west taper C of the crystallizer and the east and west upper opening width D of the crystallizer. w , pulling speed r and liquid level height h.

[0014] Optionally, in the online width adjustment status monitoring and early warning method for the continuous casting machine, the filtering method in S2 is as follows:

[0015] The moment when the pulse width modulation signal changes from 0 to 1 is recorded as the pulse width modulation start time t. s The first moment when the pulse width modulation signal changes from 1 to 0 is the corresponding end time t of the pulse width modulation. e .

[0016] Optionally, in the online width adjustment status monitoring and early warning method for the continuous casting machine, in S3, the taper ratio C R The calculation method is as follows:

[0017] ;

[0018] Among them, D i_上D is the width of the top opening of the crystallizer. i_下 T is the width of the bottom opening of the crystallizer. d H represents the temperature difference between the upper and lower inlets of the crystallizer. MD H is the height of the crystallizer. R The gap between the upper and lower foot rollers of the crystallizer is denoted as n, the number of foot rollers in the crystallizer is denoted as n, and R is the cooling shrinkage ratio constant for different steel grades.

[0019] Optionally, in the online width adjustment status monitoring and early warning method for the continuous casting machine, in S4, the calculation model for the single-sided deviation of the crystallizer under the width adjustment status includes the single-sided deviation at the bottom of the crystallizer under the width adjustment status and the single-sided deviation at the bottom of the foot roll under the width adjustment status.

[0020] The formula for calculating the unilateral deviation at the bottom of the crystallizer under the wide-width condition is as follows:

[0021] ,

[0022] The formula for calculating the single-sided deviation at the bottom of the foot roller under the width adjustment state is as follows:

[0023] ;

[0024] Where f is the compression coefficient of the foot roller disc spring.

[0025] Optionally, in the online width adjustment status monitoring and early warning method for the continuous casting machine, in step S5, the real-time output set is displayed as follows:

[0026] Real-time crystallizer width adjustment data of the continuous casting machine is collected at a frequency of 1000ms. Based on the crystallizer single-sided deviation calculation model under the width adjustment state and the collected real-time crystallizer width adjustment data, the single-sided deviation set at the bottom of the crystallizer under the width adjustment state and the single-sided deviation set at the bottom of the foot roll under the width adjustment state are calculated in real time.

[0027] Optionally, in the online width adjustment status monitoring and early warning method for the continuous casting machine, in S6, the real-time width adjustment alarm determination method is as follows:

[0028] ,

[0029] Where E represents the alarm adjustment conclusion, E=0 represents no alarm, and E=1 represents an alarm.

[0030] Optionally, in the online width adjustment status monitoring and early warning method for the continuous casting machine, in step S1, the historical crystallizer width adjustment data of the continuous casting machine is collected in the following way:

[0031] Import historical crystallizer width adjustment data of the continuous casting machine by importing files to trace back the historical width adjustment process.

[0032] Optionally, the online width adjustment status monitoring and early warning method for continuous casting machines further includes the following steps:

[0033] The real-time collected crystallizer width adjustment data, the calculated set of unilateral deviations at the bottom of the crystallizer under the width adjustment state, the calculated set of unilateral deviations at the bottom of the foot roller under the width adjustment state, and the width adjustment alarm conclusions are analyzed and displayed.

[0034] Compared with the prior art, the present invention has the following advantages:

[0035] (1) Collect relevant data on the width adjustment of the crystallizer in real time, establish a calculation model of the single-sided deviation of the crystallizer under the width adjustment state of different steel grades, and monitor and warn the width adjustment state of the continuous casting machine online to prevent steel leakage during the width adjustment of continuous casting.

[0036] (2) Through the width adjustment system of the continuous casting machine, the physical position of the equipment (including: the copper plate of the crystallizer and the foot roll) at each time node before, after and during the width adjustment is taken as the first element, and the theoretical calculation value of the billet after hot and cold shrinkage of different steel grades when passing through the specific position of the crystallizer, foot roll and other equipment at different casting speeds is taken as the second element. Graphical display and series trend analysis are performed, and on-site emergency handling, abnormal event statistics and analysis are carried out through relevant alarm outputs, so as to achieve the purpose of optimizing the width adjustment design process, optimizing the width adjustment operation process, and monitoring the status of the width adjustment equipment.

[0037] (3) Supports the process backtracking and analysis of adjustment problems of historical adjustment records by importing offline adjustment data;

[0038] (4) By configuring different crystallizer equipment parameters, it can achieve compatibility with the width adjustment data of various continuous casting machines, providing support for the width adjustment process analysis and optimization of different continuous casting production lines. Attached Figure Description

[0039] Figure 1 A flowchart of the online width adjustment status monitoring and early warning method for continuous casting machines provided in this embodiment of the invention;

[0040] Figure 2 Trend chart of mathematical model calculation results for the online width adjustment status monitoring and early warning method for continuous casting machines provided in this embodiment of the invention;

[0041] Figure 3 The actual width adjustment results of the continuous casting production lines of various plants at different times are provided for the embodiments of the present invention. Detailed Implementation

[0042] The specific embodiments of the present invention will now be described in more detail with reference to the accompanying drawings. The advantages and features of the present invention will become clearer from the following description. It should be noted that the drawings are all in a very simplified form and use non-precise proportions, and are only used to facilitate and clarify the illustration of the embodiments of the present invention.

