Full-automatic spraying control device for steel slag and control system thereof

Abstract

The application discloses a full-automatic spraying control device for steel slag and a control system thereof, and relates to the technical field of steel slag spraying, which solves the problems that the cooling condition cannot be known and blind spraying and blind cooling exist, and the problem that manual confirmation control is not scientific, and realizes a new process of intelligent spraying and scientific cooling of a steel slag hot soaking pool through real-time temperature monitoring of the steel slag pool by using thermal imaging, AI visual analysis, full-automatic water spraying control and multi-parameter analysis of heat exchange balance processes, so that the uncertain factors of manual operation are completely eliminated, the production efficiency is improved, water resources are saved, the environment is protected, real-time data in the steel slag production process are analyzed, and precise control of water inflow is realized, so that operation errors caused by manual control are avoided.

Description

Technical Field

[0001] This invention relates to the field of steel slag spraying technology, specifically to a fully automatic steel slag spraying control device and its control system. Background Technology

[0002] Currently, there are two spray cooling processes in the hot slag quenching production process of steel slag in my country. One is to install spray nozzles on the quenching cover for spray cooling, and the other is to use a dynamic device for spray cooling during the slag dumping process. The first process, spray cooling after the quenching cover is closed, cannot know the cooling situation inside the quenching tank. The surface cooling effect is good, but the deep cooling effect of steel slag is relatively poor, which has the disadvantage of "blind spraying (cooling)". The second process, spray cooling during the slag dumping process, relies on manual observation to see if the surface turns black to determine the amount of water and time for spray cooling. It requires manual confirmation and control. At the same time, it is not scientific for controlling the temperature change, heat exchange balance and water volume of steel slag, which has the disadvantage of "blind spraying (cooling) with naked eye". Summary of the Invention

[0003] To address the shortcomings of existing technologies, this invention provides a fully automatic steel slag spray control device and its control system, which solves the problems of unknowable cooling conditions, blind spraying and blind cooling, and the lack of scientific basis for manual confirmation control.

[0004] To achieve the above objectives, the present invention provides the following technical solution: a fully automatic steel slag spraying control system, comprising:

[0005] The information acquisition unit is used to acquire basic information about the target object and transmit it to the data analysis unit. The target object is steel slag, and the basic information includes temperature and color.

[0006] The data analysis unit is used to acquire and analyze the basic information of the target object being transmitted, and to acquire the historical data stored in the historical data storage unit. Then, the temperature and color in the historical data are analyzed to obtain the thresholds for starting and stopping water pumping, and these thresholds are recorded as threshold information. The threshold information is then transmitted to the multi-parameter heat balance exchange analysis unit.

[0007] The multi-parameter heat balance exchange analysis unit is used to acquire the transmitted threshold information and the real-time data transmitted by the real-time data acquisition unit. The real-time data includes real-time temperature and real-time color ratio. The unit analyzes the data to control the influent flow rate and generates influent flow rate control information, which is then transmitted to the information output unit.

[0008] The information output unit is used to acquire the transmitted water inflow control information and display it to the operator through a display device.

[0009] As a further solution of the present invention, the specific manner in which the data analysis unit generates the threshold information is as follows:

[0010] The threshold analysis method for starting water injection is as follows:

[0011] S1: Obtain the temperature within the acquisition period with time T as the acquisition period and denote it as Wi, where i = 1, 2,..., n. It should be noted here that the temperature represents the temperature at the start of water injection. Then substitute the temperature Wi into the formula Calculate the discrete value Q1 of the temperature Wi within the acquisition period, where Wp is the average value of the temperature within the acquisition period;

[0012] S1: Then compare all the temperatures Wi with the discrete value Q1. Denote the temperature with Wi > Q1 as the super-discrete value temperature and denote it as Wa, and denote the temperature with Wi < Q1 as the low-discrete value temperature and denote it as Wb. At the same time, calculate the average values of Wa and Wb respectively and denote them as Wap and Wbp, and generate a temperature range denoted as [Wbp, Wap], and use the temperature range [Wbp, Wap] as the starting water injection temperature threshold;

[0013] S3: Obtain the color ratio within the acquisition period with time T as the acquisition period and denote it as Bi, where i = 1, 2,..., n, and the color ratio represents the ratio of red and black on the surface of the steel slag at the start of water injection. Then obtain the corresponding temperature Wi of the color ratio Bi. Then establish a rectangular coordinate system with the color ratio Bi as the abscissa and the temperature Wi as the ordinate, and at the same time draw a relationship diagram of the color ratio Bi and the temperature Wi; Specifically, in the actual production process, the higher the temperature, the more red will be on the surface of the steel slag. Therefore, there is a proportional relationship between the color ratio and the temperature.

