High temperature molten metal flow resistant barrier device, system and method

Abstract

The application relates to a high-temperature molten metal leakage rapid fireproof blocking device, system and method, which comprises a flow guide module, a flow guide cabin for being embedded below the ground, a cover plate on the top of the flow guide cabin, a flow guide opening being arranged on the cover plate, the cover plate being flush with the ground, a hollow flow guide space being formed in the flow guide cabin and being used for the high-temperature molten metal leakage to flow through, and the hollow flow guide space being connected to an emergency pool; a blocking module, a blocking plate for blocking the flow guide opening and a magnetic lock, one end of the blocking plate being hingedly connected to the cover plate through a rotating shaft, the magnetic lock comprising a metal block arranged at the end of the blocking plate away from the rotating shaft and an electromagnetic block arranged on the cover plate and used for being magnetically matched with the metal block, the electromagnetic block being connected with a control circuit and being used for being disconnected with the control circuit when the high-temperature molten metal leakage is detected, and a counterweight being fixed on the rotating shaft and used for driving the blocking plate to be turned up to expose the flow guide opening when the electromagnetic block is powered off. The application has the effect of responding rapidly to realize rapid blocking of the high-temperature molten metal.

Description

Technical Field

[0001] This application relates to the field of barrier devices, and in particular to a rapid refractory barrier device, system and method for high-temperature molten metal flow. Background Technology

[0002] In the aluminum smelting, steelmaking, and metal casting industries, molten metal may leak during smelting, recycling, and transportation due to corrosion and wear of containers. When the leaked high-temperature molten material comes into rapid and close contact with cool liquids such as water, the cool liquid evaporates quickly, the high-temperature molten metal may crack or further fragment, the heat transfer area increases dramatically, causing the surrounding liquid to boil explosively and potentially generate a huge shock wave, leading to an explosion. Such an explosion could trigger a major safety accident.

[0003] Currently, the commonly used containment devices in factories typically involve embedding a lift platform in the bottom surface near the furnace. When a molten metal leak is detected, a lifting cylinder at the bottom of the platform raises it, containing the leaking high-temperature molten metal and preventing it from spreading to other areas, thus reducing the probability of an explosion upon contact with coolant. However, current lift platforms are mechanically controlled, resulting in a relatively slow response time. Summary of the Invention

[0004] In order to respond quickly and isolate the high-temperature molten metal in the event of leakage, this application provides a rapid fire-resistant barrier device, system and method for the flow of high-temperature molten metal.

[0005] The technical solution provided in this application for a rapid refractory barrier device, system, and method for high-temperature molten metal flow adopts the following: Firstly, the high-temperature molten metal flow rapid refractory barrier device provided in this application adopts the following technical solution: A rapid refractory barrier for high-temperature molten metal flow, comprising: The flow diversion module includes a flow diversion chamber for burying underground. A flow diversion port is provided on the cover plate at the top of the flow diversion chamber. The cover plate is flush with the ground. The interior of the flow diversion chamber forms a hollow flow diversion space for leaked high-temperature molten metal to flow through. The hollow flow diversion space leads to an emergency pool. The barrier module includes a barrier plate for sealing the flow outlet and a magnetic latch. One end of the barrier plate is hinged to the cover plate via a pivot. The magnetic latch includes a metal block disposed on the end of the barrier plate away from the pivot and an electromagnetic block disposed on the cover plate for magnetically engaging with the metal block. The electromagnetic block is connected to a control circuit and is used to disconnect from the control circuit when high-temperature molten metal leakage is detected. A counterweight is fixed on the pivot for driving the barrier plate to flip up when the electromagnetic block is de-energized to expose the flow outlet.

