A continuous casting push rod operation and abnormal length recognition processing method and system

Abstract

The application discloses a continuous casting stopper operation and abnormal length identification processing method and system. The method first acquires various process condition parameters in a continuous casting production process; when the various process condition parameters meet preset conditions and a stopper operation instruction is received, a slag line function is stopped, a stopper speed reduction curve is obtained according to acquired current continuous casting production process data, a pouring length value in the speed reduction curve is obtained, and whether the pouring length of a casting flow meets preset requirements is determined; finally, when the pouring length of the casting flow meets the preset requirements, automatic stopper opening and optimized cutting actions are started. The application can quickly complete automatic stopper opening, accurately position an abnormal billet area and optimize cutting according to a gauge length when a stopper or a water gap is blocked to affect normal steel flow in a continuous casting pouring site without manual operation.

Description

Technical Field

[0001] This invention relates to the field of continuous casting production technology, and in particular to a method and system for continuous casting punch operation and abnormal length identification and processing. Background Technology

[0002] The term "pumping operation" refers to a situation during normal production where large flocculent materials adhere to the stopper head or the inner wall of the submerged entry nozzle due to various reasons. This obstructs the steel flow into the mold, preventing the continuous casting process from meeting the required throughput. Consequently, the liquid level in the mold drops continuously, necessitating a rapid reduction in casting speed to maintain production. Failure to detect and address this abnormal flow in a timely manner can lead to defects in the cast billet, or even serious production accidents such as steel leakage. To resolve the flocculent flow problem in the stopper and nozzle, a timely "pumping operation" is necessary. The rapid lifting and lowering of the stopper causes the steel flow to quickly flush the inner wall of the submerged entry nozzle, forcing the flocculent materials adhering to the nozzle into the mold and clearing the steel flow channel. Simultaneously, the squeezing action between the stopper head and the upper nozzle causes the flocculent materials adhering to the stopper head to detach, ensuring a normal steel flow channel. This abnormal operation is called "pumping" in continuous casting production.

[0003] Abnormal length refers to the turbulent flow field within the crystallizer caused during the entire casting process, especially resulting in severe fluctuations in the meniscus, which easily leads to slag entrapment and thus slag inclusion defects in the cast billet. Simultaneously, the violent churning of the liquid surface disrupts the three-layer structure of the protective slag, affecting the lubrication and cooling uniformity of the billet shell, leading to defects such as surface cracks in the cast billet. Furthermore, the shedding of large flocculent materials can cause inclusions to adhere to the billet shell, forming subsurface or internal inclusion defects in the cast billet. This abnormal length of the cast billet needs to be removed. If the abnormal length cannot be accurately located, it will result in incomplete removal of defective billets or the removal of normal billets.

[0004] Cutting optimization refers to the automatic and precise removal of billets of abnormal length caused by punching operations without affecting the normal length of the cast billet.

[0005] As the world promotes intelligent manufacturing, unmanned automated steel casting technology is also being vigorously promoted. The number of on-site operators is gradually decreasing, with some periods even seeing no operators at all, and some hazardous positions remaining unattended for extended periods. If a jammed rod or turbulent flow at the nozzle causes abnormal steel flow, requiring rapid rod flushing, the inability of personnel to arrive promptly can escalate the accident due to delayed or improper handling, leading to increased quality defects such as inclusions and cracks in the cast billet. In severe cases, steel leakage accidents can occur, with losses ranging from 300,000 to 400,000 yuan per accident. Furthermore, manually judging the length and cutting position of abnormal billets can easily result in over- or under-cutting, reducing the yield and success rate of continuous casting. This is a major constraint preventing the full realization of unmanned steel casting in continuous casting. Summary of the Invention

[0006] Based on this, this application provides a method and system for continuous casting slab operation and abnormal length identification and processing. The system aims to quickly and automatically flush the slab when slab blockage or nozzle turbulence affects the normal steel flow in unattended continuous casting sites. This allows for precise location of abnormal billet areas and optimized cutting based on specified lengths. This solves the problem of untimely slab flushing in unattended continuous casting sites, which can lead to escalation of accidents. It also solves the problem of automatic identification and optimized cutting of abnormal billet lengths, significantly reducing slab quality defects and cutting waste, thereby improving the yield and success rate of continuous casting.

[0007] Firstly, a method for continuous casting punch operation and abnormal length identification and processing is provided, the method comprising:

[0008] Acquire various process condition parameters during the continuous casting production process; wherein, the process condition parameters include at least the casting machine working mode parameters, stopper rod control mode, argon gas control mode, real-time steel height parameters in the crystallizer, and liquid level control mode in the crystallizer;

[0009] When all process parameters meet the preset conditions and the punch operation command is received, the slag adjustment line function is stopped, and the punch deceleration curve is called according to the current continuous casting production process data to obtain the casting length value in the deceleration curve, and it is determined whether the casting length meets the preset requirements.

[0010] When the casting length meets the preset requirements, the automatic punching and optimized cutting actions are activated.