[0014] S4: Then obtain the maximum and minimum values of the color ratio from the relationship diagram and denote them as Bmax and Bmin respectively. At the same time, check whether the corresponding temperatures W1 and W2 at the maximum and minimum values exist in the starting water injection temperature threshold, and determine the starting water injection color ratio threshold according to the judgment result. The specific determination method is as follows:

[0015] S41: When W1 and W2 exist within the starting water injection temperature threshold, determine [Bmin, Bmin] as the starting water injection color ratio value;

[0016] S42: When W1 and W2 do not exist within the starting water injection temperature threshold, obtain the color ratios corresponding to the temperature range [Wbp, Wap] and denote them as B1 and B2, and generate a color ratio range [B1, B2] and use it as the starting water injection color ratio threshold.

[0017] S5: Similarly, determine the stop water injection threshold in the same way as the start water injection threshold determination method.

[0018] As a further aspect of the present invention, the specific method by which the multi-parameter heat balance exchange analysis unit generates influent flow control information is as follows:

[0019] P1: Obtain the real-time temperature and real-time color ratio and record them as Ws and Bs respectively. Compare the two with the starting water injection threshold. When both Ws and Bs are within the starting water injection threshold, generate a water inlet signal. Otherwise, when neither Ws nor Bs are within the starting water injection threshold, generate a monitoring signal.

[0020] P2: Acquire the inlet water signal and historical records, and analyze the relationship between color ratio and inlet water flow rate based on the historical records. The specific analysis method is as follows:

[0021] P21: Obtain m color ratios with a time period of t, denoted as Bm, where m = 1, 2, ..., n. Simultaneously, obtain the influent volumes corresponding to the changes in color ratios Bm1 and Bm2, denoted as Jm1 and Jm2, and calculate the difference in influent volumes, denoted as |Jm1 - Jm2|. Then, calculate the ratio of the color ratio change to the influent volume change, denoted as F1. , where a1 is the impact factor and is a proportional value;

[0022] P22: Similarly to the calculation method in P21, calculate all the proportions within the time period t and denote them as Fk, where k = 1, 2, ..., n-1. Then substitute them into the formula. The proportional discrete value is calculated and used as the unit standard influent value H, where Fp is the mean of Fk;

[0023] P3: Next, substitute H, Bs, and B0 into the formula. The real-time inflow rate Js is calculated, and B0 is the real-time color ratio measured in the previous measurement. The cooling time corresponding to the real-time inflow rate Js is recorded as JT, and the inflow rate per unit time is calculated and recorded as... It also generates water inflow control information.

[0024] As a further aspect of the present invention: the historical data storage unit is used to store historical data and transmit it to the data analysis unit; the real-time data acquisition unit is used to acquire real-time data and transmit it to the multi-parameter thermal balance exchange analysis unit, wherein the real-time parameters include: real-time document and real-time color ratio.

[0025] The fully automatic spray control device for steel slag is characterized in that the device includes: a horizontal and vertical two-degree-of-freedom control base, a detachable balance arm, a water-driven self-rotating nozzle, a flow meter, a control box, control software, a remote controller, a temperature sensor, and an AI vision analyzer.

[0026] The temperature sensor is used to acquire the real-time temperature of the steel slag and transmit it to the control software.

[0027] The AI ​​visual analyzer is used to acquire real-time images of steel slag and transmit them to the control software, which then analyzes the images to obtain the real-time color ratio of the steel slag.