[0006] By adopting the above technical solution, during normal high-temperature molten metal transport, the electromagnetic block and the metal block of the baffle plate are magnetically attracted, and the baffle plate completely blocks the flow port. Furthermore, the baffle plate and cover plate are flush with the ground, allowing workers to walk normally on the cover plate and baffle plate. When molten metal leaks, the processor disconnects the control circuit, causing the electromagnetic block's magnetic force to disappear. The metal block and electromagnetic block are released from their magnetic attraction, and the baffle block flips upwards under the weight of the counterweight, exposing the flow port. When the molten metal leaks and flows to the flow port, it flows from the flow port into the hollow flow space of the flow guide chamber and along the hollow flow path... The flow space flows into the emergency pool, reducing the probability of an explosion caused by the high-temperature molten metal encountering the coolant; by de-energizing the electromagnetic block and allowing the baffle plate to flip up under gravity, the baffle plate flips up in only 0.2 seconds, resulting in a faster response and effective containment of leaking high-temperature metal; a flow guide chamber is set at the bottom of the baffle plate, allowing leaking high-temperature metal to flow directly into the flow guide chamber from the flow port, which can collect and guide the leaking high-temperature molten metal without contacting the components on the baffle plate, reducing the probability of damage to the baffle module and thus affecting the response speed of the baffle module.

[0007] Preferably, multiple flow guide chambers are provided, and the multiple flow guide chambers are spliced ​​together in a predetermined shape to surround the furnace outlet. The baffle plates above the flow guide chambers are arranged in a straight line according to the arrangement of the flow guide chambers.

[0008] By adopting the above technical solutions, the flow deflector is modularly designed, allowing for customized layout according to the actual conditions of the factory, and facilitating the transportation of the flow deflector.

[0009] Preferably, the main body of the flow guide chamber is formed by stacking refractory bricks.

[0010] By adopting the above technical solutions, refractory bricks have good high-temperature refractory performance, effectively reducing the probability of sparks or explosions in high-temperature molten metal.

[0011] Preferably, the back side of the barrier plate has a non-through weight-reduction groove.

[0012] By adopting the above technical solution, opening a weight-reducing groove on the back side of the barrier plate can effectively reduce the weight of the barrier plate, accelerate the upward flipping speed of the barrier plate, and help to further improve the response speed of the barrier plate.

[0013] Preferably, the end of the barrier plate away from the rotating shaft extends horizontally outward to form a sealing plate, and the back side of the sealing plate and the barrier plate form a first mounting step for mounting the metal block. The cover plate has a second mounting step on the side facing the flow port for fixing the electromagnetic block, and the upper surface of the barrier plate and the cover plate are flush.

[0014] By adopting the above technical solution, a first mounting step for installing the metal block and a second mounting step for installing the electromagnetic block are set up. When the metal block and the electromagnetic block are magnetically attracted together, the upper surface of the barrier plate is flush with the upper surface of the cover plate, thus avoiding collisions with passersby.

[0015] Preferably, a spring block is also installed in the vertical step surface of the second mounting step of the cover plate, and an avoidance groove is provided on the vertical step surface. The spring block is used to hide in the avoidance groove when the electromagnetic block and the metal block are magnetically attracted, and to pop out at the moment the barrier plate is flipped up to cover the electromagnetic block. The first mounting step and both ends of the spring block extend to the same length as the guide port, and the distal end of the spring block and the distal end of the sealing plate are wedge-shaped and cooperate with each other.

[0016] By adopting the above technical solution, when the metal block and the electromagnetic block magnetically attract each other, causing the baffle plate to close the flow port, the spring block is forced back into the relief groove by the first installation step. The spring block is in a compressed state. When the electromagnetic block is de-energized and the baffle plate flips up, the compression on the spring block is released, allowing the spring block to pop outward under the action of the restoring force and cover the electromagnetic block. When the high-temperature molten metal flows, it will flow over the upper surface of the spring block and flow into the hollow flow space along the wedge-shaped plane at the end of the spring block. The spring block not only protects the electromagnetic block but also has a certain function of guiding the molten metal, further reducing the probability of the high-temperature molten metal damaging the electromagnetic block. The far end of the spring block and the far end of the sealing plate are wedge-shaped and cooperate with each other, which facilitates the closing and opening of the baffle plate.