[0011] Optionally, the punching process specifically includes:

[0012] The pulling speed automatically decreases according to the punch deceleration curve.

[0013] The length of the cast liquid is collected. When the length of the cast liquid meets the preset conditions, the stopper rod and liquid level interlock control are disconnected; the normal billet cutting point is marked, the automatic slag addition operation is stopped, and the argon gas is set to abnormal mode.

[0014] The stopper position P1 is collected at that time, and the stopper closes quickly at the set pressure after a delay of t1. The closing pressure of the stopper is the system set closing pressure.

[0015] Set Px as the supplementary value for the opening degree of the stopper during the punching process, and after a delay of t2, the stopper quickly opens to P1+Px; where Px is the field detection value;

[0016] The stopper rod closes rapidly at a set pressure after a delay of t3. The closing pressure of the stopper rod is the system's set closing pressure.

[0017] Set N to the set number of times the punch is used; when N meets the set number of times;

[0018] After a delay of t2, the stopper rod opens to the (P1-P0) position, where P0 is the field detection value;

[0019] Collect the casting length L, and set L4 as the preset scrap cutting length;

[0020] Adjust the argon gas to normal mode, start the slag addition operation, and inject the waste mark point.

[0021] Collect the crystallizer liquid level H, and set the minimum process liquid level H1 and maximum process liquid level H2 in the crystallizer;

[0022] When H is between H1 and H2, the secondary pull speed control is associated, and the automatic crystallizer level control function is activated.

[0023] Collect the current pulling speed V, start the punch acceleration curve, and the acceleration rate is a2;

[0024] When the pulling speed V = V1, the slag adjustment line function is activated after a delay of t4.

[0025] The automatic punching and optimized cutting program has ended.

[0026] Optionally, when the various process parameters meet the preset conditions, including:

[0027] When the casting machine's working mode is "pouring" mode, the stopper rod control mode is "automatic" mode, the argon gas control method is "remote", the molten steel height parameter in the crystallizer is within the preset process range, and the liquid level control mode in the crystallizer is "automatic".

[0028] Optionally, based on the acquired current continuous casting production process data, the casting length value in the deceleration curve is obtained by calling the punch deceleration curve, and it is determined whether the casting length meets the preset requirements; including:

[0029] Collect the continuous casting speed V, set the current casting speed to V1 = V, and set the maximum process casting speed V0 for the punch operation; call the punch deceleration curve according to the relationship between V1 and V0, and calculate the casting length value Lss in the deceleration curve;

[0030] When activating the program, collect the casting flow length Lx from the cutting position to the meniscus and the billet fixed length L0, and set k as the billet length shrinkage coefficient to calculate the length L1 of the casting flow section that is not the fixed length;

[0031] And based on the length L1, determine the length L3 of the portion of the casting flow that is insufficient to the specified length before starting the deceleration program;

[0032] Collect the current casting length L, set the cumulative casting length L2 when the program is activated, and determine whether the current casting length L is greater than the sum of L2 and L3.

[0033] Optionally, when the casting length meets the preset requirements, specifically including:

[0034] The current casting length L is greater than the sum of L2 and L3.

[0035] Optionally, the punch deceleration curve is called according to the relationship between V1 and V0, and the casting length value Lss in the deceleration curve is calculated, including:

[0036] When V1≥V0, set the deceleration rate a1, the stabilization time before deceleration Δt1, and the stabilization time after deceleration Δt2, and calculate the casting length value Lss in the deceleration curve using the first formula; wherein, the first formula specifically includes:

[0037] Lss=V0*Δt2+V1*Δt1+(V1^2-V0^2) / (2*a1).

[0038] Optionally, the punch deceleration curve is called according to the relationship between V1 and V0, and the casting length value Lss in the deceleration curve is calculated, including:

[0039] When V1 < V0, the casting speed of the punch is set to V1, the stabilization time before speed reduction is Δt1, and the stabilization time after speed reduction is Δt2 = 0. The casting length value Lss in the speed reduction curve is calculated using the second formula. The second formula specifically includes:

[0040] Lss=V1*Δt1.

[0041] Optionally, when the various process condition parameters do not meet the preset conditions or no punch operation instruction is received, the method further includes: re-acquiring the various process condition parameters in the continuous casting production process.

[0042] Optionally, the continuous casting machine status includes "Maintenance", "Ready", "Holding", "Pouring", and "Tail Billet".

[0043] Secondly, a continuous casting punch operation and abnormal length identification and processing system is provided, the system comprising:

[0044] The acquisition module is used to acquire various process condition parameters during the continuous casting production process; wherein, the process condition parameters include at least the casting machine working mode parameters, stopper rod control mode, argon gas control mode, real-time steel height parameters in the crystallizer, and liquid level control mode in the crystallizer.

[0045] The judgment module stops the slag adjustment line function when all process condition parameters meet the preset conditions and the punch operation command is received. It also calls the punch deceleration curve based on the current continuous casting production process data to obtain the casting length value in the deceleration curve and determines whether the casting length meets the preset requirements.