[0028] Beneficial effects

[0029] This invention provides a fully automatic spray control device for steel slag and its control system. Compared with the prior art, it has the following advantages:

[0030] This invention utilizes thermal imaging for real-time temperature monitoring of steel slag pools, AI visual analysis, fully automated water spray control, and multi-parameter analysis of the heat exchange balance process. This completely eliminates uncertainties associated with manual operation, enabling a new process of intelligent spraying and scientific cooling in steel slag hot-cooling pools. Simultaneously, it achieves the goals of improving production efficiency, saving water resources, and protecting the environment. Furthermore, by analyzing real-time data during the steel slag production process, it enables precise control of the water inflow, avoiding operational errors caused by human intervention. Attached Figure Description

[0031] Figure 1 This is a system block diagram of the present invention. Detailed Implementation

[0032] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0033] Example 1, please refer to Figure 1 This application provides a fully automatic spray control system for steel slag, including:

[0034] The information acquisition unit is used to acquire basic information about the target object and transmit it to the data analysis unit. The target object is steel slag, and the basic information includes temperature and color. The temperature is acquired by a set temperature sensor, and the color is obtained by acquiring an image of the steel slag through a set high-temperature resistant camera and analyzing the image.

[0035] The data analysis unit is used to acquire and analyze the basic information of the target object being transmitted, and to acquire historical data stored in the historical data storage unit. Then, it analyzes the temperature and color in the historical data to obtain the thresholds for starting and stopping water pumping, and records these as threshold information. This threshold information is then transmitted to the multi-parameter heat balance exchange analysis unit. The specific method for generating the threshold information is as follows:

[0036] The threshold analysis method for starting water injection is as follows:

[0037] S1: Obtain the temperature within the collection period with time T as the collection period and denote it as Wi, where i = 1, 2,..., n. It should be noted here that the temperature represents the temperature at the start of water injection. Then substitute the temperature Wi into the formula to calculate the discrete value Q1 of the temperature Wi within the collection period, where Wp is the average temperature within the collection period;

[0038] S2: Then compare all the temperatures Wi with the discrete value Q1. Denote the temperatures with Wi > Q1 as super-discrete value temperatures and denote them as Wa, and denote the temperatures with Wi < Q1 as low-discrete value temperatures and denote them as Wb. At the same time, calculate the average values of Wa and Wb respectively and denote them as Wap and Wbp, and generate a temperature range denoted as [Wbp, Wap], and use the temperature range [Wbp, Wap] as the starting water injection temperature threshold;

[0039] S3: Obtain the color ratio within the collection period with time T as the collection period and denote it as Bi, where i = 1, 2,..., n. And the color ratio represents the ratio of red and black on the surface of the steel slag at the start of water injection. Then obtain the corresponding temperature Wi of the color ratio Bi. Then, with the color ratio Bi as the abscissa and the temperature Wi as the ordinate, establish a rectangular coordinate system, and at the same time draw a relationship diagram of the color ratio Bi and the temperature Wi; specifically, in the actual production process, the higher the temperature, the more red on the surface of the steel slag, so there is a direct proportional relationship between the color ratio and the temperature.

[0040] S4: Then obtain the maximum and minimum values of the color ratio from the relationship diagram and denote them as Bmax and Bmin respectively. At the same time, check whether the corresponding temperatures W1 and W2 at the maximum and minimum values exist within the starting water injection temperature threshold, and determine the starting water injection color ratio threshold according to the judgment result. The specific determination method is as follows:

[0041] S41: When W1 and W2 exist within the starting water injection temperature threshold, determine [Bmin, Bmin] as the starting water injection color ratio value;

[0042] S42: When W1 and W2 do not exist within the starting water injection temperature threshold, obtain the color ratios corresponding to the temperature range [Wbp, Wap] and denote them as B1 and B2, and generate a color ratio range [B1, B2] and use it as the starting water injection color ratio threshold.

[0043] S5: Similarly, determine the stop water injection threshold by the starting water injection threshold determination method.

[0044] The thermal imaging temperature measurement and AI visual analysis of the steel slag cooling process includes real-time temperature monitoring of the steel slag pool, from slag dumping, slag turning, spraying, etc. The AI ​​visual analysis is similar to the thermal imaging temperature measurement analysis and control, mainly targeting the change in the red and black color ratio on the surface of the steel slag pool, forming a curve of the change in the red and black color ratio on the surface of the steel slag pool, and obtaining the color ratio threshold for starting and stopping water spraying, which serves as the condition for starting and stopping the automatic spraying control device.

[0045] The multi-parameter heat balance exchange analysis unit is used to acquire the transmitted threshold information and the real-time data transmitted by the real-time data acquisition unit. This real-time data includes real-time temperature and real-time color ratio. The unit analyzes this data to control the influent flow rate and generates influent flow rate control information, which is then transmitted to the information output unit. The specific method for generating the influent flow rate control information is as follows:

[0046] P1: Obtain the real-time temperature and real-time color ratio and record them as Ws and Bs respectively. Compare the two with the starting water injection threshold. When both Ws and Bs are within the starting water injection threshold, generate a water inlet signal. Otherwise, when neither Ws nor Bs are within the starting water injection threshold, generate a monitoring signal.