[0017] Secondly, this application provides a rapid refractory barrier system for high-temperature molten metal flow, employing the following technical solution: A rapid refractory barrier system for high-temperature molten metal flow includes a rapid refractory barrier device for high-temperature molten metal flow, an early warning module, and a processor. The early warning module includes an infrared thermal imager installed above the conveying trough at the furnace outlet. The infrared thermal imager monitors the conveying of molten metal in the conveying trough and forms a monitoring image sample. The processor calculates the liquid area in the monitoring image sample and compares it with a preset area increase threshold to predict the occurrence of an accident in advance. When an accident is predicted, the processor controls the solenoid valve on the control loop to disconnect.

[0018] By adopting the above technical solution, the infrared thermal imager's images of the transport tank are transmitted to the processor. The processor identifies the changes in the area of ​​molten metal in the transport tank and compares them with a preset area increase threshold. When the area of ​​the liquid in the transport tank reaches or exceeds the area increase threshold, the control valve is disconnected and the solenoid valve is de-energized, causing the barrier block to flip upward under gravity. Furthermore, the infrared thermal imager only responds to high-temperature objects, and external factors (such as water mist generated when high-temperature molten metal leaks) have little interference with it, resulting in high monitoring accuracy.

[0019] Preferably, the early warning module further includes a natural light camera and a monitor. The lens of the natural light camera is equipped with an infrared filter, and the natural light camera is connected to the alarm via a camera four-way indicator cable.

[0020] By adopting the above technical solution, the infrared thermal imager has the disadvantage of a small field of view. By using the infrared thermal imager in combination with a natural light camera, the requirements for both field of view and monitoring accuracy can be met at the same time. Adding an infrared filter to the lens of the natural light camera can avoid the interference of high temperature water mist and obtain high-resolution wide field of view video images, which is beneficial for the detection of molten metal.

[0021] Thirdly, this application provides a method for rapid refractory barrier against high-temperature molten metal flow, employing the following technical solution: A method for rapid refractory barrier against high-temperature molten metal flow includes the following steps: An infrared thermal imager monitors the flow area of ​​molten metal in the conveying tank to form monitoring image samples, while a natural light camera captures real-time video of the conveying of high-temperature molten metal. The processor processes the monitored image samples and performs accident-suspected area identification: it uses the Lucas pyramid optical flow method to extract accident video features, calculates the optical flow corner feature values ​​of the image, and combines them with a pre-trained neural network to determine whether an accident has occurred. If the processor determines that an accident has occurred, it controls the solenoid valve to disconnect and controls the alarm to sound: the baffle plate flips up under the gravity of the counterweight, exposing the guide port, and the flowing molten metal flows into the guide space from the guide port.

[0022] By adopting the above technical solution, the molten metal in the transport tank is detected in real time by the early warning module. The processor processes and analyzes the images and videos transmitted by the early warning module using a set algorithm. When an accident is detected, the solenoid valve is directly controlled to disconnect, causing the baffle plate to flip upward. If the molten metal leaks, it will be blocked by the diversion port and flow into the hollow diversion space inside the diversion chamber. The flowing molten metal is then diverted to the emergency pool for recovery. This realizes a series of actions from early warning to blocking, diversion and recovery, and the response is rapid.

[0023] Preferably, the processor processes the monitored image samples to identify suspected accident areas, specifically including: The processor performs binarization and morphological processing on the monitored image samples, and calculates the area change of the monitored image samples within the field of view; Based on the area changes within different time periods, plot the inter-frame molten metal area change trend graph; The vertex value of the trend graph is compared with the preset area increase threshold in the processor. If the vertex value exceeds the area increase threshold, an accident is determined to have occurred. If the vertex value is lower than the area increase threshold, it is determined that the molten metal is being transported normally.