[0046] The processing module activates automatic punching and optimized cutting actions when the casting length meets the preset requirements.

[0047] The technical solution provided in this application first acquires various process condition parameters during the continuous casting production process. When these parameters meet preset conditions and a punch operation command is received, the current continuous casting production process data is used to call the punch deceleration curve to obtain the casting length value in the deceleration curve, and it is determined whether the casting length meets the preset requirements. Finally, when the casting length meets the preset requirements, the automatic punch and optimized cutting actions are activated. It can be seen that this invention plays an important role in promoting unmanned automatic steel casting technology in continuous casting. After the implementation of this solution, the entire punch process and optimized cutting are effectively automated, including the acceleration and deceleration of the punch action. The number of on-site operators is gradually decreasing, and in some cases, there are no operators on-site at certain times, greatly reducing major production and quality accidents caused by punch operation delays or improper operation. Due to the punch operation, quality defects such as inclusions and cracks in the cast billet are significantly reduced, and the cutting distance is shortened from 1m to 0.5m, improving the continuous casting pass rate and metal yield. The standardized operation level of continuous casting has been significantly improved. Attached Figure Description

[0048] To more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings in the following description are merely exemplary, and those skilled in the art can derive other embodiments based on the provided drawings without creative effort.

[0049] Figure 1A flowchart illustrating a continuous casting punch operation and abnormal length identification and processing method provided in this application embodiment;

[0050] Figure 2 This is a schematic diagram illustrating the collection and monitoring of continuous casting production process conditions and the processing of continuous casting production process data in an embodiment of this application.

[0051] Figure 3 This is a schematic diagram of the automatic punching action according to an embodiment of this application;

[0052] Figure 4 This is a schematic diagram of the punch speed curve in an embodiment of this application. Detailed Implementation

[0053] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0054] In the description of this invention, the terms “comprising,” “having,” and any variations thereof are intended to cover non-exclusive inclusion, for example, a process, method, system, product, or apparatus that includes a series of steps or units is not necessarily limited to those steps or units that are expressly listed, but may also include other steps or units that are not expressly listed but are inherent to these processes, methods, products, or apparatuses, or steps or units added based on further optimizations of the inventive concept.

[0055] As the world promotes smart manufacturing, automated continuous casting is also being vigorously implemented. The number of on-site operators is gradually decreasing, and there are even periods when no operators are present on the production floor. If an urgent bar-pressing operation is needed, and personnel cannot arrive in time, the delay or improper handling could escalate the accident. This is one of the limiting factors that has prevented the complete realization of unmanned continuous casting.

[0056] The conventional approach to continuous casting punch operation and abnormal length identification is through manual observation and handling. While this method can address some issues related to punch operation and the optimization of abnormal length identification and cutting, it also has several drawbacks. First, manual punching can lead to inconsistencies in the length and location of abnormal areas on the billet due to inconsistent standards of observation and operation. Second, during subsequent abnormality calibration, individual differences can result in calibrating abnormalities too long or too short, leading to the scrapping of normal billets or quality issues. Third, operational errors during punching operations frequently cause production and quality accidents.

[0057] Currently, the conventional practice in continuous casting is to rely on manual observation and handling. While this method can address a range of issues caused by nozzle and stopper turbulence malfunctions to some extent, it also has several drawbacks. Firstly, after an anomaly occurs, human observation can be negligent and operationally delayed, easily leading to the escalation and severity of losses, a phenomenon that frequently occurs during production. Secondly, the on-site casting environment is harsh, characterized by high temperatures, high noise levels, and high dust levels; prolonged shifts can cause health problems for every tundish operator. Furthermore, without the ability to automatically identify and handle nozzle and stopper turbulence anomalies, unmanned continuous casting technology cannot be achieved.

[0058] In response to the above situation, there is an urgent need to develop an automated handling technology for continuous casting punch operation and precise identification and optimized cutting of abnormal lengths. The aim is to achieve automatic, rapid, and correct handling when punch operations are required in unattended continuous casting pouring sites. This solves the potential for escalation of accidents caused by the inability to promptly and correctly handle punch operations when they are needed in unattended continuous casting pouring sites. Based on the automation control technology of continuous casting production processes and combined with on-site operational experience, the concept is as follows: Upon receiving the punch command, the casting flow length is tracked, the punch speed curve is retrieved, the cutting mark position and punch action position are calculated, and all process parameters related to the punch operation are automatically processed, thereby achieving rapid and automated handling of punch action and optimized cutting. For details, please refer to... Figure 1 The document illustrates a flowchart of a continuous casting punch operation and abnormal length identification processing method provided in an embodiment of this application. The method may include the following steps:

[0059] Step 101: Obtain various process condition parameters during the continuous casting production process.

[0060] Among them, the process condition parameters include at least the casting machine working mode parameters, stopper control mode, argon control mode, real-time parameters of molten steel height in the crystallizer, and liquid level control mode in the crystallizer.