[0047] P2: Acquire the inlet water signal and historical records, and analyze the relationship between color ratio and inlet water flow rate based on the historical records. The specific analysis method is as follows:

[0048] P21: Obtain m color ratios with a time period of t, denoted as Bm, where m = 1, 2, ..., n. Simultaneously, obtain the influent volumes corresponding to the changes in color ratios Bm1 and Bm2, denoted as Jm1 and Jm2, and calculate the difference in influent volumes, denoted as |Jm1 - Jm2|. Then, calculate the ratio of the color ratio change to the influent volume change, denoted as F1. , where a1 is the impact factor and is a proportional value;

[0049] P22: Similarly to the calculation method in P21, calculate all the proportions within the time period t and denote them as Fk, where k = 1, 2, ..., n-1. Then substitute them into the formula. The proportional discrete value is calculated and used as the unit standard influent value H, where Fp is the mean of Fk;

[0050] P3: Next, substitute H, Bs, and B0 into the formula. The real-time inflow rate Js is calculated, and B0 is the real-time color ratio measured in the previous measurement. The cooling time corresponding to the real-time inflow rate Js is recorded as JT, and the inflow rate per unit time is calculated and recorded as... It also generates water inflow control information.

[0051] Similarly, the same analysis is performed on the water start acquisition method described above for water stop acquisition. By acquiring the real-time temperature and real-time color ratio and comparing them with the water stop threshold, the temperature and color ratio corresponding to the water stop are analyzed, and the corresponding water stop information is generated and transmitted to the information output unit.

[0052] The information output unit is used to acquire the transmitted water inflow control information and display it to the operator through a display device.

[0053] Example 2: A fully automatic steel slag spray control device. This device includes a horizontal and vertical two-degree-of-freedom control base, a detachable balance arm, a water-driven self-rotating nozzle, a flow meter, a control box, control software, and a remote controller. It has multiple operation modes, including on-site remote control operation, touch screen operation, remote computer operation (joystick) operation, and automatic linkage start-up. The system realizes one-button water spraying. After the device is started, the control arm is raised (avoiding obstacles such as safety fences), then the arm is rotated so that the self-rotating nozzle is in the center of the hot simmering tank. Then, the electric valve is automatically opened to start spraying water. At the same time, the spraying time is confirmed by the results of thermal imaging temperature measurement analysis and big data heat balance exchange analysis. The electric valve is closed to stop spraying water. Finally, the arm returns to its original position, and the spraying ends.

[0054] Furthermore, any content not described in detail in this specification is existing technology known to those skilled in the art.

[0055] The above embodiments are only used to illustrate the technical methods of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical methods of the present invention without departing from the spirit and scope of the technical methods of the present invention.