[0024] In summary, this application includes at least one of the following beneficial technical effects: 1. This application sets up a flow guide chamber with a hollow flow guide space inside and a flow guide port on the top, as well as a baffle plate magnetically attached to the flow guide port. When an accident is detected, the electromagnetic block is directly de-energized, and the magnetic attraction of the baffle plate is locked. Then, the baffle plate is flipped up under the action of the counterweight, exposing the flow guide port. When the high-temperature molten metal flows through, it will flow into the hollow flow guide space along the flow guide port, realizing a series of actions from early warning to blocking to flow guide to recovery, and the response is rapid. 2. By setting a spring block, the spring block can automatically pop out and cover the electromagnetic block when the baffle plate is flipped up, reducing the probability of the electromagnetic block being damaged during the process of high-temperature molten metal flowing into the guide port; 3. By setting up an infrared thermal imager to monitor the transportation process of high-temperature molten metal, and designing a series of algorithms in the processor to calculate the liquid area in the image monitoring sample transmitted by the infrared thermal imager and compare it with a preset area increase threshold, it is convenient to accurately and quickly predict leakage accidents. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the overall structure of the high-temperature molten metal flow rapid refractory barrier device during transportation.

[0026] Figure 2This is a cross-sectional structural diagram created to illustrate the internal structure of the flow deflector.

[0027] Figure 3 yes Figure 2 A magnified view of a portion of point A in the middle.

[0028] Figure 4 This is a structural diagram to illustrate the back structure when the barrier plate flips up.

[0029] Figure 5 This is a schematic diagram to illustrate the structure of the baffle plate flipping up to expose the flow guide.

[0030] Figure 6 This is a control block diagram of the high-temperature molten metal flow rapid refractory barrier system of this application.

[0031] Figure 7 This is a flowchart of the method for rapid refractory barrier of high-temperature molten metal flow described in this application.

[0032] Figure 8 This is a flowchart illustrating the specific process by which the processor handles the monitored image samples.

[0033] Explanation of reference numerals in the attached diagram: 1. Barrier module; 11. Barrier plate; 111. Weight reduction groove; 12. Magnetic lock; 121. Metal block; 122. Electromagnetic block; 13. Rotating shaft; 14. Counterweight block; 15. Sealing plate; 16. First mounting step; 17. Solenoid valve; 2. Flow guiding module; 21. Flow guiding chamber; 211. Refractory brick; 22. Hollow flow guiding space; 23. Cover plate; 231. Second mounting step; 2311. Clearance groove; 24. Flow guiding port; 3. Spring block; 4. Base frame; 5. Shock-absorbing spring; 6. Early warning module; 61. Infrared thermal imager; 62. Natural light camera; 63. Monitor; 64. Alarm; 7. Processor. Detailed Implementation

[0034] The following is in conjunction with the appendix Figure 1-8 This application will be described in further detail.

[0035] This application discloses a rapid refractory barrier device for high-temperature molten metal flow. (Refer to...) Figures 1-6 The high-temperature molten metal flow rapid refractory barrier device includes a barrier module 1 for blocking the high-temperature molten metal and a flow guiding module 2 for guiding and collecting the leaked high-temperature molten metal.

[0036] The flow diversion module 2 includes a flow diversion chamber 21 for underground installation. The flow diversion chamber 21 is connected to an emergency pool (not shown in the figure). The interior of the flow diversion chamber 21 forms a hollow flow diversion space 22 for leaking high-temperature molten metal to flow through, facilitating the diversion and collection of the leaked high-temperature molten metal. A cover plate 23 is fixed to the top of the flow diversion chamber 21, and a flow diversion port 24 is provided on the cover plate 23. When the flow diversion chamber 21 is buried underground, the cover plate 23 is flush with the ground.

[0037] The barrier module 1 includes a barrier plate 11 and a magnetic latch 12. When molten metal is normally conveyed within the furnace opening's conveying trough, the magnetic latch 12 locks, and the barrier plate 11 completely blocks the guide port 24. One end of the barrier plate 11 is hinged to the cover plate 23 via a pivot 13, and the magnetic latch 12 is located at the end of the barrier plate 11 furthest from the pivot 13. Specifically, the magnetic latch 12 includes a metal block 121 fixed to the end of the barrier plate 11 furthest from the pivot 13 and an electromagnetic block 122 mounted on the cover plate 23 for magnetic engagement with the metal block 121. The electromagnetic block 122 is connected to the system's control circuit, and a solenoid valve 17 is installed on the connection cable between the electromagnetic block 122 and the control circuit. When the system detects a leak of molten metal, it controls the solenoid valve 17 to close, thus disconnecting the electromagnetic block 122 from the control circuit, causing the magnetic force of the electromagnetic block 122 to disappear, thereby releasing the magnetic latch. A counterweight 14 is also fixed on the rotating shaft 13, which facilitates the baffle plate 11 to flip up quickly when the electromagnetic block 122 is de-energized, so as to expose the guide port 24.