[0061] This step mainly focuses on collecting and monitoring the continuous casting production process conditions, specifically:

[0062] The collection of production process data mentioned in step 101 includes collecting parameters of the casting machine's operating mode; collecting parameters of the stopper rod control mode; collecting parameters of the argon gas control mode; collecting real-time parameters of the molten steel height in the crystallizer; and collecting parameters of the liquid level control mode in the crystallizer. If the collected data shows that the casting machine's operating mode is "pouring" mode, the stopper rod control mode is "automatic," the argon gas control method is "remote," the molten steel height parameter in the crystallizer is within the process range, and the liquid level control mode in the crystallizer is "automatic," then proceed to step 102. Otherwise, continue collecting and automatically monitoring the casting machine's production status.

[0063] Step 102: When all process parameters meet the preset conditions and the punch operation command is received, stop the slag adjustment line function, call the punch deceleration curve based on the acquired current continuous casting production process data to obtain the casting length value in the deceleration curve, and determine whether the casting length meets the preset requirements.

[0064] This step mainly involves the processing of continuous casting production process data, specifically including:

[0065] (1) Determine whether a punch operation command has been received. If yes, proceed to the next step; otherwise, return to step 101.

[0066] (2) Stop the slag adjustment line function.

[0067] (3) Collect the continuous casting speed V, set the current casting speed to V1 = V, and set the maximum process casting speed V0 for the punch operation; determine whether V1 ≥ V0? V0 is generally taken as 0.5-0.8 m / min. If yes, proceed to step (4); otherwise, proceed to step (5).

[0068] (4) Call up the deceleration curve of the punch and set the deceleration rate a1, where a1 ranges from 0.2 to 1.2 m / min. 2 The stabilization time before speed reduction is Δt1, which is generally 0.2-0.8 min; the stabilization time after speed reduction is Δt2, which is generally 0.5-2 min; set the casting length value Lss in the speed reduction curve and calculate Lss.

[0069] Lss=V0*Δt2+V1*Δt1+(V1^2-V0^2) / (2*a1)

[0070] (5) Call the punch deceleration curve. In this case, the pulling speed before the punch is V1, the stabilization pouring time before deceleration is Δt1, Δt1 is generally taken as 0.2-0.8min, the stabilization time after deceleration is Δt2=0, set the pouring length value Lss in the deceleration curve, and calculate Lss.

[0071] Lss=V1*Δt1

[0072] (6) When activating the program, collect the length Lx of the casting flow from the cutting position to the meniscus and collect the fixed length L0 of the billet; set k as the billet length shrinkage coefficient, which is generally 1.011-1.018; set the length L1 of the portion of the casting flow section (from the cutting position to the meniscus) that is less than the fixed length after activating the program, and calculate L1.

[0073] L1 = Mod(Lx, k*L0)

[0074] (7) Set the length L3 of the portion of the casting flow that is insufficient to the fixed length before starting the deceleration program (from the cutting position to the meniscus), and calculate L3.

[0075] L3 = k * L0 - mod(L1 + Lss, k * L0)

[0076] (8) Collect the casting length L, set the cumulative casting length L2 when the program is activated; determine if L≥L2+L3, if so, proceed to step 103, otherwise continue to wait.

[0077] like Figure 2 The diagrams for collecting and monitoring continuous casting production process conditions and processing continuous casting production process data in steps 101 and 102 are given.

[0078] Step 103: When the casting length meets the preset requirements, start the punching program.

[0079] This step mainly involves the automatic punching rod action program, such as... Figure 3 A schematic diagram of the automatic punching action is provided, which specifically includes:

[0080] (1) Output a voice prompt that the punch action program has been started.

[0081] (2) At the same time, the pulling speed begins to decrease automatically according to the punch speed reduction curve.

[0082] (3) Collect the casting length L, and determine whether L≥L2+L3+Lss. If yes, proceed to the next step; otherwise, continue to wait.

[0083] (4) Disconnect the stopper rod and liquid level interlock control; mark the normal billet cutting point; stop the automatic slag addition operation; argon gas is in abnormal mode.

[0084] (5) Collect the position P1 of the stopper rod at that time, and close the stopper rod quickly with a set pressure after a delay of t1. The value of t1 can be 1-3s. The closing pressure of the stopper rod is the closing pressure set by the system.

[0085] (6) Let n be a timer, n = 1.

[0086] (7) Set Px as the supplementary value of the stopper opening during the punching process, and delay t2 for the stopper to open quickly to P1+Px; t2 can be 1-3s, and Px is the field detection value, which is generally 4-10mm.

[0087] (8) The stopper rod closes quickly at the set pressure after a delay of t3. The value of t3 can be 1-3s. The closing pressure of the stopper rod is the closing pressure set by the system.

[0088] (9) n = n + 1.

[0089] (10) Set N to the number of times the punch is set, usually 2-5 times. Determine if N = n. If it is true, proceed to the next step; otherwise, return to step (7).