[0043] In the following, if the methods described herein include a series of steps, the order of these steps presented herein is not necessarily the only order in which these steps can be performed, and some of the steps described may be omitted and / or some other steps not described herein may be added to the method.

[0044] To address the problems existing in the prior art, this invention provides a method for online width adjustment status monitoring and early warning of continuous casting machines, such as... Figure 1 As shown, the method includes the following steps:

[0045] S1: Collect historical crystallizer width adjustment data of the continuous casting machine. Specifically, the historical crystallizer width adjustment data of the continuous casting machine is collected as follows: Import the historical crystallizer width adjustment data of the continuous casting machine via file import to trace the historical width adjustment process. The historical crystallizer width adjustment data includes the east and west taper C of the crystallizer and the width D of the top opening on the east and west sides of the crystallizer. w , pulling speed r and liquid level height h.

[0046] S2: Automatically filter historical crystallizer modulation data in non-modulation states based on the modulation signal; in one embodiment, the filtering method is as follows: capture the first moment when the modulation signal changes from 0 to 1 and record it as the modulation start time t. s The first moment when the pulse width modulation signal changes from 1 to 0 is the corresponding end time t of the pulse width modulation. e .

[0047] S3: Calculate the taper ratio C of different steel grades under the widening condition. R Taper ratio C R The calculation method is as follows:

[0048] ;

[0049] Among them, D i_上 D is the width of the top opening of the crystallizer. i_下 T is the width of the bottom opening of the crystallizer. d H represents the temperature difference between the upper and lower inlets of the crystallizer. MD H is the height of the crystallizer. R The gap between the upper and lower foot rollers of the crystallizer is denoted as n, the number of foot rollers in the crystallizer is denoted as n, and R is the cooling shrinkage ratio constant for different steel grades.

[0050] S4: Establish a calculation model for the single-sided deviation of the crystallizer under the width adjustment state; the calculation model for the single-sided deviation of the crystallizer under the width adjustment state includes the single-sided deviation at the bottom of the crystallizer under the width adjustment state and the single-sided deviation at the bottom of the foot roller under the width adjustment state;

[0051] The formula for calculating the unilateral deviation at the bottom of the crystallizer under the wide-width condition is as follows:

[0052] ,

[0053] The formula for calculating the single-sided deviation at the bottom of the foot roller under the width adjustment state is as follows:

[0054] ;

[0055] Where f is the compression coefficient of the foot roller disc spring.

[0056] S5: Real-time acquisition of crystallizer width adjustment data, and real-time output of the set of single-sided deviations at the bottom of the crystallizer and the set of single-sided deviations at the bottom of the foot roll under the width adjustment state; the real-time output method is as follows: real-time crystallizer width adjustment data of the continuous casting machine is acquired at a frequency of 1000ms, and the single-sided deviations at the bottom of the crystallizer and the bottom of the foot roll under the width adjustment state are calculated in real time based on the calculation model of the single-sided deviation of the crystallizer under the width adjustment state and the acquired real-time crystallizer width adjustment data; since there are multiple sets of real-time crystallizer width adjustment data involved in the calculation, multiple sets of single-sided deviations at the bottom of the crystallizer and the bottom of the foot roll under the width adjustment state can be obtained, forming the set of single-sided deviations at the bottom of the crystallizer and the set of single-sided deviations at the bottom of the foot roll under the width adjustment state.

[0057] S6: Real-time width adjustment alarm determination is performed based on the single-sided deviation set at the bottom of the crystallizer under width adjustment state and the single-sided deviation set at the bottom of the foot roller under width adjustment state. Specifically, the real-time width adjustment alarm determination method is as follows:

[0058] ,

[0059] Where E represents the alarm adjustment conclusion, E=0 represents no alarm, and E=1 represents an alarm.

[0060] Optionally, the online width adjustment status monitoring and early warning method for continuous casting machines further includes the following steps:

[0061] The system analyzes and displays the real-time collected crystallizer width adjustment data, the calculated set of unilateral deviations at the bottom of the crystallizer under the width adjustment state, the calculated set of unilateral deviations at the bottom of the foot roller under the width adjustment state, and the width adjustment alarm conclusions. The display methods include digital and graphical formats.

[0062] The online width adjustment status monitoring and early warning method for continuous casting machines provided by this invention can also be applied to various casting machines, and can provide the main basis for verifying the advantages and disadvantages of various width adjustment process designs.

[0063] Furthermore, this invention incorporates crystallizer equipment size parameters into the calculation formula, making the calculation model of this invention widely applicable to various types of crystallizers and various width adjustment processes.

[0064] like Figure 2 and 3 As shown, in order to verify the accuracy of the calculation results and alarm conclusions of the calculation model of the present invention, actual production data was sampled on the continuous casting production line of a steel plant in China. After the data was imported into the model, the output results were basically consistent with the actual production situation.