[0038] To facilitate the installation of the electromagnetic block 122 and the metal block 121, the end of the barrier plate 11 away from the rotating shaft 13 extends horizontally outward to form a sealing plate 15. The sealing plate 15 and the back side of the barrier plate 11 form a first mounting step 16 for installing the metal block 121. The cover plate 23 has a second mounting step 231 on the side facing the guide port 24 for fixing the electromagnetic block 122. When the electromagnetic block 122 and the metal block 121 are magnetically attracted, the upper surface of the barrier plate 11 is flush with the upper surface of the cover plate 23, which can avoid obstructing the normal walking of workers.

[0039] This application utilizes the gravity of the barrier plate 11 to flip up when the power is cut off by magnetic attraction. The barrier plate 11 flips up in only 0.2 seconds, resulting in a faster response. Leaking molten metal flows onto the cover plate 23 and, upon passing through the guide port 24, flows into the hollow guide space 22 of the guide chamber 21, and then into the emergency pool, reducing the probability of an explosion caused by the molten metal encountering the coolant. Furthermore, the molten metal flows directly into the guide chamber 21 without contacting the components on the barrier plate 11, thus preventing damage to the barrier module 1.

[0040] Furthermore, this application also provides a non-through weight-reducing groove 111 on the back side of the barrier plate 11, which can effectively reduce the weight of the barrier plate 11 to accelerate the flipping speed of the barrier plate 11, making the barrier plate 11 respond more quickly and facilitating the rapid containment of leaking high-temperature molten metal. In order to make the barrier plate 11 flip up smoothly, multiple weight-reducing grooves 111 are provided and are evenly distributed on the back side of the barrier plate 11 to ensure that the barrier plate 11 is subjected to uniform force.

[0041] Preferably, the flow guide chamber 21 is manufactured in a modular form, allowing for customized layout according to the actual conditions of the factory and facilitating its transportation. During installation, multiple flow guide chambers 21 are used and spliced ​​together in a predetermined shape to surround the conveying trough. During arrangement, attention should be paid to the arrangement of the flow guide chambers 21, ensuring that the baffle plates 11 are arranged in a straight line, without any staggered arrangement. This prevents the flowing high-temperature molten metal from leaking through the gaps between adjacent baffle plates 11, ensuring the effectiveness and comprehensiveness of the high-temperature molten metal containment.

[0042] Since the flow-guiding chamber 21 needs to contain and guide the flowing high-temperature molten metal, in order to effectively reduce the probability of sparks or explosions from the high-temperature molten metal, each flow-guiding chamber 21 is formed by stacking refractory bricks 211 with good high-temperature fire resistance. This application uses the example of the flow-guiding chamber 21 being stacked into a cuboid shape for illustration.

[0043] Reference Figure 1 To facilitate the transport of the air-guiding chamber 21 to the factory, a base frame 4 is installed at the bottom of the air-guiding chamber 21. Shock-absorbing springs 5 ​​are installed at the four corners of the base frame 4, with the axis of the shock-absorbing springs 5 ​​parallel to the base frame 4. The base frame 4 is hinged with buckles (not shown in the figure). During transport, firstly, fasteners (not shown in the figure) for engaging with the buckles are tied to the air-guiding chamber 21. Then, the air-guiding chamber 21 is placed on the four shock-absorbing springs 5 ​​of the base frame 4. The buckles and fasteners work together to secure the air-guiding chamber 21, and the shock-absorbing springs 5 ​​at the four corners reduce the vibration experienced by the air-guiding chamber 21, ensuring its safe transport.