[0090] (11) After a delay of t2, the stopper rod is opened to the (P1-P0) position, where P0 is the field detection value, which is generally 5-12mm.

[0091] (12) Collect the casting length L, set L4 as the preset scrap cutting length, generally 0-1m; determine L==Lss+L2+L3+L4? If true, proceed to the next step, otherwise continue to wait.

[0092] (13) Adjust the argon gas to normal mode, start the slag addition operation, and inject the waste mark point.

[0093] (14) Collect the liquid level H of the crystallizer, set the minimum liquid level H1 and the maximum liquid level H2 of the crystallizer. H1 is generally 700-750mm and H2 is generally 820-870mm. Determine whether H1≤H≤H2? If it is true, proceed to the next step. Otherwise, output an alarm to remind manual intervention.

[0094] (15) When H is between H1 and H2, the secondary pull speed control is associated; the automatic control function of the crystallizer liquid level is started.

[0095] (16) Collect the pulling speed V, start the punch speed curve, the speed is a2, and the normal value is 0.1-0.5m / min2.

[0096] (17) When the pulling speed V = V1, the slag adjustment line function is started after a delay of t4. The value of t4 is generally 30-90s.

[0097] (18) The automatic punching and optimized cutting program ends.

[0098] The present invention will be further described in detail below through specific embodiments.

[0099] 1. Continuous casting related production process conditions

[0100] 1.1 In this example, the continuous casting machine has five working modes: "maintenance", "preparation", "holding", "pouring", and "tail billet". Among them, the "pouring" mode is the normal working mode.

[0101] 1.2 The stopper rod control has two control modes: "automatic" and "manual". The "automatic" mode is the normal control mode.

[0102] 1.3 The argon gas control mode has two control modes: "remote" and "local". The "remote" mode is an automatic control mode.

[0103] 1.4 The crystallizer liquid level height control mode has three control modes: "fully automatic", "semi-automatic" and "manual", among which "fully automatic" mode is the normal control mode;

[0104] 1.5 The maximum pulling speed of the punch operation in the process setting is V0 = 0.7 m / min;

[0105] 1.6 The minimum molten steel level in the crystallizer is set to H1 = 730 mm, and the maximum level is set to H2 = 850 mm.

[0106] 2. An automated method for the precise identification and optimized cutting of abnormal lengths in continuous casting punch operation, comprising three main parts: a first stage of collecting and monitoring continuous casting production process conditions, a second stage of processing continuous casting production process data, and a third stage of automated punch action program. The method is characterized by the following steps:

[0107] 2.1 Collection and monitoring stage of continuous casting production process conditions

[0108] (1) Collect the working mode parameters of the continuous casting machine and confirm that it is actually the "pouring" mode;

[0109] (2) Collect the control mode of the stopper rod and confirm it is "automatic" mode;

[0110] (3) The control mode for collecting argon gas was confirmed to be "remote" mode;

[0111] (4) Collect the liquid level control mode in the crystallizer and confirm that it is actually the "fully automatic" control mode;

[0112] (5) Collect real-time parameters of the molten steel height in the crystallizer and confirm that the height at that time was H = 810 mm;

[0113] (6) Confirm that the collected casting machine working mode is "pouring" mode; the stopper control mode is "automatic"; the argon control mode is "remote"; the molten steel height control mode in the crystallizer is "automatic" mode; the molten steel height in the crystallizer is 810mm, which is within the process range of 850mm to 730mm in the molten steel height in the crystallizer; if all the above conditions are met, then proceed to the second stage of continuous casting production process data processing.

[0114] 2.2 Continuous Casting Production Process Data Processing

[0115] (1) Determine whether the punching bar operation instruction has been received. If yes, proceed to the next step; otherwise, return to the first stage of continuous casting production process condition collection and monitoring. In this example, the punching bar operation instruction issued by the system has been received.

[0116] (2) The slag adjustment line function is suspended, but the slag adjustment line function has been put into use in actual production.

[0117] (3) The current pulling speed is collected as V1 = 1.6 m / min, V1 > V0 = 0.7 m / min.

[0118] According to the punch velocity curve, see Figure 4 As shown, the deceleration rate is set to a1 = 0.4 m / min2, the stabilization time before deceleration is Δt1 = 0.5 min, and the stabilization time after deceleration is Δt2 = 1 min; calculate the casting length value Lss in the deceleration curve.

[0119] Lss=V0*Δt2+V1*Δt1+(V1^2-V0^2) / (2*a1)

[0120] =0.7*1+1.6*0.5+(1.6^2-0.7^2) / (2*0.4)=4.088m

[0121] (4) When the system receives the punch command, collect the casting length Lx from the cutting position to the meniscus = 42.36m, the production length is 10.5m, set the length shrinkage coefficient k = 1.013, and calculate the length L1 of the casting section (from the cutting position to the meniscus) that is less than the standard length after the program is activated.