[0065] Compared with the prior art, the present invention has the following advantages:

[0066] (1) Collect relevant data on the width adjustment of the crystallizer in real time, establish a calculation model of the single-sided deviation of the crystallizer under the width adjustment state of different steel grades, and monitor and warn the width adjustment state of the continuous casting machine online to prevent steel leakage during the width adjustment of continuous casting.

[0067] (2) Through the width adjustment system of the continuous casting machine, the physical position of the equipment (including: the copper plate of the crystallizer and the foot roll) at each time node before, after and during the width adjustment is taken as the first element, and the theoretical calculation value of the billet after hot and cold shrinkage of different steel grades when passing through the specific position of the crystallizer, foot roll and other equipment at different casting speeds is taken as the second element. Graphical display and series trend analysis are performed, and on-site emergency handling, abnormal event statistics and analysis are carried out through relevant alarm outputs, so as to achieve the purpose of optimizing the width adjustment design process, optimizing the width adjustment operation process, and monitoring the status of the width adjustment equipment.

[0068] (3) Supports the process backtracking and analysis of adjustment problems of historical adjustment records by importing offline adjustment data;

[0069] (4) By configuring different crystallizer equipment parameters, it can achieve compatibility with the width adjustment data of various continuous casting machines, providing support for the width adjustment process analysis and optimization of different continuous casting production lines.

[0070] The above are merely preferred embodiments of the present invention and do not constitute any limitation on the present invention. Any equivalent substitutions or modifications made by those skilled in the art to the technical solutions and content disclosed in the present invention without departing from the scope of the present invention shall be deemed to have remained within the protection scope of the present invention.

Claims

1. A method for online width adjustment status monitoring and early warning of a continuous casting machine, characterized in that, Includes the following steps: S1: Collect historical crystallizer width adjustment data of the continuous casting machine. The historical crystallizer width adjustment data includes the east and west taper C of the crystallizer and the east and west upper opening width D of the crystallizer. w Pulling speed r and liquid level height h; S2: Automatically filter historical crystallizer pulse-width data in non-pulsation states based on the pulse-width modulation signal. The filtering method is as follows: Capture the first moment when the pulse-width modulation signal changes from 0 to 1 and record it as the pulse-width start time t. s The first moment when the pulse width modulation signal changes from 1 to 0 is the corresponding end time t of the pulse width modulation. e ; S3: Calculate the taper ratio C of different steel grades under the width adjustment condition. R ; Taper ratio C R The calculation method is as follows: ； Among them, D i_上 D is the width of the top opening of the crystallizer. i_下 T is the width of the bottom opening of the crystallizer. d H represents the temperature difference between the upper and lower inlets of the crystallizer. MD H is the height of the crystallizer. R The gap between the upper and lower foot rollers of the crystallizer is n, the number of foot rollers in the crystallizer is n, and R is the cooling shrinkage ratio constant for different steel grades. S4: Establish a calculation model for the single-sided deviation of the crystallizer under the width adjustment state; The calculation model for the single-sided deviation of the crystallizer under the width adjustment state includes the single-sided deviation at the bottom of the crystallizer under the width adjustment state and the single-sided deviation at the bottom of the foot roller under the width adjustment state. The formula for calculating the unilateral deviation at the bottom of the crystallizer under the wide-width condition is as follows: ， The formula for calculating the single-sided deviation at the bottom of the foot roller under the width adjustment state is as follows: ； Where f is the compression coefficient of the foot roller disc spring; S5: Real-time acquisition of crystallizer width adjustment data, and real-time output of the set of single-sided deviations at the bottom of the crystallizer under width adjustment and the set of single-sided deviations at the bottom of the foot roller under width adjustment. The real-time output of the collection is done in the following ways: Real-time crystallizer width adjustment data of the continuous casting machine is acquired at a frequency of 1000ms. Based on the crystallizer single-sided deviation calculation model under width adjustment and the acquired real-time crystallizer width adjustment data, the single-sided deviation sets at the bottom of the crystallizer and the single-sided deviation sets at the bottom of the foot roll under width adjustment are calculated in real time. S6: Real-time width adjustment alarm judgment is performed based on the set of single-sided deviations at the bottom of the crystallizer under width adjustment state and the set of single-sided deviations at the bottom of the foot roller under width adjustment state. The method for determining real-time width adjustment alarms is as follows: ， Where E represents the alarm adjustment conclusion, E=0 means no alarm, and E=1 means an alarm.

2. The method for online width adjustment status monitoring and early warning of a continuous casting machine as described in claim 1, characterized in that, In S1, the method for collecting historical crystallizer width adjustment data of the continuous casting machine is as follows: Import historical crystallizer width adjustment data from the continuous casting machine via file import to trace back the historical width adjustment process.

3. The method for online width adjustment status monitoring and early warning of a continuous casting machine as described in claim 1, characterized in that, It also includes the following steps: The real-time collected crystallizer width adjustment data, the calculated set of unilateral deviations at the bottom of the crystallizer under the width adjustment state, the calculated set of unilateral deviations at the bottom of the foot roller under the width adjustment state, and the width adjustment alarm conclusions are analyzed and displayed.

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