[0044] Since the high-temperature molten metal flows from the inlet 24 into the hollow guide space 22, it passes through the electromagnetic block 122. To reduce the probability of the high-temperature molten metal submerging the electromagnetic block 122 and causing damage, a spring block 3 is also installed in the vertical step surface of the second mounting step 231 of the cover plate 23. A clearance groove 2311 is opened on the vertical step surface. When the electromagnetic block 122 and the metal block 121 are magnetically attracted, that is, when the baffle plate 11 blocks the inlet 24, the spring block 3 is squeezed back into the clearance groove 2311 by the first mounting step 16, and the spring block 3 is in a compressed state. When the electromagnetic block 122 is de-energized and the baffle plate 11 flips up, the compression on the spring block 3 is released, and the spring block 3 pops out under the action of the restoring force and covers the electromagnetic block 122. When the high-temperature molten metal flows, it will flow over the upper surface of the spring block 3 and smoothly enter the hollow guide space 22, reducing the erosion of the electromagnetic block 122, reducing the probability of damage to the electromagnetic block 122, and saving costs. At the same time, the spring block 3 will also give the barrier plate 11 an outward pushing force when it overcomes the pressure and extends in, which is conducive to the rapid opening of the barrier plate 11, further improving the opening speed of the barrier plate 11 and improving the response speed of the barrier module 1.

[0045] Furthermore, both ends of the first mounting step 16 and the spring block 3 extend to the same length as the guide port 24, facilitating complete shielding of the electromagnetic block 122. Simultaneously, the distal end of the spring block 3 and the distal end of the sealing plate 15 are designed as wedges that cooperate with each other. On one hand, this facilitates the compression of the spring block 3 into the clearance groove 2311 under the pressure of the wedge-shaped surface at the end of the sealing plate 15, achieving the closure of the barrier plate 11. On the other hand, the sloped wedge-shaped surface at the distal end of the spring block 3 can also serve as a guide surface for the high-temperature molten metal, further reducing the probability of the high-temperature molten metal immersing and damaging the electromagnetic block 122.

[0046] The implementation principle of the high-temperature molten metal flow rapid refractory barrier device in this application embodiment is as follows: According to the actual situation of the factory, multiple flow guide chambers 21 are transported and buried underground according to the design drawings to surround the conveying trough. During normal high-temperature molten metal conveying, the electromagnetic block 122 and the metal block 121 of the barrier plate 11 are magnetically attracted, and the barrier plate 11 completely blocks the flow port 24. The barrier plate 11 and the cover plate 23 are flush with the ground, and workers can walk normally on the cover plate 23 and the barrier plate 11. When the system detects a high-temperature molten metal leakage in the conveying trough, the processor 7 causes the control solenoid valve 17 to disconnect, so that the magnetic force of the electromagnetic block 122 disappears, releasing the magnetic attraction between the metal block 121 and the electromagnetic block 122. Under the gravity of the counterweight block 14, the barrier block flips upward to expose the flow port 24. At the moment the barrier block flips up, the spring block 3 pops out under the action of the restoring force, covering the electromagnetic block 122. When molten metal leaks and flows to the guide port 24, the high-temperature molten metal flows over the upper surface of the spring block 3 and, under the guiding action of the wedge-shaped surface of the spring block 3, flows into the hollow guide space 22 of the guide chamber 21, and then smoothly flows into the emergency pool for collection through the guide space 22.

[0047] This application also discloses a rapid refractory barrier system for high-temperature molten metal flow. (Refer to...) Figures 1-6 The high-temperature molten metal flow rapid refractory barrier system includes the aforementioned flow guiding module 2 and barrier module 1, as well as an early warning module 6 and a processor 7 for monitoring the conveying of high-temperature molten metal in the conveying trough.

[0048] The infrared thermal imager 61 has the advantages of responding only to high-temperature objects, being less affected by external factors (such as water mist generated when molten metal leaks), and having high monitoring accuracy. Therefore, the early warning module 6 of this application includes an infrared thermal imager 61 fixed above the conveying trough at the furnace outlet. Specifically, the infrared thermal imager 61 captures video images inside the conveying trough. Utilizing the thermal imaging principle of the infrared thermal imager 61, a monitoring image sample is formed and transmitted to the processor 7 in real time. The processor 7 calculates the liquid area of ​​the molten metal in the monitoring image sample and compares it with a preset threshold for the increase of the molten metal area in the conveying trough, thus predicting the occurrence of accidents in advance. When the liquid area in the conveying trough exceeds the threshold for the increase of the area, the control valve is disconnected, the solenoid valve 17 is de-energized, and the barrier block flips upward under the action of gravity.