[0122] L1=Mod(Lx,k*L0)=Mod(42.36,1.013*10.5)=3.983m

[0123] This means that another 3.983m needs to be poured before reaching the normal length cutting position.

[0124] (5) Calculate the length L3 of the casting flow required to be poured in the casting flow section (from the cutting position to the meniscus) before starting the deceleration program.

[0125] L3 = k*L0 - Mod(L1 + Lss, k*L0)

[0126] =1.013*10.5-Mod(3.983+4.088,1.103*10.5)=2.566m

[0127] This indicates that another 2.566m of pouring is needed to initiate the deceleration process.

[0128] (6) When the punching command is received, the cumulative pouring length L of the continuous casting is collected. In this example, L2 = L = 846.35m is collected. The pouring length L of the casting stream is collected. When L = 848.92m, L ≥ L2 + L3 = 846.35 + 2.566 = 848.916m is satisfied. A voice prompt is output and the punching speed reduction curve is activated.

[0129] (7) Continue to collect the casting length L. When L = 853.01m, L ≥ L2 + L3 + Lss = 846.35 + 2.566 + 4.088 = 853.004m, and release the interlock control of the stopper rod and liquid level.

[0130] (8) Cancel the secondary control of drawing speed; mark the normal billet cutting position.

[0131] (9) Suspend the operation of adding protective slag; adjust the argon gas to abnormal mode.

[0132] (10) The opening of the stopper rod at this time is P1 = 57 mm, and the value is t1 = 1 s. After a delay of t1 = 1 s, the automatic stopper rod program is started. The stopper rod closes quickly with the set system pressure. In this example, the closing pressure of the stopper rod is 55 bar. Due to the turbulent flow at the head of the stopper rod, the closing position of the stopper rod is 15 mm.

[0133] (11) The number of punches in this example is N=3. The opening of the stopper needs to be compensated by Px during the punching process. In this example, Px=4mm, that is, the opening of the stopper during the punching process is P1+Px=57mm+4mm=61mm.

[0134] (12) The stopper opening compensation value Px at this stage needs to be statistically analyzed and calibrated according to the on-site working conditions. The statistics must include different shift operations as the main factors and take the average value as the calibration value. The specific statistics are shown in Table 1.

[0135] Table 1. Explanation of the calculation of stopper opening compensation value Px during the punching process.

[0136]

[0137] (13) After one stroke is completed, the timer n = 1.

[0138] (14) Take the value t2 = 1s. After a delay of t2 = 1s, the stopper rod is quickly opened to 61mm.

[0139] (15) Take the value t3 = 1.5s. After a delay of t3 = 1.5s, the stopper rod closes quickly with the set pressure. Since there is still turbid material at the head of the stopper rod, the stopper rod closes at 11mm.

[0140] (16)n==n+1.

[0141] (17) In this example, the number of punches is set to N=3. Repeat steps (14)-(16) until n=N=3, and the punching action ends.

[0142] (18) After the punch is completed, the stopper opening needs to be compensated by P0. In this example, P0 = 7mm, that is, the stopper opening P1-P0 after the punch is completed is 57mm-7mm = 50mm.

[0143] (19) The stopper opening compensation value P0 at this stage needs to be statistically analyzed and calibrated according to the on-site working conditions. The statistics must include different shift operations as the main factors and take the average value as the calibration value. The specific statistics are shown in Table 2.

[0144] (20) In this example, the waste cutting length L4 = 0.5m is taken. When the casting length L = 857.49 is collected, L ≥ L2 + Lss + L3 + L4 = 846.35 + 4.088 + 3.983 + 2.566 + 0.5 = 857.487 is satisfied.

[0145] (21) Adjust the argon gas to normal mode; start the slag addition operation; cut off the waste mark point during injection.

[0146] (22) Collect the crystallizer liquid level H = 802 mm, satisfy H1 = 730 mm ≤ H ≤ H2 = 850 mm, associate with the secondary pull speed control, and start the crystallizer liquid level automatic control system.

[0147] (23) Collect the pulling speed V, start the punch acceleration curve, see Figure 4 As shown, the acceleration rate is taken as a2 = 0.1 m / min2.

[0148] (24) When the pulling speed reaches V1=1.6m / min, take the value t4=60s, and after a delay of t4=60s, start the slag adjustment line function.

[0149] (25) The automatic punching and optimized cutting program ends.

[0150] Table 2. Explanation of the calculation of stopper opening compensation value P0 after the punching process.

[0151]

[0152] In summary, this invention is an automated handling method for the operation of continuous casting punches and the accurate identification and cutting optimization of abnormal lengths. Upon receiving a punch instruction, the automated handling program is activated, avoiding the occurrence of defects in the casting billet quality or even major accidents such as steel leakage caused by neglect or delayed manual response.

[0153] The impact of the slag-pumping process on the liquid level fluctuation in the crystallizer is minimized. To further reduce the impact of the slag-pumping process on the flow field inside the crystallizer, the timing for stopping the slag adjustment line, switching the argon control mode, stopping the slag addition operation, unlocking the crystallizer liquid level and stopper rod interlocking control is precisely calculated and implemented automatically.