Claims

1. A full-automatic spray control system for steel slag, characterized in that, The application relates to a steel slag water spraying control system, which comprises the following parts: an information acquisition unit for acquiring target object basic information and transmitting the information to a data analysis unit, wherein the target object is steel slag, and the basic information comprises temperature and color; the data analysis unit is used for acquiring the transmitted target object basic information and analyzing the information, acquiring historical data stored in a historical data storage unit, analyzing the temperature and the color in the historical data to obtain starting water spraying and stopping water spraying threshold values, recording the threshold values as threshold information, and transmitting the threshold information to a multi-parameter heat balance exchange analysis unit; the multi-parameter heat balance exchange analysis unit is used for acquiring the transmitted threshold information, acquiring real-time data transmitted by a real-time data acquisition unit, wherein the real-time data comprises real-time temperature and real-time color proportion, analyzing the real-time data to control water inflow and generate water inflow control information, and transmitting the water inflow control information to an information output unit; the information output unit is used for acquiring the transmitted water inflow control information and displaying the information to an operator through a display device; the data analysis unit generates threshold information in the following specific manner: the starting water spraying threshold value analysis manner is as follows: S1: acquire the temperature in the acquisition period with the time T as the acquisition period and record it as Wi, and i=1, 2, …, n, then substitute the temperature Wi into the formula The discrete value Q1 of the temperature Wi in the acquisition period is calculated, wherein Wp is the average value of the temperature in the acquisition period; S1: all temperatures Wi are compared with a discrete value Q1, the temperature of Wi>Q1 is recorded as an over-discrete value temperature and marked as Wa, the temperature of Wi<Q1 is recorded as a low-discrete value temperature and marked as Wb, the average values of Wa and Wb are calculated and marked as Wap and Wbp respectively, a temperature interval is generated and marked as [Wbp, Wap], and the temperature interval [Wbp, Wap] is taken as the starting water spraying temperature threshold value; S3: the color proportion in a collection period is acquired with time T as the collection period and marked as Bi, i=1, 2, …, n, the color proportion represents the proportion of red and black on the surface of the steel slag when the water spraying starts, the temperature Wi corresponding to the color proportion Bi is acquired, a right-angle coordinate system is established with the color proportion Bi as the horizontal coordinate and the temperature Wi as the vertical coordinate, and a color proportion Bi-temperature Wi relation graph is drawn; S4: the maximum value and the minimum value of the color proportion are acquired according to the relation graph and marked as Bmax and Bmin respectively, whether the temperatures W1 and W2 corresponding to the maximum value and the minimum value exist in the starting water spraying temperature threshold value is acquired, and the starting water spraying color proportion threshold value is determined according to the judgment result, and the specific determination manner is as follows: S41: when W1 and W2 exist in the starting water spraying temperature threshold value, [Bmin, Bmin] is determined as the starting water spraying color proportion value; S42: when W1 and W2 do not exist in the starting water spraying temperature threshold value, the color proportion corresponding to the temperature interval [Wbp, Wap] is acquired and marked as B1 and B2, a color proportion interval [B1, B2] is generated and taken as the starting water spraying color proportion threshold value; S5: the stopping water spraying threshold value is determined in the same manner as the starting water spraying threshold value; the multi-parameter heat balance exchange analysis unit generates water inflow control information in the following specific manner: P1: Real-time temperature and real-time color ratio are obtained and recorded as Ws and Bs respectively, and compared with the starting water threshold, when Ws and Bs are both within the starting water threshold, a water inlet signal is generated, otherwise, when Ws and Bs are both not within the starting water threshold, a monitoring signal is generated; P2: Obtain the water inlet signal, obtain the historical record, and analyze the relationship between the color ratio and the water inlet flow according to the historical record, the specific analysis method is as follows: P21: acquire m color proportions as Bm with t as a time period, and m = 1, 2, …, n, at the same time, acquire the corresponding water inflow Jm1 and Jm2 when the color proportion Bm1 changes to Bm2, and calculate the difference of water inflow as |Jm1-Jm2|, then calculate the color proportion change and the water inflow change proportion as F1, and wherein a1 is an influence factor, and is a proportional value; P22: In the same way as the calculation method in P21, all the proportional values in the time period t are calculated as Fk, and k = 1, 2, …, n-1, which are then substituted into the formula The proportional discrete values are calculated and taken as the unit standard inflow value H, wherein Fp is the average value of Fk. P3: Then, H, Bs and B0 are substituted into the formula The real-time water inflow amount Js is calculated, B0 is the real-time color ratio measured last time, the cooling time corresponding to the real-time water inflow amount Js is recorded as JT, and the water inflow speed per unit time is calculated and recorded as , and the water inflow control information is generated.

2. The full-automatic spray control system of steel slag according to claim 1, characterized in that, The historical data storage unit is used for storing historical data and transmitting it to the data analysis unit, the real-time data acquisition unit is used for acquiring real-time data and transmitting it to the multi-parameter heat balance exchange analysis unit, wherein the real-time parameters include: real-time document and real-time color ratio.

3. The full-automatic spraying control device for steel slag according to any one of claims 1-2, characterized in that, The device comprises: a horizontal and vertical two-degree-of-freedom control base, a detachable balanced cross arm, a water-driven self-rotating source nozzle, a flowmeter, a control box, control software, a remote controller, a temperature sensor and an AI vision analyzer. The temperature sensor is used for acquiring the real-time temperature of the steel slag and transmitting it to the control software. The AI vision analyzer is used for acquiring the real-time image of the steel slag and transmitting it to the control software, and analyzing it through the control software to obtain the real-time color ratio of the steel slag.

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