[0049] Although the infrared thermal imager 61 is less affected by external factors, it has the disadvantage of a small field of view. To increase the field of view of the early warning module 6, the early warning module 6 also includes a natural light camera 62, which works in conjunction with the infrared thermal imager 61, located above the conveyor trough, and a monitor 63 located in the monitoring room. The monitor 63 is used to display the images captured by the natural light camera 62 and the infrared thermal imager 61 in real time. Although the natural light camera 62 has a large field of view, it is easily affected by high-temperature water mist. Therefore, this application adds an infrared filter to the lens of the natural light camera 62, which can avoid the interference of high-temperature water mist and obtain high-resolution wide-field video images, which is beneficial for the detection of molten metal.

[0050] This application also discloses a method for rapid refractory barrier against high-temperature molten metal flow. (Refer to...) Figures 1-8 The rapid refractory barrier method for high-temperature molten metal flow includes the following steps: S1: Infrared thermal imager 61 monitors the flow area of ​​molten metal in the conveying tank and forms a monitoring image sample; natural light camera 62 captures real-time video of the conveying of high-temperature molten metal.

[0051] S2: Processor 7 processes monitoring image samples and identifies suspected accident areas: Processor 7 uses the Lucas pyramid optical flow method to extract accident video features, calculates image optical flow corner feature values, and combines them with a pre-trained neural network to determine whether an accident has occurred. Specifically, this includes the following steps: S21: Processor 7 performs binarization and morphological processing on the monitored image samples, and calculates the area change of the monitored image samples within the field of view.

[0052] S22: Draw a trend chart of molten metal area change between frames based on the area change within different time periods.

[0053] S23: Compare the vertex value of the trend graph with the area increase threshold preset in processor 7.

[0054] S24: If the vertex value is below the area increase threshold, the molten metal is judged to be being transported normally. If the vertex value exceeds the area increase threshold, an accident is judged to have occurred.

[0055] S3: If the processor 7 determines that an accident has occurred, it controls the solenoid valve 17 to disconnect and controls the alarm 64 to sound an alarm: the baffle plate 11 flips up under the gravity of the counterweight 14, exposing the guide port 24, and the flowing molten metal flows into the guide space from the guide port 24.

[0056] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A rapid refractory barrier device for high-temperature molten metal flow, characterized in that: include: The flow guiding module (2) includes a flow guiding chamber (21) for being buried below ground. A flow guiding port (24) is provided on the cover plate (23) on the top of the flow guiding chamber (21). The cover plate (23) is flush with the ground. The interior of the flow guiding chamber (21) forms a hollow flow guiding space (22) through which leaked high-temperature molten metal flows. The hollow flow guiding space (22) leads to the emergency pool. The barrier module (1) includes a barrier plate (11) that blocks the flow port (24) and a magnetic latch (12). One end of the barrier plate (11) is hinged to the cover plate (23) via a pivot (13). The magnetic latch (12) includes a metal block (121) disposed at the end of the barrier plate (11) away from the pivot (13) and an electromagnetic block (122) disposed on the cover plate (23) for magnetically engaging with the metal block (121). The electromagnetic block (122) is connected to the control circuit and is used to disconnect from the control circuit when high-temperature molten metal leakage is detected. A counterweight (14) is fixed on the pivot (13) for driving the barrier plate (11) to flip up when the electromagnetic block (122) is de-energized to expose the flow port (24). A spring block (3) is also installed in the vertical step surface of the cover plate (23). A clearance groove (2311) is provided on the vertical step surface. The spring block (3) is used to hide in the clearance groove (2311) when the electromagnetic block (122) and the metal block (121) are magnetically attracted, and pops out at the moment the barrier plate (11) is flipped up to cover the electromagnetic block (122).