[0154] The punching operation is fully automatic and safe. The number of punches can be adjusted according to actual conditions. The opening value of the stopper during and after punching is statistically calculated based on actual production to ensure consistency with actual production operations.

[0155] Precise marking of cutting positions optimizes scrap length. The scrap length can be adjusted based on the fixed length and actual punch conditions. Cutting position markings are accurate to the millimeter level, avoiding over- or under-cutting that can occur during manual marking, thus improving the billet qualification rate and increasing metal yield.

[0156] This system reduces human error and improves operational standardization. Once the punching program is activated, the system automatically adjusts the casting speed according to the set speed curve. After punching, the system automatically returns to the production state before punching, requiring no manual intervention throughout the entire process. This reduces the intensity of manual operation, improves continuous casting production efficiency, and avoids inconsistencies in process control caused by individual differences in manual operation, which could lead to frequent anomalies and prevent the achievement of standardized punching operations.

[0157] This application also provides a continuous casting punch operation and abnormal length identification and processing system. The system includes:

[0158] Acquire various process condition parameters during the continuous casting production process; wherein, the process condition parameters include at least the casting machine working mode parameters, stopper rod control mode, argon gas control mode, real-time steel height parameters in the crystallizer, and liquid level control mode in the crystallizer;

[0159] When all process parameters meet the preset conditions and the punch operation command is received, the punch deceleration curve is called according to the current continuous casting production process data to obtain the casting length value in the deceleration curve, and it is determined whether the casting length meets the preset requirements.

[0160] When the casting length meets the preset requirements, the punching program is started.

[0161] The continuous casting sprue operation and abnormal length identification processing system provided in this application embodiment is used to implement the aforementioned continuous casting sprue operation and abnormal length identification processing method. Specific limitations regarding the continuous casting sprue operation and abnormal length identification processing system can be found in the limitations of the continuous casting sprue operation and abnormal length identification processing method described above, and will not be repeated here. Each part of the aforementioned continuous casting sprue operation and abnormal length identification processing system can be implemented wholly or partially through software, hardware, or a combination thereof. The aforementioned modules can be embedded in or independent of the processor in the device in hardware form, or stored in the memory of the device in software form, so that the processor can call and execute the operations corresponding to the above modules.

[0162] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0163] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A method for continuous casting punch operation and abnormal length identification and processing, characterized in that, The method includes: Acquire various process condition parameters during the continuous casting production process; wherein, the process condition parameters include at least the casting machine working mode parameters, stopper rod control mode, argon gas control mode, real-time steel height parameters in the crystallizer, and liquid level control mode in the crystallizer; When all process parameters meet the preset conditions and the punch operation command is received, the punch deceleration curve is called according to the current continuous casting production process data to obtain the casting length value in the deceleration curve, and it is determined whether the casting length meets the preset requirements. When the casting length meets the preset requirements, the automatic punching and optimized cutting actions are activated. The automatic punching and optimized cutting action specifically includes: The pulling speed automatically decreases according to the punch deceleration curve. The length of the cast liquid is collected. When the length of the cast liquid meets the preset conditions, the stopper rod and liquid level interlock control are disconnected; the normal billet cutting point is marked, the automatic slag addition operation is stopped, and the argon gas is set to abnormal mode. The stopper position P1 is collected at that time, and the stopper closes quickly at the set pressure after a delay of t1. The closing pressure of the stopper is the system set closing pressure. Set Px as the supplementary value for the opening degree of the stopper during the punching process, and after a delay of t2, the stopper quickly opens to P1+Px; where Px is the field detection value; The stopper rod closes rapidly at a set pressure after a delay of t3. The closing pressure of the stopper rod is the system's set closing pressure. Set N to the set number of times the punch is used; when N meets the set number of times; After a delay of t2, the stopper rod opens to the (P1-P0) position, where P0 is the stopper rod opening compensation value after the punching process, which is 5-12mm; Collect the casting length L, and set L4 as the preset scrap cutting length; Adjust the argon gas to normal mode, start the slag addition operation, and inject the waste mark point; Collect the crystallizer liquid level H, and set the minimum process liquid level H1 and maximum process liquid level H2 in the crystallizer; Link the secondary pull speed control and activate the automatic crystallizer level control function; Collect the current pulling speed V, start the punch acceleration curve, and the acceleration rate is a2; When the casting speed V==V1, the slag adjustment line function is activated after a delay of t4; where V1 is the current continuous casting speed when the punch program is activated. The automatic punching and optimized cutting program has ended.

2. The method for continuous casting punch operation and abnormal length identification and processing according to claim 1, characterized in that, When all process parameters meet the preset conditions, including: When the casting machine's working mode is "pouring" mode, the stopper rod control mode is "automatic" mode, the argon gas control method is "remote", the molten steel height parameter in the crystallizer is within the preset process range, and the liquid level control mode in the crystallizer is "automatic".

3. The method for continuous casting punch operation and abnormal length identification and processing according to claim 1, characterized in that, Based on the acquired current continuous casting production process data, the casting length value in the deceleration curve of the punch is obtained by calling the deceleration curve, and it is determined whether the casting length meets the preset requirements; including: Collect the continuous casting speed V, set the current casting speed to V1=V, and set the maximum process casting speed V0 for the punch operation; call the punch deceleration curve according to the relationship between V1 and V0, and calculate the casting length value Lss in the deceleration curve; When activating the program, collect the casting flow length Lx from the cutting position to the meniscus and the billet fixed length L0, and set k as the billet length shrinkage coefficient to calculate the length L1 of the casting flow section that is not the fixed length; Based on the aforementioned length L1, determine the length L3 of the portion of the casting flow that is insufficient to the specified length before initiating the speed reduction procedure. Collect the current casting length L, set the cumulative casting length L2 when the program is activated, and determine whether the current casting length L is greater than the sum of L2 and L3.

4. The method for continuous casting punch operation and abnormal length identification and processing according to claim 3, characterized in that, When the casting pouring length meets the preset requirements, specifically including: The current casting length L is greater than the sum of L2 and L3.

5. The method for continuous casting punch operation and abnormal length identification and processing according to claim 3, characterized in that, Based on the relationship between V1 and V0, the corresponding punch deceleration curve is invoked, and the casting length value Lss in the deceleration curve is calculated, including: When V1≥V0, set the deceleration rate a1, the stabilization time before deceleration Δt1, and the stabilization time after deceleration Δt2, and calculate the casting length value Lss in the deceleration curve using the first formula; wherein, the first formula specifically includes: 。 6. The method for continuous casting punch operation and abnormal length identification and processing according to claim 3, characterized in that, Based on the relationship between V1 and V0, the corresponding punch deceleration curve is invoked, and the casting length value Lss in the deceleration curve is calculated, including: When V1 < V0, the casting speed of the punch is set to V1, the stabilization time before speed reduction is Δt1, and the stabilization time after speed reduction is Δt2 = 0. The casting length value Lss in the speed reduction curve is calculated using the second formula. The second formula specifically includes: 。 7. The method for continuous casting punch operation and abnormal length identification and processing according to claim 1, characterized in that, When the various process condition parameters do not meet the preset conditions or no punch operation instruction is received, the method further includes: re-acquiring the various process condition parameters in the continuous casting production process.

8. The method for continuous casting punch operation and abnormal length identification and processing according to claim 1, characterized in that, The status of a continuous casting machine includes "maintenance", "preparation", "holding", "pouring", and "tailing".

9. A continuous casting punch operation and abnormal length identification and processing system, characterized in that, The system includes: The acquisition module is used to acquire various process condition parameters during the continuous casting production process; wherein, the process condition parameters include at least the casting machine working mode parameters, stopper rod control mode, argon gas control mode, real-time steel height parameters in the crystallizer, and liquid level control mode in the crystallizer. The judgment module, when all process condition parameters meet the preset conditions and the punch operation command is received, calls the punch deceleration curve based on the acquired current continuous casting production process data to obtain the casting length value in the deceleration curve, and determines whether the casting length meets the preset requirements. The processing module activates automatic punching and optimized cutting actions when the casting length meets the preset requirements. The automatic punching and optimized cutting action specifically includes: The pulling speed automatically decreases according to the punch deceleration curve. The length of the cast liquid is collected. When the length of the cast liquid meets the preset conditions, the stopper rod and liquid level interlock control are disconnected; the normal billet cutting point is marked, the automatic slag addition operation is stopped, and the argon gas is set to abnormal mode. The stopper position P1 is collected at that time, and the stopper closes quickly at the set pressure after a delay of t1. The closing pressure of the stopper is the system set closing pressure. Set Px as the supplementary value for the opening degree of the stopper during the punching process, and after a delay of t2, the stopper quickly opens to P1+Px; where Px is the field detection value; The stopper rod closes rapidly at a set pressure after a delay of t3. The closing pressure of the stopper rod is the system's set closing pressure. Set N to the set number of times the punch is used; when N meets the set number of times; After a delay of t2, the stopper rod opens to the (P1-P0) position, where P0 is the stopper rod opening compensation value after the punching process, which is 5-12mm; Collect the casting length L, and set L4 as the preset scrap cutting length; Adjust the argon gas to normal mode, start the slag addition operation, and inject the waste mark point; Collect the crystallizer liquid level H, and set the minimum process liquid level H1 and maximum process liquid level H2 in the crystallizer; Link the secondary pull speed control and activate the automatic crystallizer level control function; Collect the current pulling speed V, start the punch acceleration curve, and the acceleration rate is a2; When the casting speed V==V1, the slag adjustment line function is activated after a delay of t4; where V1 is the current continuous casting speed when the punch program is activated. The automatic punching and optimized cutting program has ended.

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