2. The high-temperature molten metal flow rapid refractory barrier device according to claim 1, characterized in that: Multiple flow guide chambers (21) are provided, and the multiple flow guide chambers (21) are spliced ​​together in a set shape to surround the furnace outlet. The baffle plates (11) above the flow guide chambers (21) are arranged in a straight line according to the arrangement of the flow guide chambers (21).

3. The high-temperature molten metal flow rapid refractory barrier device according to claim 2, characterized in that: The main body of the flow guide chamber (21) is formed by stacking refractory bricks (211).

4. The high-temperature molten metal flow rapid refractory barrier device according to claim 1, characterized in that: The back side of the barrier plate (11) is provided with a non-through weight reduction groove (111).

5. The high-temperature molten metal flow rapid refractory barrier device according to claim 1, characterized in that: The barrier plate (11) extends horizontally outward from the end away from the rotating shaft (13) to form a sealing plate (15). The sealing plate (15) and the back side of the barrier plate (11) form a first mounting step (16) for mounting the metal block (121). The cover plate (23) has a second mounting step (231) for fixing the electromagnetic block (122) on the side facing the guide port (24). The upper surface of the barrier plate (11) and the cover plate (23) are flush.

6. The high-temperature molten metal flow rapid refractory barrier device according to claim 5, characterized in that: Both ends of the first mounting step (16) and the spring block (3) extend to the same length as the guide port (24), and the distal end of the spring block (3) and the distal end of the sealing plate (15) are wedge-shaped and cooperate with each other.

7. A rapid refractory barrier system for high-temperature molten metal flow, characterized in that: The device includes the high-temperature molten metal flow rapid refractory barrier as described in any one of claims 1-6, and further includes an early warning module (6) and a processor (7). The early warning module (6) includes an infrared thermal imager (61) installed above the conveying trough at the furnace outlet. The infrared thermal imager (61) monitors the conveying of molten metal in the conveying trough and forms a monitoring image sample. The processor (7) calculates the liquid area in the monitoring image sample and compares it with a preset area increase threshold to predict the occurrence of an accident in advance. When the accident is judged to have occurred, the solenoid valve (17) on the control circuit is disconnected.

8. The high-temperature molten metal flow rapid refractory barrier system according to claim 7, characterized in that: The warning module (6) also includes a natural light camera (62) and a monitor (63). The lens of the natural light camera (62) is equipped with an infrared filter, and the natural light camera (62) is connected to the alarm (64) through a camera four-way marker line.

9. A method for using a high-temperature molten metal flow rapid refractory barrier system as described in claim 8, characterized in that: Includes the following steps: The infrared thermal imager (61) monitors the flow area of ​​the molten metal in the conveying tank and forms a monitoring image sample; the natural light camera (62) captures the conveying video of the high-temperature molten metal in real time. The processor (7) processes the monitoring image samples and performs accident suspected area identification: the Lucas pyramid optical flow method is used to extract accident video features, calculate the optical flow corner feature value of the image, and combine the pre-trained neural network to determine whether an accident has occurred; If the processor (7) determines that an accident has occurred, it controls the solenoid valve (17) to disconnect and controls the alarm (64) to sound an alarm: the baffle plate (11) flips up under the gravity of the counterweight (14), exposing the guide port (24), and the flowing molten metal flows into the guide space from the guide port (24).

10. The method for rapid refractory barrier against high-temperature molten metal flow according to claim 9, characterized in that: The processor (7) processes the monitoring image sample and performs accident suspected area discrimination, specifically including: the processor (7) performs binarization and morphological processing on the monitoring image sample and calculates the area change of the monitoring image sample within the field of view; Based on the area changes within different time periods, plot the inter-frame molten metal area change trend graph; The vertex value of the trend graph is compared with the preset area increase threshold in the processor (7); If the vertex value exceeds the area increase threshold, an accident is determined to have occurred. If the vertex value is lower than the area increase threshold, it is determined that the high-temperature molten metal is being transported normally.

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